Kogan North Gas Processing Facility – Life Extension works

With KNGPF nearing the end of its design and contracted life, a new operating contract required targeted life extension works. A FEED study identified excessive vibration within the compressor package as a critical issue requiring rectification.

Vibration remediation is inherently complex, as modifying stiffness and strength in one component can alter load paths and dynamic behaviour elsewhere in the system. The project required detailed mechanical, civil and structural design for compressor foundation modification, structural steel skid works, pedestal stiffening and hold-downs.

Dynamic analysis was undertaken to assess the influence of soil shear modulus variation on foundation response. Works needed to be documented to “Issue for Construction” level and sufficiently integrated to enable independent third-party review. Upgrades to major cooling fan blades were also required.

All works had to be sequenced within existing shutdown windows to minimise operational disruption.

Following FEED, we progressed detailed multi-discipline design for the selected compressor re-life solution.

We undertook dynamic analysis to validate foundation performance under varying soil conditions and developed detailed designs for skid strengthening, re-grouting works, pedestal stiffening and foundation modifications. Fan blade upgrades were reviewed and incorporated into the broader rectification scope.

Engineering deliverables were prepared to “Issue for Construction” standard, including technical assessments, constructability reviews and comprehensive reporting to support third-party verification. The design was structured to provide clear integration across civil and structural elements.

Careful planning and sequencing were embedded into the design to enable progressive skid upgrades within constrained shutdown periods.

The project delivered a feasibility report, cost estimates and full detailed design to support life extension of the KNGPF compressor package and associated infrastructure. Engineering documentation was prepared to “Issue for Construction” level, enabling independent third-party review and endorsement of the civil and structural design.

Tender support and construction phase services maintained continuity from design through delivery, reducing interface risk and preserving design intent. The integrated solution addressed excessive vibration through targeted strengthening, re-grouting and foundation modifications, supported by dynamic analysis of soil–structure interaction.

By sequencing works within existing shutdown windows, upgrades were completed with minimal operational disruption. The outcome provides documented engineering assurance and supports continued safe and reliable facility operation beyond its original design life.