SAPREF’s R340 million project to replace its seven product transfer pipelines has been completed on schedule in the first quarter of 2008. The pipelines, varying form 6-14 inches in diameter, run underground about 12 km from the refinery to the harbour through residential, commercial, and industrial areas.

The contract was awarded to WBHO-Shearwater Joint Venture in December 2005 and installation of the first new pipe commenced in July 2006.

The project involved firstly scanning the entire pipeline servitude to identify the existing pipelines and other buried services, followed by digging trenches at 20 m intervals to determine the exact locations of the lines and services. Before excavation work could start, detour routes for traffic were built and community and other stakeholders were engaged. Once the new lines were installed, the trenches were backfilled and the area restored to original as stipulated in the Environmental Management Plan for the project.

The new pipes are constructed from seamless carbon steel pipe with a three layer polypropylene coating as a primary protection against corrosion. Cathodic protection provides secondary protection. Run down temperatures peak at about 80 deg C depending on the product being transferred.

Numerous challenges had to be overcome in executing the project, such as restricted work areas, inclement weather, public and workforce safety, access to private properties and working in close proximity to lines carrying product. An extensive community communication and engagement plan supported the project.

The project achieved over 1,2 million hours without a lost time injury or a recordable incident. The contractors were awarded first prize for safety by the Master Builders Association.

Throughout the project SAPREF continued to keep residents informed of the work through personal visits by the community liaison officers, flyers in letter boxes and notices in the community newspapers.

At the height of the work about 77% of the people employed on the project came from neighbouring communities. The project also provided for community members to acquire skills in shrink sleeving, rigging and traffic marshalling.

In restoring the work areas 100 indigenous trees and 3000 square metres of grass were planted.

SAPREF thanks community members for their patience while the project rolled out.