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Otway Valve Management Project

Beach Energy

Australia

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The project

Beach Energy is an oil and gas exploration and production company with headquarters in Adelaide. Founded in 1961, it operates across five basins in Australia and New Zealand, supplying natural gas, crude oil and natural gas liquids to domestic and international markets.

The Otway Project is a major gas extraction initiative in the offshore Otway Basin, Victoria, 32–80km from Port Campbell. It’s designed to sustain east coast domestic gas supply by developing subsea reserves from the Geographe and Thylacine fields.

The challenge

The order comprised 18 unique line items across 26 valves – a small-batch, high-variation scope rather than a standard run. There were also several complicating factors:

  • Multiple DBB valve manufacturers were already installed on site, each with different face-to-face dimensions
  • Two previous owners of the asset had left conflicting valve specifications behind
  • The scope spanned ½” to 2″ DBB valves, including injection and sampling valves, in both carbon and stainless steel
  • Extended hydrostatic and gas testing was required, along with Fugitive Emission testing to ISO 15848 Part 2

The solution

Colson worked through the specification conflicts before manufacturing began. That meant a detailed technical review with the contractor to agree a single valve specification – including NDE and testing requirements – from the competing legacy narratives.

From there, Colson engineered all 18 unique lines from scratch, producing new internal drawings, bills of materials and cross-sectional drawings for each. Where a line item needed a specific face-to-face dimension, that dimension was matched exactly, avoiding rework on existing pipework and welding.

Supporting documentation – GA drawings, test procedures, NDE procedures – was produced on a compressed cycle to keep pace with the project schedule, backed by the same quality and traceability standards applied across every Colson order. The carbon steel valves were supplied unpainted, in their natural finish, with a protective spray for shipment; the customer applied paint at a later stage as part of a wider valve package, to protect against corrosion.

Bodies, mono-flanges and flanges were machined in-house, with final assembly and inspection completed before shipment.

Outcome

Delivery was achieved 12 weeks from drawing approval, despite the complexity of the project and the specification work needed up front.

Built on trust and integrity

Our reputation is built on consistently doing what we say we will. We give realistic lead times, flag problems early, and deliver what we promise. It sounds straightforward, but in industries where supply chain failures are common, it makes a real difference. That is why our customers come back to us, project after project, year after year.