Project Management Term Paper

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[. . .] According to its corporate profile, Keppel Offshore & Marine, integrating the experience and expertise of Keppel FELS, Keppel Shipyard, Keppel Singmarine and Keppel yards overseas, was established in 2002 (About Us 2004). Keppel Shipyard Benoi is a wholly-owned subsidiary of Keppel Corporation, one of the largest offshore and marine groups in the world. The company enjoys a strategic network of 16 yards serving regions including Asia Pacific, Gulf of Mexico, Brazil, Caspian Sea, Middle East and the North Sea (About Us 2004). The Keppel Shipyard (Benoi) specifications are set forth in the table below.

Yard Size

350,000 sq m

Berthage

1,163 m

Drydocks

No. 1 drydock

300,000 dwt

350m x 60m

No. 2 drydock

170,000 dwt

300m x 60m

Mooring Quay

No. 1 quay

Length 217m x Depth 7m

No. 2 quay

Length 352m x Depth 10m

No. 3 quay

Length 270m x Depth 8m

No. 4 quay

Length 224m x Depth 7m

Landing Quay

Length 100m x Depth 5m

Slipway

Length 230m x Width 40m

Dock and wharf cranes

Gantry cranes

80 tonnes

100 tonnes

25 tonnes

50 tonnes

20 tonnes

45 tonnes

15 tonnes

Source: Keppel Shipyard 2004].

The physical layout of the Keppel Shipyard (Benoi) is illustrated in Figure 1 below.

Figure 1. Physical Layout of Keppel Shipyard (Benoi) [Source: Keppel Shipyard 2004].

1.1.2 Recent Successful Technological Innovations.

1.1.2.1 Increased Productivity & Waste Reduction in Tank Blasting.

This innovation reflects technology transfer from industrial bridge painting contractors and equipment suppliers to the shipyards. Bridge contractors have realized the savings offered by Recyclable Ferrous Metallic Abrasive (RFMA) for many years and their equipment and process knowledge have evolved to a point where they are finally to be used in a shipyard. The innovation of this waste reduction in Tank Blasting had integrated the bridge industry procedures and equipment into a cost saving process for the shipyard, resulting in projected savings of 15 to 25% in Tank Blasting costs. Keppel has been adopting and practicing this hybrid technology since June 2003.

1.1.2.2. Innovation in Welding using Laser Pipe Welding.

This innovative programme has determined the weld quality and return on investment that a shipyard can expect by applying recent advances in laser welding technology to pipe welding during ship fabrication. Conventional pipe welding often requires multi-pass welding of beveled joints. Significant cost savings are anticipated due to elimination of multipass requirements while taking advantage of the deep penetration offered by keyhole laser welding, which will enable direct, single-pass butt-welding of pipes with little or no bevel required. Specific laser welding technologies that will be addressed include high power Nd:YAG (up to 6 kW, more than twice the power available for previous NSRP laser pipe welding studies), fiber laser technology and laser-assisted GMA (hybrid) welding. This innovation has reduced about 20% of process time as compared to the previous method because of single pass run as compared to conventional multiple root runs and finishing run.

1.1.2.3. Tandem Spin-Arc Welding Process.

This innovation has successfully met manufacturing needs in the small batch-mixed production environment of ship conversion with a new arc welding approach that will easily accommodate the multiple parameter-torch setups needed for the full range of fillet weld sizes and dependably provide seam tracking at high production rates. This project had integrated the excellent seam tracking - small fillet performance of Spin-Arc gas metal arc welding (GMAW) with a high deposition trailing GMAW torch to develop a new variant of tandem GMAW. It has been proven that the Tandem Spin Arc process had offered the best weld quality, seam tracking performance, and productivity over the full range of fillet weld sizes (3 to 8 mm) for ship construction. Productivity has been significantly improved with lesser defect. Fillet weld is to weld joint steel materials in a T- Shape form with cutting of bevel on steel plate. It is more on reinforcement materials.

All of these innovations in processes and constructions techniques enabled Keppel to successfully bid for a major construction project described below.

1.2 Project Overview and Objective. The objective of the TPG 500 project was to deliver four completed strips to the Caspian Sea where Keppel O&M's subsidiary, Caspian Shipyard Company (CSC), which will then integrate the strips in a floating drydock in Baku.

Figure 2: Artist's Conception of Completed Rig (Source: BP awards U.S.$20 million follow-up job to Keppel yard in the Caspian 2004).

The completed TPG 500 jackup shown in Figure 2 above will be the first world-class gas-condensate platform to be located in the Caspian Sea. The platform hull itself is comprised of 15,000 tonnes of steel and was formed of 12 block sections and over 680 steel panels. The hull strips were completed within the 12-month timeframe, and with a safety achievement of more than four million man hours without a lost time incident and won a Silver award at the recent Annual Safety Performance Award organized by the Singapore Ministry of Manpower (BP awards U.S.$20 million follow-up job to Keppel yard in the Caspian 2004).

The TPG 500 was fabricated in four sections; the sections were then trial-assembled in the Keppel Fels dry dock to minimise assembly time during the in-country assembly stage in Azerbaijan. This precautionary step also helped to ensur that the hull sections fitted perfectly together before the components are shipped to Baku. In Baku, the four sections will be assembled to form the platform substructure to be installed offshore in 2006 (Shah Deniz Loads Out TPG 500 Platform Hull from Singapore 2004).

The hull sections are scheduled to be transported by a heavy-lift vessel (Mighty Servant III) operated by Dockwise. The fabrication of the accommodation block for 120 personnel has also been completed by Keppel Fels safely and on schedule, and will be shipped separately using a heavy lift vessel.

Finally, the parties to the Shah Deniz Production Sharing Agreement (PSA) are:

BP (operator - 25,5%)

Statoil (25,5%)

The State Oil Company of Azerbaijan Republic (SOCAR - 10%),

LUKAgip (10%)

NICO (10%)

Total (10%), and TPAO (9%) (Shah Deniz Loads Out TPG 500 Platform Hull from Singapore 2004).

1.3 Work Process of Slated Construction. On July 26, 2004, British Petroleum (BP) announced it has awarded a $20 million follow-up job to Keppel. Keppel announced that it had delivered the main hull sections of the BP Shah Deniz TPG 500 platform on schedule to BP Exploration (Shah Deniz) Ltd. A year after securing this U.S.$96 million contract. Following the successful completion of this highly complex fast-track project, the joint entity, Keppel FELS and Keppel Offshore & Marine (Keppel O&M) has now received a U.S.$20 million award by BP Exploration (Shah Deniz) Ltd. To integrate these hull sections for the jackup platform. According to Mr. Choo Chiau Beng, Chairman & CEO of Keppel O&M, "Our near market, near customer strategy of having a network of shipyards in strategic locations has enabled Keppel Offshore & Marine, as a service provider of choice, to provide our customers with the shared expertise and total solutions of the Group. "CSC and Keppel FELS are participating with Technip and BP in the execution of this fast-track project." A self-installing jackup drilling/production/quarters platform, the TPG 500 jackup will be the first world-class gas-condensate drilling/production platform to be installed in the Caspian Sea when it is completed in the third quarter of 2006.

For the work on the hull sections, Keppel FELS achieved four million man-hours with zero loss time incident and won a Silver award at the recent Annual Safety Performance Award organised by the Singapore Ministry of Manpower. Mr. Tong Chong Heong, Managing Director/Chief Operating Officer of Keppel Offshore & Marine (Keppel O&M) said, "The TPG 500 clearly reflects how Keppel can execute our contracts successfully amid challenges while maintaining a high standard of safety practices. "To meet the contractual schedule, we had to start production while the detailed engineering work was still being carried out by BP's designer, Technip. This called for the project teams to be very innovative, flexible and meticulous in the management of each phase of the project. "I am glad that the strong teamwork and open communication between Keppel FELS, BP and Technip have facilitated the smooth execution of this project."

According to Dr. Rob Kelly, President of BP Shah Deniz, "I would like to congratulate everyone at Keppel FELS and the overall Shah Deniz Singapore Team for safely and successfully delivering the four main strips of the TPG 500 platform. "It was always going to be a very tough challenge to meet our tight schedule for sailaway and I have been delighted with the drive, commitment and flexibility shown by everyone to meet our expectations. "However, what has pleased me most of all is that this has been achieved safely, with over 4 million man-hours worked on the project without a Day Away From Work Case. "Everyone can be rightly proud of what has been achieved and Keppel FELS have definitely lived up to… [END OF PREVIEW]

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