dolphin apr-jun04.pdf - Jurong Shipyard Pte Ltd

JURONG SHIPYARD
PTE LTD
Business Reg. No.: 199908265G
(A subsidiary of SembCorp Marine Ltd)
Another
Record-Breaking
Success!
Jurong Shipyard achieved yet another
record-breaking feat when it performed the
heaviest skidding weight and the fastest
rig-mating time in the region with the
Development Driller II, the second US$285
million newbuild semi-submersible unit
owned by GlobalSantaFe Corporation
(GSF), on May 19, 2004.
MITA (P) 084/06/2004 April - June 2004
Load-out operation completed within record time of 10 hours
The Development Driller II, a Friede and
Goldman ExD-designed fifth-generation
dynamic-positioning deepwater semisubmersible
rig, was successfully
assembled by the yard within record time.
The skidding process was completed
within 10 hours, while the mating
sequence took merely half a day, the
fastest in the region.
Not a first for Jurong Shipyard, this
achievement echoes the success of the
Development Driller I, a similar semisubmersible
unit constructed using the same
Development Driller II sets fastest rig-mating record of half a day
breakthrough technique in June last year.
Leveraging on the experience and knowhow
gained, the shipyard upped the total
skidding weight to 17,600 tons – 600 tons
heavier than the previous operation.
Jurong Shipyard has positioned itself as an
innovator in the niche building of
sophisticated semi-submersible oil rigs.
This time, the 14,600-ton upper hull, built on
a 3,000-ton skid truss, was outfitted with
more equipment and installations such as
anchor winches and cement units. Despite
the heavier load, the skidding was completed
an hour ahead of its earlier record.
Heaviest skidding weight of 17,600 tons achieved
With the repeat success of its proprietary
load-out and mating-in-dock technique,
The team behind the success

Fresh From The yard
Fast-Track Upgrading
of
Nan Hai Fa Xian
Nan Hai Fa Xian, a 254,642 dwt Floating
Production Storage and Offloading (FPSO)
vessel, is all set to continue exploration at
Huizhou Field, South China Sea, after
completing a fast-track major upgrading
operation at Jurong Shipyard from March 27
to June 2, 2004.
Operation Highlights
• Topside Facilities Upgrading
Scope of topsides upgrading included replacement of process separators, renewal of
pipelines, the installation of new owner-furnished crane and relocation of existing deck
crane, as well as accommodation modification for a further 10 years and an increase in
crew capacity from 90 to 120.
Nan Hai Fa Xian undergoing drydock repairs
The Nan Hai Fa Xian project, one of Jurong
Shipyard’s highest value ship repair jobs, was
awarded in 2003 by the CACT Operators
Group, comprising China National Offshore Oil
Corporation (CNOOC), Agip China B.V.,
Chevron Overseas Petroleum Limited and
Texaco China B.V.
During the 67-day operation, the yard carried
out topside facilities upgrading and
refurbishment, overhaul of the buoyant turret
mooring system and drydocking repairs on the
248.9m x 55.6m x 25.6m FPSO.
Process separators replacement in progress
Renewal of process pipelines underway
• Buoyant Turret Mooring System Overhaul
This comprised the overhaul of main winch and replacement of HPU for connection and
disconnection, reconditioning of existing swivels and renewal of seals, flushing as well as
dismantling and installation of turret production piping. Together with the manufacturer, detailed
inspections were also conducted on the structural connector and connector actuating system.
With excellent teamwork and co-operation from
the owner’s side, Jurong Shipyard’s swift
execution and good safety record garnered
praise from Project Manager Mr Steve Horne.
“We are very pleased with the high standards
of safety and quality delivered. The
professionalism and
capabilities of the
Jurong Shipyard
team contributed to
the successful and
timely completion of
this project despite
its tight schedule,”
said Mr Horne.
This operation marks
Nan Hai Fa Xian’s
Mr Steve Horne
second drydocking at
Jurong Shipyard. Earlier in 1995, it had stopped
over for a 27-day repair and upgrading
operation involving de-bottlenecking, integration
of process equipment, turret modification,
pipeworks and steelworks.
Inspection of bottom turret connector actuating system
• Drydocking Repairs
Major scope of repairs also included
drydocking works, class survey and repairs,
hull bottom plates renewal, steel renewal
totalling 2,500 tons as well as gritblasting and
coating of cargo tanks, water ballast tanks,
produced water tanks totalling 115,000m 2 .
The complete underwater area of ship hull
was also grit blasted and coated totalling
28,000m 2 . Other works included overhaul,
repair and renewal of pipes and valves as
well as equipment, machines and control
system for tanks and in the engine room.
Replacement of Hydraulic Power Unit (HPU)
Shell bottom plate renewal
02

Spotlight
The Heart of Shipping
Posidonia 2004 Exhibition
Jurong Shipyard showcased its globalised
marine engineering capabilities on the
international stage during the Posidonia 2004
“The Heart of Shipping” Exhibition, held from
June 7 to 11, 2004, in the Greek port city of
Piraeus.
The biennial exhibition, held at Piraeus
Exhibition Centre, is one of the largest and
most publicised shows in the marine industry.
This year’s event drew about 16,400 visitors
from diverse sectors in the shipping industry,
including ship owners, ship brokers,
shipbuilders, equipment and machinery
manufacturers as well as service providers
from about 80 different countries.
Another shot for the Posidonia album
Bonds of friendship strengthened
Jurong Shipyard and nine other participating
companies were part of a Singapore team, led
by the Maritime and Port Authority of Singapore
(MPA) and co-ordinated by the Association of
Singapore Marine Industries (ASMI). Heading
a 30-member delegation, Minister of State for
Health and Transport Dr Balaji Sadasivan,
together with MPA CEO Rear Admiral Lui Tuck
Yew, were also there in Piraeus to promote
Singapore as a shipping hub of choice and to
meet up with Greek shipowners and local
exhibitors.
Greece’s Prime Minister Costas Karamanlis officially opens
the Singapore Pavilion, together with Dr Balaji Sadasivan,
Minister of State for Health and Transport.
Visitor turnout to the Singapore-International
Maritime Centre (IMC) Pavilion was very good
and customer response was positive with
shiprepair deals secured. The exhibition also
provided plenty of opportunities for the yard to
expand its networks, forge new alliances and
cement existing ties with partners from Greece
and all over the world.
With the success of Posidonia 2004, Jurong
Shipyard will continue to participate in the next
shipping meet in two years’ time.
Good visitor turnout at the Singapore Pavilion
Tanker sisters on the go
Jurong Shipyard carried out yet another
successful repair operation on sister vessels
Nara and Savannah, 47,172 dwt tankers owned
by Tanker Pacific Management (Singapore)
Pte Ltd this quarter.
Nara and Savannah, both measuring 182.50m
x 32.22m x 19.13m, arrived at the yard on May
28 and June 5, 2004 respectively, to undergo
drydocking repairs and refitting, comprising
overhaul of main engine, generator, valves in
deck, pump room, sea water pumps, and
mountings, cleaning and surveying of auxiliary
boiler and exhaust gas economiser, and
renewal of bottom rudder pintle bush and sea
water pipes. Other works included hull blasting
and painting, tailshaft weardown and aft seal
Networking platform for the maritime community
bonding, anchor repairs, sea chest blasting and
coating, hull anodes installation.
Significant aspects of the repairs involved the
modification of forward mooring arrangements
and the installation of additional pressure
vacuum valves stands. Additionally, Savannah
underwent steel renewal in No. 5 starboard
water ballast tank.
Nara departed the yard on June 10 while
Savannah set off on June 18, 2004, after their
successful repairs. With the jobs done to
satisfaction, Jurong Shipyard was awarded
another project by Tanker Pacific Management
to service Headway, a 152,378 dwt tanker
arriving early July 2004.
Visiting VIPs: (From left) Mr Lim Tau Kok, General Manager
of Neptune Shipmanagement Services Pte Ltd, and Dr Balaji
Sadasivan with Chua Teck Lian, Jurong Shipyard’s Senior
General Manager of Commercial Division
03

Feature
Feature
Largest US$628.8M (S$1.068B) P-54 FPSO Conversion Deal
Barao De Mauá, a 280,000 dwt VLCC, to be converted to
the P-54 FPSO
The P-54 Notice of Award by PNBV was signed
and accepted by Jurong Shipyard on June 17,
2004, in a ceremony held at the Presidential
Palace in Brasilia, Brazil. The shipyard’s largest
order to-date, the FPSO EPC (Engineering,
Procurement and Construction) turnkey
conversion project entails converting the
Exchanging well wishes after the signing
Jurong Shipyard has been chosen by Petrobras Netherlands BV (PNBV), a wholly owned
subsidiary of world-renowned integrated energy company Petrobras SA, as the preferred
contractor for a US$628.8 million (S$1.068 billion) Floating Production Storage Offloading
(FPSO) conversion project.
280,000 dwt Very Large Crude Carrier (VLCC)
Barao De Mauá to a FPSO platform, to be
renamed Petrobras 54 (P-54).
Work on the P-54 is expected to commence in
August 2004, with Jurong Shipyard undertaking
the marine hull conversion and sister shipyard
Mauá Jurong handling the fabrication and
subsequent installation, integration and
commissioning of topsides production modules
in Brazil.
Don Lee, General Manager of Offshore Division, signing the Notice
of Award for the P-54 project, witnessed by (from left) Rio de Janeiro
Governor Rosinha Matheus, Brazil’s Minister of Mines and Energy
Dilma Rousseff and Petrobras President Mr José Eduardo Dutra
Scheduled for completion in 38 months, the
vessel will be one of the largest converted
FPSO units in the world, capable of full capacity
oil production and treatment at 180,000 bpd,
gas compression capability at 6,000,000 m3/d
and water injection capability at 39,000 m3/d.
Expected to operate for 25 years without
drydocking, the P-54 will be deployed on site
in the Roncador Field, Campos Basin, offshore
Brazil, where it will be moored by a Spread
Mooring System (DICAS) with 20 mooring lines,
composed together by chain/ polyester rope/
chain segments. Oil will be produced through
13 oil production wells and 8 water injection
wells, via an external portside balcony. The
gas will be exported to shore through a 10”
flexible riser connected externally to the portside
of the FPSO.
Don Lee congratulated by Brazil’s President Luiz Inacio Lula
da Silva (third from left)
Strong partnership - Petrobras President Mr José Eduardo
Dutra and Don Lee enjoying good rapport
“Jurong Shipyard will rely on its immense
experience and its accumulated knowledge
to positively and confidently execute the
latest P-54 project within schedule and of
high quality as demanded by Petrobras.”
– Mr Don Lee,
General Manager of Offshore Division
Taking the Lead in
Offshore Conversion
A world leader in offshore conversion, Jurong Shipyard’s proven capabilities can
be attested by its track record of successful FPSO, FSO and FPU deliveries. It has todate
converted the most number of vessels for Petrobras, with the latest P-54 award
being its seventh floating unit conversion for Brazil since 1997.
Jurong Shipyard set the standards for offshore
conversion with a series of large-scale
conversions for Brazil’s offshore oil and gas
industries – the P-37 FPSO, the P-38 FSO
and P-40 FPU. The projects, involving the
conversion of the P-37 from the 270,000 dwt
VLCC Friendship, the P-38 FSO from the
261,729 dwt VLCC World Eminence, and the
P-40 FPU from the world’s largest semisubmersible
DB-100, were simultaneously
carried out from 1998 to 2000.
Even though the demands were exacting,
Jurong Shipyard, through meticulous planning
and skilful execution, successfully delivered
the floating units in accordance with the high
quality standards set by the owners and
Petrobras. The P-37 FPSO, christened in
November 1999 and delivered to Brazil’s
Maritima Petroleo e Engenharia Ltda in early
2000, set the record of producing its first oil
within two months of its deployment to Marlim
Field, Campos Basin, offshore Brazil.
The P-38 and the world’s largest floating unit
P-40, respectively owned by Petro Dia 1 and
Petro Dia 2 of Japan’s Mitsubishi Corporation,
were christened during a double christening
ceremony in August 2000. The pair are
currently on charter to Petrobras’ subsidiary
Brasoil at Brazil’s South Marlim Oilfield.
The yard’s FPSO conversion track record
was given another boost in 2003 with the
delivery of the FPSO Fluminense to MODEC
International LLC. The FPSO, converted from
the 356,000 dwt TT Sahara, is now on lease
to Shell Brazil Ltda for service at the Bijipura
/ Salema Oilfields in Brazil.
The same year also saw the successful
marine conversion of the P-43 FPSO from
the 270,000 dwt VLCC Stena Continent for
Kellogg Brown and Root Inc (USA). The
FPSO, bound for the Brazil’s Barracuda
Oilfield, is now undergoing topsides
commissioning and testing in Mauá Jurong,
Brazil, with delivery scheduled in the third
quarter of 2004.
Another FPSO, the P-50, is set to sail for
Mauá Jurong in early July after completing
its marine conversion in Jurong Shipyard.
Converted from the 280,000 dwt VLCC Felipe
Camarao, the FPSO is expected to arrive at
the Brazilian yard in the third quarter of 2004
for topside modules installation, integration
and commissioning. It is destined for Brazil’s
Albacora Leste Oilfield upon its delivery to
Petrobras Netherlands BV scheduled in the
second half of 2005.
Destination: Brazil
P-37 FPSO
Field: Marlim Oilfield, Brazil
Storage Capacity: 2 million barrels of oil
Production Capacity: 150,000 b/d oil; 4.65 MMN m 3 /d gas
Water Depth: 905m
P-40 FPU
Field: South Marlim Oilfield, Brazil
Storage Capacity: 2 million barrels of oil
Production Capacity: 150,000 b/d oil; 6.0 MMN m 3 /d gas
Water Depth: 1,080m
FPSO Fluminense
Field: Bijupira / Salema Oilfields, Brazil
Storage Capacity: 1.2 million barrels of oil
Production Capacity: 92,000 b/d oil; 2.12MMN m 3 /d gas
Water Depth: 800m
P-50 FPSO
Field: Albacora Leste Oilfield, Brazil
Storage Capacity: 2.8 million barrels of oil
Production Capacity: 180,000 b/d oil; 6.0 MMN m 3 /d gas
Water Depth: 1,240m
P-38 FSO
Field: South Marlim Oilfield, Brazil
Storage Capacity: 2 million barrels of oil
Water Depth: 1,020m
P-43 FPSO
Field: Barracuda Oilfield, Brazil
Storage Capacity: 2 million barrels of oil
Production Capacity: 150,000 b/d oil; 6.0 MMN m 3 /d gas
Water Depth: 800m
04
05

Spotlight
Mauá Jurong
welcomes BG Yeo
Mauá Jurong, Jurong Shipyard’s sister yard
in Brazil, hosted BG (NS) George Yeo,
Minister for Trade and Industry, and his
business delegation when they visited Brazil
on June 6 and 7, 2004.
Despite his busy schedule, the minister took
time to meet up with Singaporeans working
in Rio de Janeiro and their families at a
get-together dinner on June 6, 2004. The
relaxed and casual occasion saw BG Yeo
sharing experiences with the 10 Jurong
Shipyard employees currently on overseas
posting to Mauá Jurong.
Briefing session during the speedboat cruise
Enjoying the sea breeze
Arrival at Mauá Jurong Quay
During the tour, BG Yeo praised the yard’s
high quality standards and comprehensive
safety management systems as well as its
offshore conversion capabilities. He also
commended the yard for making speedy
progress in its current jobs – including the
topsides commissioning and testing of the
P-43 FPSO and the fabrication of P-50 FPSO
topside production modules.
Get-together dinner: BG Yeo with Jurong Shipyard employees
on posting to Mauá Jurong
The minister and his delegation also visited
Mauá Jurong Shipyard, on June 7, 2004.
After a speedboat cruise around the scenic
and mountainous Guanabara Bay, the guests
were warmly received by the yard’s senior
management and given a guided tour around
the shipyard and a short presentation on key
business operations.
A robust exchange of ideas
Having a good time of interaction
On a yard tour led by Mauá Jurong’s Senior Project
Manager John Chen
Leaders in Mauá: (From left) Don Lee, GM of Jurong Shipyard’s Offshore Division, BG (NS) George Yeo, Minister for Trade
and Industry, Mauá Jurong’s Chairman Omar Peres, Executive Director Chan Nai Eng, Marketing Director José Simas, and
former Executive Director Chew Yam Poey, who is now the Executive Director of Jurong Machinery & Automation.
At the P-43 project site
06

To nurture capable young talents for Singapore's
marine industry, SembCorp Marine, Jurong
Shipyard's parent company, has given out four
undergraduate scholarships worth $10,000
each to promising final-year Mechanical and
Production Engineering (MPE) students from
Nanyang Technological University (NTU).
Jurong Shipyard and sister yard Sembawang
Shipyard offered two scholarships each as part
of the Association of Singapore Maritime
Industries (ASMI) Marine & Offshore
Undergraduate Scholarship Programme. The
scheme is open to all full-time, final year MPE
students who opted for the Marine and Offshore
Engineering final-year specialisation - a new
programme offered by the university.
Prior to the scholarship application, a briefing
and exhibition was jointly organised by NTU,
Economic Development Board, ASMI and
participating companies at the university's
premises on May 22, 2004 to give students a
clearer idea of the marine industry.
The recipients were chosen after a stringent
selection and interview process based on
People Focus
Nurturing Leaders of
Tommorrow
Explaining the work scope in the shipyard
academic excellence and outstanding
co-curricular activities record. Upon graduation,
students are required to serve a one-year bond
in the respective yards.
Re-Training Workers for the
Marine Industry
Interviewing a potential candidate
To encourage more Singaporeans to join
the yard workforce, Jurong Shipyard is
participating in the Place n Train (PnT) Marine
Re-Skilling for Employment Programme, to
re-train displaced local workers from other
industries for the marine trade.
Under the programme, jointly initiated by the
Association of Singapore Marine Industries
(ASMI) and the Workforce Development
Authority (WDA), selected candidates would
receive skills training in one of the five tracks
- Marine General Welding, Marine Mechanics,
Marine Pipe Fitting, Marine Steel Fitting and
Marine Electrical Technology.
As part of this effort, a job fair cum selection
and recruitment exercise, was held on May 28,
2004 at South West Community Development
Sharing with students the career prospects in the
marine industry
Council (CDC). About 110 people turned up
for the event, which featured an exhibition,
presentations as well as selection interviews
by participating yards to select a common
pool of workers for the scheme. A total of
48 candidates were eventually selected for
the programme.
Following the exercise, WDA and ASMI
then assigned selected workers to the
various yards for employment and two
months of full-time marine trade skills
training. Jurong Shipyard's first batch of
PnT workers have begun their eight-week
training on June 21, 2004.
Enhancing Safety Awareness
Always ready and on guard - that is our shipyard’s emergency response
motto. To boost the safety awareness of our employees, a series of activities
were organised within the yard this quarter.
Aimed at familiarising employees with proper
crisis response procedures, a fire drill and a
bomb evacuation drill were conducted at the
Pulau Samulun yard office and the Tanjong
Kling corporate office respectively on May 5
and 14, 2004.
Corporate Office emergency bomb evacuation exercise
A Safety Workshop was also held
Fire evacuation drill in the yard
in the yard on June 25, 2004.
Attended by senior management of Jurong Shipyard and other
SembCorp Marine yards, including Sembawang Shipyard, Jurong
SML Shipyard and PPL Shipyard, the workshop saw the
presentation of the Group Safety Action Plan and the sharing
of safe work practices for various yard activities, such as hot
work and spray painting.
Group Safety Workshop
07

Happenings
May Day 2004
Gold Award
Jurong Shipyard’s continuing commitment
towards good union-management relations and
employee welfare, training and development
has earned it the Plaque of Commendation
(Gold) awarded by the National Trades Union
Congress (NTUC).
The plaque was presented to Mr Wong Weng
Sun, Jurong Shipyard’s Executive Director,
by Mr Lim Boon Heng, NTUC’s Secretary-
General, during the May Day Dinner held at
Suntec City Convention Hall on April 29, 2004.
Congratulations to Jurong Shipyard’s
union-management team! Let’s continue
to work together towards harmonious
labour relations and organisation
excellence!
Jurong Shipyard’s Executive Director Mr Wong
Weng Sun receiving the Plaque of Commendation (Gold)
from Mr Lim Boon Heng, NTUC’s Secretary General
Singing session - Union and management in harmony
Partner in
Organisation
Excellence
Jurong Shipyard was accorded the Partner
in Organisation Excellence Award by
SPRING (Standards Productivity and
Innovation Board) Singapore on May 20,
2004, in recognition of its contributions to
organisation and innovation excellence.
Commitment to Employee Welfare
Union-Management Partnership
With a shared vision of promoting employee
welfare, Jurong Shipyard has been working
closely with the branch union since its
inception under the Pioneer Industries
Employees’ Union (PIEU) in 1969. After the
PIEU was dissolved in 1981, this close unionmanagement
relationship continued when
the branch union came under a new
organisation, the Shipbuilding and Marine
Employees’ Union (SMEEU).
Over the years, the management has been
actively supporting union activities through
monetary contributions and community
welfare projects, including the co-sponsoring
of the union’s special welfare fund which
provides assistance for members through
book vouchers, educational scholarships for
their children, hospitalisation claims and
medical screening. The strong synergy is
further demonstrated when the management
provided two permanent union offices within
its premises to give members easy access.
Reflecting its belief in people empowerment,
the shipyard set up the Jurong Shipyard
Multi-Purpose Co-operative Society in 1967,
allowing the union to manage the
transportation, canteens and a convenience
Instead of the usual morning exercise,
employees gathered at the corporate office
carpark on Saturday, May 8, 2004, for a
fun-filled boxercise session in their sports
gear. This session organised by Jurong
Shipyard’s Workplace Health Promotion
(WHP) Committee aims to encourage
employees to exercise regularly and to lead
a well-balanced healthy lifestyle.
store within its premises. The first such cooperative
of its kind to be registered in
Singapore, its role today has expanded to
include the payment of dividends and the
issue of bonus shares as well as gift vouchers
to members.
People-centred Focus
To develop employees to their full potential
the management organises numerous
courses, ranging from tradesmen skills-based
training to personal enrichment courses.
Beyond professional development, the
shipyard also encourages employees to lead
healthy and active lifestyles through its
Workplace Health Program. This
commitment to employee health has won
the company the Singapore Health Award
(Silver) for four consecutive years, from 2000
to 2003.
Beyond the organisational level, Jurong
Shipyard plays an active role in supporting
the nation and community. Towards this end,
it has enthusiastically responded to NTUC’s
many efforts for job redesign and job
matching to aid the unemployed public, as
well as hosted educational visits for NTUC
leaders to update them on developments in
shipyard operations.
Building health & wellness
Human Resource Training
Manager Lim Kwok Kuen
receiving the Partner in
Organisation Excellence
Award from Dr Joseph
Pious, SPRING
Singapore’s General
Manager, Productivity and
Innovation Group
The committee also took an active lead in
organising activities like a First Aid Course
and a Colorectal Cancer Awareness Talk
this quarter on April 30 and June 14, to
equip employees with skills and knowledge
for maintaining health and wellness.
Promoting health and fitness in the yard
08