Aibel (Thailand) Ltd. Module Business Aug 2011
Aibel Thailand - Scope of Services Hydrocarbon discovery
Feasibility/ Concept studies
FEED
Engineering
Construction
Decommissioning
Aibel Thailand
Aibel Thailand value chain in oil services Detail engineering Procurement Fabrication System Completion (MC & Commissioning)
© Aibel 2011
MMO
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Aibel (Thailand) Ltd. The module business was opened in Thailand in 1999 to give Aibel in-house capability to deliver high quality, competitively priced modules on time to their clients. With its innovative construction solutions, Aibel have delivered an extensive number of successful projects over the past 12 years. Aibel are delivering a complete range modules for clients and their projects around the world. Aibel achieves it’s success with high standards of Safety, Quality and on time deliveries. Aibel is with it’s proven track record and industry technology experience ready to provide you with the best in module fabrication and project execution. Headquarter - Stavanger
Location
© Aibel 2011
Norway UK
150
Singapore
300
Thailand
200
Total
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4000
4650
About Aibel (Thailand) Ltd. Yard capacity 15,000 Tons of Modules per Year Procurement : Aibel has frame agreements with & pre-qualified many suppliers. Largest Module – up to 15,000 Tons per single unit, dependent on foot print Pressure Vessels and Piping to PED and other local requirements, Welding procedures for CS, SS, Duplex, SuperDuplex, 6MO, Titanium etc Manhours per year: 4,000,000 – 6,000,000
© Aibel 2011
Pressure Vessels according to ASME & PD 5500, Painting, up to and including Norsok spec
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Aibel (Thailand) Ltd. – Services/Products Services: Construction management Planing Procurement Pre-fabrication Construction/fabrication Assembly and installation Mechanical completion Pre-commissioning Commissioning If you are considering to modularize your plant, we can provide you with advice and solutions.
© 2008 © Aibel 2011
Capabilities:
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FPSO Topsides Gas Dehydration Packages CO2 Removal Packages Sea water Packages Water injection Packages Chemical injection skids Gas compression Packages Power generation Packages Electrical buildings Living quarters Modules -5-
LNG Modules (Regas) LNG Process modules Process modules (all types) Large sized structures
Facilities - Aibel Laem Chabang Assembly Yard Land area: 100,000 Sqm Covered area: 1,800 Sqm Office 1,450 Sqm Warehouse 500 Sqm Canteen 1,500 Sqm Subcontractor office Yard Ground Bearing Strength: 15 T/Sqm Distance to loadout: 650 m Road restrictions: Overhead unlimited , 10 T/Sqm Electric: 3 Phase, 380V. 2 x 1500 Amp 1 x 400 Amp Potable water Security: Port / Customs security + Aibel Security
WH#1
© Aibel 2011
Office, Warehouses and Lay-down Area
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WH#2
Fabrication - Area • Fabrication area: • Covered area:
80,000 Sqm 3,500 Sqm Office 1,100 Sqm Warehouse 1,400 Sqm Canteen
Laydown
• Laydown area : 7,500 Sqm • Bearing Strength: 15 T/Sqm • Electric: 3 Phase, 380V. 2 x 1500 Amp 1 x 400 Amp • Water: Potable Yes • Gantry crane : 25 T @ 4 • Gantry crane : 10 T @ 2 • Over head crane : 16 T @ 2 • Over head crane : 10 T @ 1 • Mobile crane : 35 T @ 1 • Mobile crane : 25 T @ 1
© Aibel 2011
Yard 1
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Fabrication Facilities
© Aibel 2011
At the fabrication shop most of the work is done indoor. There are two large covered bays which are used for steel structure. There are two separate shops for piping i.e. one shop for carbon steel and the second for white metals.
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Welding
© Aibel 2011
Aibel have already qualified welding procedures which will cover for almost all welds on FPSO projects. Aibel will re-qualify and issue certificate for all of the welders who will work on the projects. Aibel will prepare a weld map with joint numbering. Aibel will use an external third party company to do NDE. Aibel will produce a weekly report showing defect rate.
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Welding – NDE Phased Ray On current project Aibel has started to use ”Phased Array” instead of ”RT”. The main advantage with this is not having to use a radioactive source and the fact that this testing can be done while other work continues. 1 crew can shoot 30-40 welds a day.
PMI (Positive Material Identification) is used to confirm the correct electrodes were used
ATH will follow the specification for type and amount of NDE testing. ATH will use an independant 3rd party company to do this testing.
Ultrasonic Testing
© Aibel 2011
Magnetic Particle Inspection
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Cleaning/Blasting/Surface Protection & Fireproofing For Cleaning/Blasting/Painting Aibel will have trained their people to Norsok specification. Aibel will follow clients spec on the project.
© Aibel 2011
Aibel will prequalify all blasters, spray painters and touch up painters.
Bresle sampler (salt test) according to ISO 8502-6 - 11 -
Painting & Fire proofing The facilities and equipment were set-up with advice from Aibel Norway. Major upgrade to the facilities were done in 2011.
ATH have applied PFP on several of their previous projects. Aibels supervisor have been trianed / approved by International paint for the application of Chartek 7.
© Aibel 2011
Aibel together IP or Jotun representative will do adhesion test as per contract spec.
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Load-out jetty The jetty is constructed by using 2,000 ton caisson blocks
+ 3.00 MSL + 0.00 MSL
17.00 m
- 2.48 MSL = LLW.
- 16.00 MSL 13.50 m
Load-out jetty
© Aibel 2011
Laem Chabang Assembly Yard - Wharf Details - Size - Bearing Capacity T/m² - Tidal Range (Mhhw-Mllw) - Water at mean low low water
(L) 500 m, (W) 150 m 10 T/m² 2m 16 m
Maximum vessel that can be accommodated at the nominated water access point
300 m, 16 m mll draft
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Moving – Weighting / Inland transport / Roll on
© Aibel 2011
Aibel will use hydraulic jacks / load cells and SPMTs supplied by either Mammoet or ALE. Both of these companies have operations in Thailand and have loaded out modules for Aibel previously.
Route Leamchabang port to Singapore
Route Leamchabang port to Korea
Self Propelled vessel 3-5 Days Tug and Barge 5-7 Days
Self Propelled vessel 10 -12 Days Tug and Barge 20 Days
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© Aibel 2011
Track Record
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Previous Projects - Process Module Bergesen Offshore, Norway ‘Sendje Ceiba’ • Water Injection M 50, • Process Separation P 2 M 11 •Subsea Utility Module M • Process Separation P1 M 10 • Process Separation P1 M10
34 x 24 x 20m, Weight 700T 28 x 22 x 11m, Weight 488T 28 x 19 x 8m, Weight 450T 28 x 16 x 8m, Weight 510T 28 x 16 x 8m, Weight 510T
© Aibel 2011
Aibel TH Scope of Work • Steel, Piping, E/I Bulk Procurement • M/E/I Detailed Engineering • Structural steel, Piping Fabrication • Vessels engineering & supply • E/I Install and Pre-Commissioning • Transport modules to SG
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Previous Project - Process Module ConocoPhillips Corocoro FSO • Riser Porch 19 x 8 x 13m, Weight 58T • Seawater Treatment Module 30 x 25 x 8m, Weight 450T • Pig Launcher Skid 15 x 7 x 6m, Weight 50T
© Aibel 2011
Aibel TH Scope of Work • Structural Detailed Engineering • Steel/Piping/E&I Bulk & Coating Procurement • Structural steel & Piping Fabrication • E/I Installation, Pre-commissioning • Coating • Transport to South Korea
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Previous Projects - Process Module Woodside (Chinguetti) Bergesen Offshore, Norway • Process Separation M12 28 x 18.4 x 10m, Weight 465T • Water Injection M50 28 x 11 x 19m, Weight 288T • Gas Compression M60 28 x 17 x 17m, Weight 852T
© Aibel 2011
Aibel TH Scope of Work • Detailed Engineering • Steel, Piping, E/I Bulk Procurement • Structural steel, Piping Fabrication • Vessels Supply • E/I Install and Pre-Commissioning • Control Room Design & Supply including HVAC and fit out • Transport module to SG
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Previous Projects - Seawater Treatment Package Canadian Natural Resources (West Espoir) Prosafe Production Singapore Seawater Treatment Skids & Dearator • Skids: 11,5 x 3.5 x 5m , Weight 35T • Deaerator: 3m Diameter, 15 m High, Weight 15T
Aibel TH Scope of Work
© Aibel 2011
Steel, Piping, E/I Bulk Procurement Structural steel, Piping Fabrication Vessels Engineering & Supply E/I Install and Pre-Commissioning
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Previous Projects - Process Module Statoil (Ormen Lange) VA Gastech, Norway Gas Compression Skid Aibel TH Scope of Work
Detailed Engineering Steel, Piping, E/I Bulk Procurement Structural steel, Piping Fabrication Vessels Engineering & Supply E/I Install and Pre-Commissioning Transport module to Norway
© Aibel 2011
16m Long, 7.5m Wide, 8m High, Weight 100T
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Previous Projects – Process/Power & Wellhead Modules Statoil (Volve) Maersk Contractors Process/Power Module & Wellhead module Aibel TH Scope of Work
Detailed Engineering Steel, Piping, E/I Bulk Procurement Structural steel, Piping Fabrication Vessels Engineering & Supply E/I Install and Pre-Commissioning Loadout module to ship - Norway
© Aibel 2011
80m Long, 20m Wide, 25m High, Weight 4,400T
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Previous Projects - Topside Modules Reliance - Indian Oil Company Aker Floating Production - Smart 1 U10 – Power Module (Steam Turbine) U11 – Power Module (Gas Turbine) U20 – Local Control Room Module U70 – Utility Module
182 T 295 T 440 T 290 T
Aibel TH Scope of Work
© Aibel 2011
Steel, Piping and E/I Bulk Procurement Structural steel construction HVAC & Architecture Load out and Sea-fastening
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Previous Projects - Topside Modules Woodside (Vincent) Maersk Contractors 8 Modules + Central Pipe Rack Weight 7,400T • M99 – Piperack • M30 – Flare Module • M71 – Closed Drain Module • M10 – Oil Separation Module • M11 – LP Oil Separation & PW Module • M70 – Utility Module • M85 – Power Generation Module • M60 – HP Gas Compression Module
Aibel TH Scope of Work
© Aibel 2011
• Area & Detail Engineering • Steel, Piping, E/I Bulk Procurement • Structural steel, Piping Fabrication • Vessels Engineering & Supply • E/I Install and Pre-Commissioning • Load-out module to barge - Singapore
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Woodside (Vincent) Maersk Contractors
M20 – 355 Tons 15 x 12 x 11m
© Aibel 2011
M85 – 1,635 Tons 34 x 23 x 21m
M10 - 1,235 Tons 28 x 21 x 15m
M60 - 1,392 Tons 34 x 20 x 15m
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M11 - 1,005 Tons 18 x 15 x 18m
M70– 721 Tons 23 x 15 x 19m
Previous Projects - Topside Modules Petrobras Prosafe Production Pte. Ltd
M26B
FPSO Cidade De Sao Mateus •M26A - Manifold Module 44.5 x 10 x 16 m, 850 tons •M26B - Manifold Module 44.5 x 10 x 16 m , 956 tons •M23 - Gas Export Module 22 x 5.5 x 16 m, 177 tons •M34 - Chemical Injection Module 15 x 13 x 11.5 , 198t •M55 - Heating Medium Equip 12.3 x 9.9 x 16 m , 318t
Aibel TH Scope of Work • Steel, Piping and E/I Bulk Procurement • Structural steel,Piping fabrication • E/I Install and Pre-Commissioning • Loadout and Sea-fastening M23
M55
© Aibel 2011
M34
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M26A
Previous Projects - Topside Modules Petrobras (TUPI) MODEC Offshore Production Systems FPSO Cidade de Angra dos Reis MV22
Total Weight 10,000
Feb 09 – Apr 10 4P : CO2 Injection
5P : Gas Re-inject / Comp
3P : HP Separation
• 1P – KO Drum Skid • 2P – LP Separation Module • 3P – HP Separation Module • 6P – Access & Water Injection Mod. • 1PW, 5&6PW – Manifold & Riser Porch • M99/1 – Interconnecting Spools • 4P – CO2 Injection Module • 5P – Gas Reinjection/Compression Module • 2PW, 3&4PW – Manifold & Riser Porch • M99/2 – Interconnecting Spools
6P : Water Injection
2P : LP Separation 6PW : Riser Porch S6
1P : Flare scrubber
FPSO Cidade De Angra Dos Reis – Portside Modules) 5PW : Riser Porch S5
Aibel TH Scope of Work
© Aibel 2011
Steel, Piping, E/I Bulk Procurement Structural steel, Piping Fabrication E/I Install and Pre-Commissioning Loadout module to ship/barge – Laem Chabang
4PW : Riser Porch S4
1PW : Riser Porch S1
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2PW : Riser Porch S2
3PW : Riser Porch S3
Modec’s - FPSO Cidade de Angra dos Reis MV22 (TUPI)
© Aibel 2011
Modules in the yard
3P Module
2P Module
1PW Module - 27 -
© Aibel 2011
Modec’s - FPSO Cidade de Angra dos Reis MV22 (TUPI)
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TUPI Modules for Modec
3P : HP Separation 1,205 ton
4P : CO2 Injection 832 ton
5P : Gas Re-inject / Comp 767 ton
6P : Water Injection 978 ton
6PW : Riser Porch 193 ton 2P : LP Separation 985 ton
© Aibel 2011
1P : Flare scrubber 155 ton
1PW : Riser Porch 520 ton
FPSO Cidade De Angra Dos Reis – Portside Modules
3PW : Riser Porch 811 ton
2PW : Riser Porch 695 ton - 29 -
5PW : Riser Porch 695 ton
4PW : Riser Porch 740 ton
Current Projects - Topside Modules Petrobras (Guara) Modec and Toyo Offshore Production Systems Pte Ltd
1P-1 ELECTROSTATIC TREATER 1 SKID
1P-2 ELECTROSTATIC TREATER 2 SKID
1P-4 ELECTROSTATIC TREATER STAIR TOWER
FPSO Cidade de Sao Paulo MV23
Total Weight 8,000 Skid
3P-1 3P-2 3P-3 4P-1 4P-2 2S-1 2S-2 4S-1 4S-2
© Aibel 2011
1P-1 1P-2 1P-4 2P-1 2P-3 2P-4 5P-1 5P-2 3S-2 3S-3 3S-4
2P-1 FREE WATER KO DRUM +TEST SEPARATOR SKID
2P-3 HEAT EXCHANGER SKID
2P-4 SUB-PIPE RACK
3P-1 CO2 COMPRESSION SKID A
3P-2 CO2 COMPRESSION SKID B
Oct 10 – Sept 11
Description
Compressor Skid CO2 COMPRESSION SKID A CO2 COMPRESSION SKID B CO2 COMPRESSION STAIR TOWER REINJECTION COMPRESSION SKID A REINJECTION COMPRESSION SKID B MAIN COMPRESSION A SKID A MAIN COMPRESSION A SKID B MAIN COMPRESSION B SKID A MAIN COMPRESSION B SKID B Process Skid ELECTROSTATIC TREATER 1 SKID ELECTROSTATIC TREATER 2 SKID ELECTROSTATIC TREATER STAIR TOWER FREE WATER KO DRUM +TEST SEPARATOR SKID HEAT EXCHANGER SKID SUB-PIPE RACK COOLING MEDIUM EXCHANGER + SEA WATER INJECTION PUMP A / B SKID COOLING MEDIUM SKID MOLECULE SIEVE ADSORBER SKID REGEN GAS HEATER / COOLER / FILTER / BLOWER SKID DEW POINT CONTROL SKID
1st Shipment 1-Aug-11
WEIGHT (MT)
3P-3 CO2 COMPRESSION STAIR TOWER
2nd Shipment 1-Sept-11 3S-4 DEW POINT CONTROL SKID
668 711 32 418 416 514 453 530 510 392 366 41 674 148 166 482 188 705 148 122
3rd Shipment 1-Oct-11
4P-1 REINJECTION COMPRESSION SKID A
3S-3 REGEN GAS HEATER / COOLER / FILTER / BLOWER SKID
3S-2 MOLECULE SIEVE ADSORBER SKID
FPSO Cidade De Sao Paulo MV-23
4S-2 MAIN COMPRESSION B SKID B
4S-1 MAIN COMPRESSION B SKID A
2S-2 MAIN COMPRESSION A SKID B
2S-1 MAIN COMPRESSION A SKID B
5P-2 COOLING MEDIUM SKID
5P-1 COOLING MEDIUM EXCHANGER + SEA WATER INJECTION PUMP A / B SKID
Aibel TH Scope of Work
Steel, Piping, E/I Bulk Procurement Structural steel, Piping Fabrication E/I Install and Pre-Commissioning Loadout modules to along ship – Laem Chabang
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4P-2 REINJECTION COMPRESSION SKID B
Current Projects – Fixed Platform Statoil (Gudrun)
Total Weight 6,000
May 11 – Aug 12
• M20 – Wellbay • M30 - Process Area 1 module L(m) 52 x W(m) 27 x H(m) 22
Aibel TH Scope of Work
© Aibel 2011
Structural steel, Piping Fabrication Equipment Installation Surface Protection Insulation E/I Install and Pre-Commissioning
Module
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Description
WEIGHT (MT)
F-00
Flare Stack
309
M20
Wellbay General Area
1,736
M30
Process General Area
3,074
Aibel Thailand - HSE Statistic 2008-2010 2008
2009
2010
2011 (April)
remarks
Fatal accidents
0
0
0
0
Including Subcontractors
Lost Time Incident
1
1
1
0
Including Subcontractors
Restricted Work Cases
2
1
0
0
Including Subcontractors
Medical Treatment Cases
5
11
5
3
Including Subcontractors
1.08%
0.71%
0.79%
0.62%
Only own employees
823
2,085
1,916
1,943
Including Subcontractors
1,158,083
2,431,440
2,394,603
1,084,042
Including Subcontractors
LTIR (Loss Time Incident Rate)
0.86
0.41
0.42
0.00
Per 1,000,000 hours
TRIR(Total Recordable Incident Rate)
6.91
5.35
2.51
2.77
Per 1,000,000 hours
Year
Sickness absence Hazard reports/Unsafe Conditions
© Aibel 2011
Total working hours
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Yard Standard – ISO Certification Aibel Ltd. (Thailand) were accredited to: -ISO 9001:2008 on 07-Aug-06 -OHSAS 18001:2007 on 21-Dec-06 -ISO 14001:2004 on 18-Dec-07
Upgraded certification ISO 9001 : 2000 to ISO 9001 : 2008 and OHSAS 18001: 1999 to OHSAS 18001: 2007
Accredited for the following activities:
© Aibel 2011
The detailed engineering, bulk procurement and project management of manufacturing onshore and offshore modules and facilities, consisting of fabrication, assembly, installation, precommissioning and commissioning of structure, piping, vessels, mechanical equipment, electrical and instrumentation systems.
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© 2008 © Aibel 2011
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