Season for ferries - · PDF fileBaltic Sea, the North Sea, the En-glish Channel and the entire north- ... Over two million manhours without accident on FPF-1 FPU project Frequent visitor

Season for ferries

Photo: Jakub Bogucki

Customer Magazine ISSUE 1 (13) 2014

Blitz on scrubbers

Heavy lifts in the heights

Petrofac awarded us

DFDS entrusted to us scrubbers installation on-board it’s ships againPages 3 - 5

Key milestone on the FPF-1 project achieved. Heavy equipment lifted up!Pages 17 - 18

Over two million manhours without accident on FPF-1 FPU projectPage 19in

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remontowarepair&conversions

customermagazineISSUE 1(13) March 2014

During January 2015, new environ-mental regulations will come into force which will be of crucial signifi-cance to the shipping industry in the Baltic Sea, the North Sea, the En-glish Channel and the entire north-ern-European transportation net-work.

Under these new environmen-tal regulations, ships operating in these areas will only be able to use oil with a maximum of 0.1% sulphur. Such oil is significantly more expen-sive than oil with 1% sulphur, which is commonly used today. Fuel pric-es will therefore become much more expensive and subsequently increase sea transport costs. This could potentially lead to freight be-ing forced onto European roads and result in an increase in road congestion and other environmen-tal problems.

It means something very import-ant for fleet owners and operators. The time is inexorably coming up. Shipowners sailing within the SECA must do something to follow the new rules. In this case – they have to invest in scrubber systems instal-lation on-board the ships they oper-ate, otherwise they may go out of business. For this reason they prob-ably stay awake long into the night, since it’s a scene from their worst nightmare…

But, there is nothing to be afraid of. We have recognized the prob-lem which these owners have faced consulting them and suppliers of

marine equipment and marine envi-ronment protection systems as well at a very early stage.

We are thus ready to assist own-ers and operators with conversions, upgrading and retrofitting projects involving any equipment, upgrade design or system of choice brought by our customers. We are ready to come up with solutions and to ac-complish scrubber systems retrofit-ting jobs smoothly.

In July and August 2013 we in-stalled Alfa Laval PureSOx exhaust gas cleaning systems aboard four DFDS Seaways ro-ro ships. That operation was followed by anoth-er scrubbers installation in Octo-ber 2013 on a large double – ended car – passenger ferry operated by Scandlines.

Recently, DFDS has entrusted to us scrubbers installation on-board it’s seven further vessels (see de-tails on pages 3 – 5). Some expe-rienced European shipyards were considered for this job, but even-tually all the vessels have gone to Remontowa. DFDS has trusted us again.

And now it’s like in this famous rock song by Europe. “The Final Countdown” has begun. The less time remain to the “zero” day, the more owners have a blitz on scrub-bers! We have knowledge, experi-ence, skilled workforce and facilities. And we have the last minute offer, however still available.

You can trust us, too.

It’s the final countdown

Remontowa Repair & Conversion is a quarterly customer magazine of Remontowa Shiprepair Yard, member of Remontowa Holding S.A. Publisher: Temat Ltd., Na Ostrowiu 1, 80-958 Gdańsk, Poland.Editor-in-Chief: Grzegorz Landowski. Phone: +48 58 307 17 90, e-mail: [email protected] content of the magazine (with the exception of photos) may by reproduced provided the source.

We have a blitz on scrubbers!We assist DFDS in following an innovative course to meet the new sulphur rules

Having in our track record scrubber systems installed onboard DFDS’s ships in 2013, Remontowa has been entrusted with this task by the same owner again.

DFDS founded in 1866, headquartered in Copenhagen and listed on NASDAQ OMX Copenhagen is one of the largest fer-ry and ro-ro operators in Northern Europe. With a fleet of 42 passenger/car ferries and freight only ro-ro’s, the company de-livers to over 8,000 customers high performance and superior reliability through shipping & port terminal services, and trans-port & logistics solutions. For more than five million passen-gers, many travelling in their own cars, DFDS provides safe overnight and short sea ferry services. It employs some 6,000 people, located in offices across 20 countries.

The company applies a pro-active policy having defined its own strate-gy of transition to new sulphur rules. And Remontowa largely contributes to the process of getting DFDS ready for new emission regulations.

Victoria Seaways, one of the seven ships to be fitted with scrubbers at Remontowa during preparations for this task in March 2014. Photo: Jerzy Uklejewski

3 We have a blitz on scrubbers!

8 Season for ferries

14 We are a team!

15 Safe Scandinavia undocked

17 Heavy lifts in the heights

19 Petrofac awarded us!

6 The Boskalis ships palette

12 We’ve breathed new life into mature ships

We assist DFDS in following an innovative course to meet the new sulphur rules

There is a time when we must keep our docks ready for them...

Planning & Project Tracking at Conversion Department

One of the most complex projects nears (mechanical) completion

Key milestone on the FPF-1 project achieved

Over two million manhours without accident on FPF-1 FPU project

Frequent visitor brings part of its dredging fleet to us again

Growing business in fishing vessels and Eastern European sectors

contentseditorial

Grzegorz LandowskiEditor-in-Chief

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From 1 January 2015, a new set of rules will limit the sulphur emissions to 0.1% from the current limit of 1.0% in SECAs (Sulphur Emission Control Areas). These areas include the Bal-tic Sea, the North Sea and the Chan-nel, which are DFDS’ primary market areas. According to recent DFDS An-nual Report’s business environment overview - the price of MGO (Marine Gas Oil) with a content of 0.1% sul-phur is currently 40-50 % higher than 1.0 % bunker fuel and this price dif-ference is expected to continue in the future.

The DFDS’ transition strategy to overcome the considerable financial challenge of the new rules has three elements:� Installation of scrubbers on 21

ships by 2017 � Roadshows and meetings ongo-

ing to prepare freight customers and market for a cost increase� Consolidation of routes.Remontowa has already been as-

sisting DFDS in applying its new strategy. In the course of the summer of 2013, scrubbers were installed on three freight ro-ro ships. Further ships are to follow soon - scrubber in-stallation is planned for another sev-en ships during 2014. At Remontowa again.

Within the next phase in DFDS’ Project Blue Sky another batch of ships are to receive Alfa Laval PureSOx scrubbers during vessels’ scheduled drydockings from April through November 2014. It was ini-tially considered between sending all the ships of this year’s scrubber retrofitting batch to one shipyard and splitting the group of seven ships among two or three shipyards, but eventually Remontowa was chosen as destination for all seven ships in-volved in this year’s scrubber instal-lation process.

The work is to be carried out during the ships’ normal, scheduled dry-docking time, which is expected to extend the out-of-service period for each ship from the scheduled 14 days to an additional one week or so, similarly to three ships fitted with scrubbers at Remontowa in 2013.

The first, pilot or experimental DFDS’ scrubber installation, on-board

Shipowners and operators will soon face hard real-ity of new regulations. It is the last minute for action now. The new emissions limitations are coming into force on January 1st 2015.According to IMO MARPOL Annex VI regulation 14 sulphur emissions is to be limited to the level equal to emission achieved by using Low Sulphur Marine Gas Oil (LSMGO 0,1%Sulphur) in the ECA zone. In ECA zones it has already been lowered to 1%, while even more stricter 0,1% will be applied as from Jan-uary 1st 2015.Numerous countries and harbors attract the Own-ers with port and fairway fees incentives and “green awards” dependent on vessels emission, encourag-ing them to reduce content of harmful substances in ship’s exhaust gases. One of the ways of achieving this goal is the usage of scrubbers. IMO Marine Envi-ronment Protection Committee 184 (MEPC184) has developed regulations and certification procedures related to using Exhaust Gas Scrubbers to comply low emission requirements.European Union takes its own part in Low Emis-sions legislation process as well with EU Directive 2005/33/EC which came in force on January 1st, 2010 and recognizes air pollution caused by high

sulphur content marine fuel combustion as harming human health, damaging the environment, public and private property and cultural heritage, and con-tributing to acidification. The UE Directive regulates the use of low sulphur fuel (below 0.1% sulphur con-tent by mass) in European Union Since 1st January 2010. Also non-EU members of European Economic Area (EEA), including Norway and Iceland, are following rules similar to EU Directive 2005/33/EC. However EU direc-tive allows for application of an alternative solu-tion: using of standard marine fuel combined with Exhaust Gas Cleaning Systems (EGCS), which results in emissions on level achievable by using low sulphur fuel. This provides an opportunity for significant cost savings for the Owners trading in ECA zone as the price difference between HFO (3,5% sulphur) and LSMGO (0,1% sulphur) is - in today’s market - about 320-350USD per each metric ton. Taking into account a daily consump-tion of a mid-size vessel at about 20-30 tons of fuel oil, the resulting cost difference while using in SECA zone a standard HFO (3,5% sulphur) along with Exhaust Gas Scrubber looks worth consid-ering.

The cost, which deserves consideration...

Actual and foreseen scrubber installations at Remontowa in the coming years.

repairs

the 37,939 gross tonnage freight ferry Ficaria Seaways, was performed in Ger-many as a joint development project between DFDS, Alfa Laval and MAN in July 2009. Only main items like the scrubber (then - the largest scrubber in the world installed on a marine vessel) and water pump were installed at the yard, while all piping and electrical wiring were made subsequently with the ship in operation.

Similar pattern, but with wider range of works - some piping and some fur-ther other work done at the yard, was adopted in 2013, when the next three installation projects, involving three freight ferries - the 32,289 gross tonnage sisterships Petunia Seaways and Magnolia Seaways as well as the 24,196 gross tonnage Selandia Seaways were completed by Remontowa. While the sisters Petunia and Magnolia have single MAN propulsion units and involved one scrubber installation each, Selandia features two Sulzer four-stroke en-gines, so two scrubbers installations - one for each diesel engine - had to be carried out in this case.

A new batch of DFDS vessels to receive scrubber installations at Remon-towa during 2014 comprises: two ro-pax vessels from Kiel-Klaipeda and Karlshamn-Klaipeda routes - Victoria Seaways (built 2009, GT 25,518), Op-tima Seaways (built 1999, GT 25,206), adding to five freight ro-ro ships: Britannia Seaways (2000, GT 24,196, Esbjerg - Immingham route), Suec-ia Seaways (1999 built, GT 24,196, Vlaardingen - Felixstowe route), Primu-la Seaways (2004, GT 32,289; Gothenburg - Brevik - Gent) and sisterships Freesia Seaways (2005; Gothenburg - Brevik - Gent) and Begonia Seaways (2004 built, both GT 37,939; Gothenburg - Brevik - Immingham).

- We are conducting a very developed talks also with other owners oper-ating in the SECA – Zbigniew Andruszkiewicz, member of the Remontowa’s board admits - so I can say, that amount of such installations in our shipyard will be growing up!

Victoria Seaways with the Alfa Laval’s scrubber system installed at the end of March 2014.Photo: Jerzy Uklejewski

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The Boskalis ships palette

Frequent visitor brings part of its dredging fleet to us again

In February, at least five floating units from the Boskalis fleet arrived to Remontowa S.A. for extensive repairs.

Royal Boskalis Westminster NV is a leading global maritime services company operating in the dredging, ports, offshore energy and inland in-fra sectors. Its main clients include oil companies, port operators, govern-ments, shipping companies, interna-tional project developers, insurance companies and mining companies. Through Smit, Boskalis is also active in towage and salvage. The compa-ny delivers innovative one-stop solu-tions to major maritime challenges.

Boskalis has 11,000 employees, including its share in partner compa-nies. The Netherlands based com-pany operates in some 75 countries across six continents. The versa-tile fleet of Boskalis consists of over 1,000 vessels and equipment. This includes one of the largest fleets of dredgers.

- As Boskalis is active also on the Baltic, Remontowa, the leading shiprepair yard in the region is a nat-ural choice and has proven itself as a reliable partner to Boskalis, which is also reflected in Remontowa sales in 2013. The Dutch company returns to Remontowa as a Client for such ad-vantages our yard is able to offer as quality of service, flexibility and the ability to mobilise assets and work-force on short notice – Piotr Kubicz, Western European Market Commer-cial Office Manager explained.

Almost for the whole February as many as five floating units from the Boskalis fleet have been staying at Gdansk Shiprepair Yard Remontowa S.A. At some point of time it was even six vessels. In January the 96.1 m long and 22.5 m wide trailing hop-per suction dredger Crestway was serviced for 25 days. On February 24. 2014, after completed repairs, four Boskalis’ split hopper barges, namely the Frigg, Rind, Long Sand and Cork Sand left the yard. At that time cutter suction dredger Edax, re-mained at the yard for a wider range of repair and maintenance works.

It was not the first time that Remon-towa hosted and serviced Boska-lis’ vessels, but the first stay of that many ships of this Owner at a time.

Two pairs of sister vessels, over 20 years old, Dutch built split hopper barges - Frigg and Rind (60.1 m of length overall and 12.2 m beam) and Long Sand with Cork Sand (65.2 m long and 12.2 m beam) have under-

gone quite a significant range of works due to their age and specific mode of operation.

Onboard Frigg and Rind, two generating sets have been replaced with new machinery on each. Rollers and hinges have been repaired. Part of the fi-fi system piping in engine room has been repaired and another part, on the open deck, replaced. Seals of the hopper, in its lower part, have been re-placed with new ones. New bilge pump has been installed as well, not to mention lots of other minor repairs including some hull steelwork in various regions. Both hopper barges have also been in dock, undergoing mainte-nance works and painting.

Repairs and maintenance of another two sister split hopper barges - Long Sand and Cork Sand - involved such works as replacement of eight wooden plank lining areas 1 m wide and 4 m long each, some girder steelworks, dis-assembly and then reassembly of shaft line cover (for the purpose of mea-surements of clearance / backlash and replacement of shaft sealings), re-placement of bottom sealings in hopper (hold) and some minor steelwork. Cork Sand has had its two propellers replaced when the ship was in dock.

Much more works have been commissioned for the cutter suction dredger Edax. The 1986, Merwede shipyard built, 89.2 m long and 16.4 m wide vessel has had its spud well (spud guide) overhauled, especially the lower clamping ring, disassembly, modification and reassembly of the main spud ring, ma-chining of the cutter head bearing sleeve, works on keel (sea chest) coolers, overhaul, repairs and measurements of the wheels of the stern trolley, over-haul of bottom sea chest valves and many items more.

Trailing hopper suction dredger Crestway during its stay at Remontowa in January 2014.

repairs

Hopper barge Frigg sailing on the waters of the Gdansk Bay on its way to Gdansk.Below: the Boskalis’ hopper barges and cutter suction dredger Edax upon arrival to Remontowa. Photo: Jakub Bogucki (above) / Jerzy Uklejewski

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Season for ferriesThere is a time when we must keep our docks ready for them...

Winter months for some North European shipyards is the period, when they host much more ferries to scheduled maintenance and repairs comparing with the rest of the year. Remontowa is one of the few yards attracting the biggest number of ferries.

Over the recent months one of the ferries to be met at Remontowa was the 165 m long ro-pax Stena Baltica (ex. Cotentin), which spent almost 50 days in Gdansk. Some of that time the ship spent waiting for the decisions on its new deployment, as it meanwhile changed hands. Now the vessel is operat-ing on the Gdynia - Karlskrona ferry route. The 171 m long, ro-pax ferry Urd spent thirteen days on repairs, while a large, 200 m long combi (combined rail-car-passenger) ferry Mecklenburg-Vorpommern was hosted at Remon-towa for 12 days of repairs and maintenance, including docking. Our yard has also recently served Polish 146 m ferry Baltivia, French ferry Mont St . Michel, 174 m long as well as 161 m long King Seaways and 172 m long Sassnitz.

Baltivia (5492 t deadweight, 145.96 m LOA, 24.03 m beam, 8 m depth, with a draught of 6.26 m, achieving speed of 20 knots, loading 80 trucks / trailers, with ro-ro lane length of 1,408 m and 250 passenger capacity), a ro-pax built in 1981 and completely modernized in 2002, belonging to Polish Baltic Ship-ping Co. since 2007, spent 17-days (including 16 days in a dock) at Remon-towa. Sailing for a few months now on the Swinoujscie - Ystad route (formerly Gdańsk - Nynashamn ), she has undergone inspections and annual class repairs supplemented by, among others, some damage repair steelworks on the left side, after minor collision with a quay, which caused some denting on the left side in the ship’s bow section.

Another (besides Baltivia) ship from Polferries - Polish ferry opera-tor - serviced recently at Remontowa was the 34 years old car and pas-senger ferry Scandinavia. The range of works was quite wide, including maintenance and painting in a dock.

Stena Line brought to Remontowa a couple of ships this last winter sea-son. One of them was Sassnitz, built in 1989 (GT 21 154, deadweight 3100 t, 172.1 m of overall length, 24.2 m width and 5.3 m draught). Since January last year, she has been employed by the ferry operator Stena Line on the Sassnitz (Germa-ny) - Trelleborg (Sweden) route. The ferry arrived to Gdansk for 2-year class renewal, which meant review-ing and checking almost all machin-ery, items of equipment and systems. The scope of the repairs, which is not surprising with such a ship - not in its youngest years - was quite sig-nificant. Already in the process of re-pairs, additional work was commis-sioned by the Owner and widened the scope or works to be done at Remontowa.

Cleaning and painting of the un-derwater hull (about 5200 sq m) or the repairs and renovation of four ex-haust gas boilers, as well as an aux-iliary boiler, adding to hull steelwork, including some in one of the ballast tanks - these are just a few examples from a long list of repair specification.

King Seaways operated by Den-mark’s DFDS Seaways, visited Remontowa for less than three weeks repairs. The ferry, having already been in service for 27 years, offers more than 2,000 passenger capacity and approx. 600 units car capacity. The scope of repair works was con-siderable and included, among oth-

Dieppe Seaways during undocking.

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11customermagazine

Refurbished Scandinavia departing from the shipyard.

repairs

Polish – operated Baltivia in the night...

Pont Aven leaving the yard after completion of repairs.

ers, steelwork on the hull and decks 7 and 12 and even replacement of shell plating on top of the funnel stack, besides replacing more than 200 pieces of anti-corrosion anodes or repairs and maintenance of six lifeboats and re-placement of the air conditioning plant with a brand new one. This, of course, were just a few excerpts from the long list of contracted work. Among the most interesting ones there was installation of rudder blade bulbs expected to reduce fuel consumption.

Large scope of work has been carried out on the French ferries Mont St. Mi-chel (173.1 m LOA, 28.5 m beam) and Pont Aven (184 m LOA, 31 m beam) - both operated in the livery of Brittany Ferries - the major ferry operator on the English Channel and Bay of Biscay. For 12-year-old Mont St. Michel, staying in Gdansk from 9 to 31 January, servicing by Remontowa included mainte-nance of the hull with silicone paint application. Silicone paint offers better du-rability and lower surface friction at the same time, which facilitates fuel sav-ing. The silicone paint, at special application regime, was used on the area of some 5300 sq m. When applying silicone paint, the shipyard must take special precautions and keep almost sterile conditions and appropriate tem-perature. Also the above water part of the hull and decks have been painted.

Similarly, a wide range of work concerned Pont Aven, which left the Gdansk based yard on February 19.

Also in February repair and maintenance works were carried out onboard Stena Line’s Stena Vision, deployed on Gdynia - Karlskrona route over the re-cent years. One of the most visible result of this ferry’s recent stay at Remon-towa is the new bulbous bow it received. The old one was cut off and replaced with new 53-ton structure of a new design, better shaped for hydrodynamic efficiency and thus - for fuel savings. Another important task for Remontowa on this ferry was to install the new MES (Marine Evacuation System).

Another ferries serviced recently at Remontowa were Dieppe Seaways and Victoria Seaways in DFDS Seaways livery and large Stena Line ro-pax Stena Scandinavica deployed on the Kiel-Gothenburg route, with both ships docked for hull maintenance, among other works.

All photos: Jakub Bogucki

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repairs

We’ve breathed new life into mature ships

Growing business in fishing vessels and Eastern European sectors

Over the recent years, Remontowa S.A. enjoys a considerable workload from Russian Owners and Operators of fishing vessels. Recently, three vessels of this kind, from the same Owner based in Kaliningrad, have been nearing completion of repair, upgrade and maintenance works - Boris Syromiatnikov, Lira and Kurshskaya Kosa.

In case of the first of the mentioned ones, Remontowa has installed and turn-key delivered entirely new pro-cessing plant. But the range of up-grade was even wider. Remontowa installed new main engines and sev-eral new, modern items of equipment and systems that definitely enhance the fishing and fish processing capa-bilities onboard Boris Syromiatnikov.

It is worth recalling that over the re-cent years is was not the first so ex-tensive, thorough modernization of

the fishing vessel performed by Remontowa. Previously, there have been Melkart 2 and Lira, which since May 2012 performs very well in operation after extensive modernization and re-engining.

Certainly, the fact that the Russian Owner is very pleased with much im-proved fishing and processing capabilities of Lira has been the main rea-son behind recent decision to order extensive upgrade of another deep-sea trawler - Boris Syromiatnikov.

- Remontowa has already established its position in the market for this kind of service, but we still have to be very active to acquire new contracts - says Zygmunt Czapiewski, manager of the Eastern European Market Commercial Office. - I’m confident the Owners appreciate our complex, “one stop shop” of-fer of comprehensive modernization of the fish factory ships and ship repair, with supplies of all or the most of systems, machinery and equipment, through their installation and assembly, to professional start-up of equipment and sys-

tems, their calibration and fine-tun-ing during operation on the fishing grounds, in the real and demanding sea environment conditions. It goes without saying that each subsequent contract, completed on time and in high quality expected by the Owners is the best advertising of our capabil-ities.

More often world’s leading manu-facturers of marine equipment and systems endorse our yard as the right place, where one can get swift, comprehensive, high quality and safe installation, start-up and cali-bration of shipboard machinery and systems (just to mention top German engine makers or manufacturers of freezing equipment for fishing ves-sels). That proves the profession-alism and renown, that Remontowa trade mark enjoys - concludes Zyg-munt Czapiewski.

Wide ranging, extensive upgrades and modifications, like the one seen on Boris Syromiatnikov is a complex task, as the existing compartments are crammed with machinery and it is difficult to trace new equipment transport paths, as it usually requires lots of de-installations and removals. Dismantling old equipment and in-stalling new items of equipment and systems is a tedious work.

However, careful preparation of conversion or upgrade design by Remontowa Marine Design and Con-sulting Ltd., as well as proper coor-dination of repair, maintenance and modification works, with supervision from managers for production coordi-nation, allows for successful comple-tion of the project.

On Boris Syromiatnikov among the biggest and most important tasks was the replacement of main engines and reduction gears with new ones, as well as turn-key project of build-ing entirely new fish processing fac-tory, including numerous specialist items of machinery, such as convey-ors, fish processing equipment, sort-ers, 21 cabinets freezers, machinery for laminating and cardboard boxes packaging of frozen fish blocks. New wall and ceiling linings were installed.

Adding to the above, shaft genera-tors were overhauled, time-worn boil-er was replaced with a new one sup-plied by Alfa-Laval. New compressors and other items of freezing equipment were installed in cool engine room.

Old insulation and linings in the hold no. 2 were completely stripped and re-placed with new ones. New MMS Tendos system (for draining water from fresh fish tanks) was installed. And that’s not all from the extensive range of repairs and upgrade.

Another deep-sea trawler - Lira - has recently undergone a wide range of minor repair work. More significant items on the repair specification includ-ed: cleaning of seven fuel tanks, overhaul of electric motors, repairs to trawl winches; repairs of sea water piping and boiler.

Somewhat wider range of works have been accomplished onboard Kur-shskaya Kosa. These included maintenance and painting; inspection of the valves, replacement of the seals on the controllable pitch propeller control box, repairs to the shaft line, also with stern tube seal replacement, weld fix-ing of Kort nozzle cracks, repairs of cracks in the boiler, installation of new fishfinder and echosounder, etc.

These swift modifications and repairs, and - in the case of the trawler Boris Syromiatnikov - thorough upgrade with re-engining, constitute a part of a sys-tematic positive trend - seen over the recent few years - of revenue growth and the number of vessels serviced by Eastern European Market Commer-cial Office of Remontowa.

Boris Syromiatnikov departing from Remontowa after completion of the conversion... Photo: Jerzy Uklejewski

An entirely new fish processing factory was built onboard the ship.Photo: Jerzy Uklejewski

The ship has also been entirely re-engined.Photo: Jerzy Uklejewski

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offshore

In Remontowa, on each step of the Project we pay a special attention to de-tailed project schedule. During the planning process it is necessary to de-fine various work tasks that must be accomplished within estimated period of time. Our project team analyzes all available options, potential risks, choice of technology, task duration and required resources.

After preparation work has been completed, project data is being input into Primavera, then Base Line is being set up and Master Schedule with resourc-es requirements confirmed by management.

During the execution phase, on weekly basis, schedule is updated and progress report including S-curve prepared. If any of the items becomes crit-ical, the alert to project team is generated. Planning team also continuously estimates required resources, during the project execution therefore help to quickly identify potential bottlenecks, which allows us to avoid problems by re-scheduling, methodology change or managing resource allocation. During the weekly schedule review, project team sets project priorities. If some fac-tors are crucial for project, planning team pays special attention and monitors the progress on daily basis; additionally any discrepancy between the base line and the actual is reported. Depending on project team needs and work specific, planning team uses different indicators e.g. Visual Progress Reflec-tion, Ron Down Curve, S-curve, Alert Report etc.

In order to track projects, Remontowa has built a team of specialists who are only dedicated to monitor the progress in project execution. Every day experts visually check and report percentage of completion for tasks which were defined in Project schedule. After physical measurements on site or in the prefabrication workshop are done, collected data is inputted in to the spe-cial system called “Tracker” and daily report is generated. Thanks to accurate information, Project Schedule can be updated and any plan variation can be quickly identified and required action can be taken.

We are a team!Planning & Project Tracking at Conversion Department

Planning is critical to the success of any project of any size. Planning is a goal-oriented, continuous and ongoing process. It helps to minimize uncertainty and risk, gives a view of the future and leads to more effective use of available resources. It also helps managers to anticipate and mitigate possible future problems. Plans help us to know if a project is on a right track and can be delivered on time.

Our specialist team every day analyzes the progress in project execution.Photo: Media4Sea

Safe Scandinavia undocked

One of the most complex projects nears (mechanical) completion

Conversion and upgrade of semi-submersible accommodation platform Safe Scandinavia ranks high among the most complex projects completed at Remontowa to date. The works are being carried out by the shipyard through mechanical completion procedure till full commissioning. In March 2014 the platform has been undocked.

Prosafe team during the undocking operation at Remontowa S.A.Photo: Jakub Bogucki

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ISSUE 1(13) March 2014 17customermagazine

Let us recall, that the Prosafe - oper-ated semi-submersible accommoda-tion and workshop unit Safe Scandi-navia arrived to Remontowa S.A. late November 2013, to undergo repairs, maintenance and upgrade.

The focus and aims of the proj-ect are amongst others, to increase her mooring capability (by replac-ing 12 mooring winches and anchor cables), replace the original deck cranes and refurbish the cabins. The range of works ordered at the yard increased in the course of the float-ing unit’s stay at Remontowa. Berth cabin modules have been replaced with new ones, hulls and columns maintenance and painting have been performed with the unit lifted up on the shipyard’s own heavy-lift barge REM Lift 25 000 (the docking operation was performed in Decem-ber 2013).

As most of the extensive range of works, mentioned above, had been completed – the undocking of the unit went smoothly on a fine, sunny day of March 8, 2014.

However, a considerable portion of works still remained to be done and the platform was not expected to de-

part from the yard immediately. During intensive finishing touches of the proj-ect hundreds of employees have been involved in the works onboard the platform. The completion of repair and upgrade works were on the agenda after undocking, not to mention test-runs and activation of the unit’s systems. Also heeling (stability) tests were to be executed prior to Safe Scandinavia departure.

According to Robert Hoefta, mechanical completion manager, a special team works on preparing full completion of the project to hand over the up-graded platform to the Owner. The team operates within a “conversion com-pletion department” at Remontowa, focused on preparing and implement-ing a system, which we call “mechanical completion”, the system known in offshore sector shipyards worldwide. “Mechanical completion” means that when the shipyard is finishing its own works, we have to prepare a set of documents, which we call “mechanical completion documents”, and which are supported with quality control documents (including material and weld-ing traceability reports and lots more).

The purpose of the “mechanical completion system” is that when we hand over the part of the project to the Owners, for example some system built by the shipyard we hand over not only the work completion, but also the docu-mentation completion. After works on each system are completed we carry out what we call “final completion linewalk”, which is basically aimed at final checking of completeness of systems. We take all documents onboard and verify them against the actual state of the completed works and systems built by the yard.

So, we deliver not only the physical effect of the yard’s work, which is the converted rig, but also the full documentation reflecting the actual state of the floating unit after completion of the project. It is normal at every shipyard in the world that actual shape of the ship after completion is not 100 percent - equal to design documentation. So, we deliver the floating offshore unit with full documentation not differing slightly from the final, actual state of the unit (as design documentation normally differs), but checked against and showing the actual state and shape of the unit after completion of the project.

offshore offshore

Robert Hoefta (on the right), mechanical completion manager at the shipyard’s conversion department.Photo: Media4Sea

Heavy lifts in the heights

Key milestone on the FPF-1 project achieved

Precise and difficult operation of large structures and equipment transport made for another milestone for the project FPF -1.

Technically sophisticated and perfectly planned operation of lifting heavy equipment onto the platform’s deck was smoothly performed by the shipyard’s team. Photo: Cezary Gierszewski/5xMedia

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offshore

The scheduled several days opera-tion of complex transport, concerning several large structures and items of equipment weighing tens of tons at high altitude of the main deck of the platform (height of the largest set of structures with equipment reached about 10 floors, more than 30 meters in height) had been planned and pre-pared for months.

As craneage available on site was not able to meet such requirements, it was necessary to hire a piece of equipment that was. Powerful and high reaching floating crane Uglen was brought to Remontowa to carry out these complex operations.

- Heavy Lift Operation is consid-ered by the management of the FPF-1 project as a milestone - key stage point of the project - Krzysz-tof Dusiński, FPF-1 topsides proj-ect manager explains. Uglen float-ing crane, secured by Petrofac, was contracted three months in advance before works scheduled for particular days of January.

Available time window has been effectively utilised in 100 percent, with the operation carried out accord-ing to the plan drawn already three months earlier, still at the stage of docking (lift-up) of the submersible platform.

The schedule has been complet-ed just as foreseen. Our yard, along with the subcontractors, had to pro-vide pipe racks and supporting struc-tures for various items of equipment. The main tasks of Uglen was to lift two large items onto the platform deck, i.e. high-pressure oil separa-tor and so called off-gas compres-sor. The structures and equipment to be lifted to topsides varied in size and weight, with length of 10 up to 15 m, width of approximately 5 me-ters and height of 10 m. The heavi-est item weighed about 100 tons! In total there were five such structures.

Precise logistics planning resulted in collision-free and efficient comple-tion of the entire operation. First talks regarding the preparations, involving our special task force team, took place already half year earlier before the ac-tual operation. It was then, when the date of operation was set for January 16, 2014. Extensive phase of prepa-rations commenced three months be-fore actual operation.

The whole plan of lift-up shipments of structures and equipment was de-pendent on sequence of installation on main deck, so as not to block further shipments and to ensure optimal use of a very short time to carry out this task with availability of the floating crane. Everything had to be worked out in great detail, including all works necessary around the actual heavy-lift and transport tasks, given the short Uglen availability timeframe.

The first operation began on Thursday, January 16 in the morning and the last was performed on Tuesday morning. Even not as a main actor on the scene, shipyard’s own floating crane REM 220 played an important role in these operations. The crane transported structures from the assembly area to the place, from which Uglen lifted them and transported onto the FPF-1 deck.

Among most challenging tasks there have been last-minute changes in range of ordered works and Owners’ requirements. Structural and strength calculations and lasted literally until the last moments before the start of ship-ments. Sometimes last-minute modifications of supporting structures have been necessary.

What is more - safety issues had to be treated on a par with all of the above - precision, quality and compliance with the terms of the workflow. Each oper-ation began with the so-called “tool box talk”, or talk with the involved perform-ers prior to the task. Every day there were also meetings with the Owners, where the sequence of operations and potentially dangerous aspects oper-ation were discussed and compliance of the ongoing operations with plans and preparations was presented to the insurance company hired by Petrofac. That was meant to eliminate the possible risks related to occupational safety and to ensure smoothness of execution.

Building the floating production unit FPF-1, basing on an upgraded semi-submersible platform, the Remontowa’s workers have already been working without accident for over 400 days, which translates into over two million manhours without an incident.

The Owner of the FPF-1, Petrofac, main-tains a custom of awarding such spectacu-lar achievements, and so did our shipyard receive special award - occasional statu-ette.

Receiving an award for maintaining a high level of health, safety and culture of work is one of the highest forms of recog-nition. The importance of received award is further underlined with the large scale of the FPF-1 project, its complexity and technical advancement with hundreds of employees of all shipyard trades and pro-fessional specialities working on it. Such accolade is also an excellent showcase for the company, as well as valuable asset for shipyard’s marketing department.

The ceremony of the award handing over took place on March 11, 2014, on the quay at the FPF-1 platform with attendance of all employees involved, the shipyard’s work-ers and subcontractors, members of task force teams from Remontowa and Petro-fac, fire-fighters, health and safety inspec-tors, designers, as well as representatives of the shipyard’s management, led by CEO Jarosław Flont and member of the board for conversions Janusz Czajkowski. Rep-resentatives of the Owners were present as well, with Marwan Chedid, Chief Exec-utive ECOM, Rob Jewkes, COO IES and Craig Muir.

Marwan Chedid, handing an award stat-uette to Jarosław Flont, expressed his thanks for all activities so far, leading to ex-cellent safety track record. He also empha-sized great advancement of safety culture, seen since the FPF-1 project commenced.

Jarosław Flont said he is confident the award would further mobilize everyone to strive to improve levels of work safety cul-ture even more. He emphasized safety is a priority for the management of Remontowa S.A., not only in relation to FPF-1 project, but across the whole company and also expressed thanks to everyone involved, especially the supervisory staff.

Petrofac awarded us!

Over two million manhours without accident on FPF-1 FPU project

The shipyard’s own floating crane REM 220 played an important role in these operations.Photo: Jerzy Uklejewski

Documents

Season for ferries - · PDF fileBaltic Sea, the North Sea, the En-glish Channel and the entire north- ... Over two million manhours without accident on FPF-1 FPU project Frequent visitor