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SEMBAWANGSHIPYARD

From left to right: H.K. Lim (Marine Manager), M.T. Toh (Senior Marine Manager),P.K. Ong (Executive Director), Royce Lim (Marine Manager)

and C.G. Neo (Assistant General Manager, Operations).

Shipyard Operations Review

Sembawang Shipyard is a wholly ownedsubsidiary of SembCorp Marine,operating primarily from a 60-hectareshipyard on Singapore's north coast.The shipyard has four docks totaling710,000 dwt with adjacent engineeringfacilities. It has almost 4 kilometres ofcontinuous deep and sheltered berthageof up to 14 metres in depth. Theshipyard's 100,000 dwt drydock is oneof the deepest in Southeast Asia witha draft of 13.6 metres allowing cruiseand naval vessels to dock withoutrestrictions.

Sembawang Shipyard was kept busyin 2001 as steel throughput increasedby about 50 per cent from 7,400 tonsto 11,100 tons. Projects for the yearincluded some high value added ones,including five main engine bedplaterenewals, three major upgrades, twomajor af loat works, one FPSOconversion, one FSU conversion andone jumboisation. Some of its majorprojects undertaken during the yearwere:

Crown OdysseyThe main work carried out during therefit was the renewal of the starboardfather main engine crankshaft, whichthe yard's refit team carefully planned,executed and completed within animpressive record of 16 days. Otherwork included the inspection and repairsto the rudder and propeller, tank cleaningand coating, the overhaul of variousauxiliary equipment, pipework renewaland the installation of kokum sootblowing system in the engine room.Formerly known as the NorwegianCrown, this 34,242 grt cruise liner has527 staterooms and penthouse suites,accommodat ing up to 1 ,050passengers. The project was completedin January 2001 when the CrownOdyssey sailed to Langkawi on itsmaiden cruise.

Venus GloryThe 300,000 dwt Venus Glory was thefirst in a series of five projects in thehighly specialised work of bedplaterenewal. Built by Daewoo HeavyIndustries in 2000, the vessel arrived inthe shipyard in January 2001. Adedicated project team, consisting of

members who were also responsiblefor the earlier success of Star Ohio wasdeployed on the Venus Glory toaccelerate the learning curve. Thispropelled the yard to yet anothersuccessful completion of bedplaterenewal within 68 days, which includedthe time for owner's repair.

Mars GlorySister vessel Mars Glory, the second inthe series of bedplate renewal projects,arrived in March 2001. The same teamwas deployed and were able to furtherref ine the methodologies andprocedures used on the earlier projects,such as minimising lifting operations,increasing precise execution and

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contributions towards the developmentof Asia Pacif ic cruise industry.

To uphold its high level of service andquality for customers, SembawangShipyard continued to upgrade itsfacilities during the year. The new S$0.5million enclosed blasting facility atSembawang Shipyard was officiallyopened on June 26, 2001. Measuring2,800 square metres, the new facilitywould enable blasting and paintingprocesses to be car r ied outsimultaneously, without being affectedby weather conditions. As such, the

yard would be able to produce at aconsistently good quality and at a higherproductivity level. A winch and trolleysystem was also installed within thefacility to increase the efficiency ofmaterial handling. The facility wasdesigned to be environmentally friendlyas its enclosure would minimise dustand paint fumes from polluting thesurrounding areas.

To provide greater focus to its safetyactivit ies, Sembawang Shipyardlaunched a five-year plan to gear itselffor EMS (Environment ManagementSystem) certification. In 2001, theshipyard conducted a review ofregulations, code of practices andrelevant Singapore Standards andenforced them accordingly. Inaccordance to the Association ofSingapore Marine Industries' guidelines,it colour-coded all service pipelines tomonitor and prevent the accidentalrelease of harmful materials and waste.

The shipyard also carried out anevaluation of its safety system. Auditswere conducted externally by DetNorske Veritas (DNV) and internallyamong its six production departments.An action plan was subsequentlydeveloped and put into place.

In addition, the yard stepped up onprotective facilities and equipment,formalised inspection and safetyprocedures and reviewed work permits.A safety campaign on material handlingwas held and safety promotionalact iv i t ies for each product iondepartment. In July 2001, a SafetyImprovement Team convention was heldin-house, drawing participation from 14teams. One of the teams went on towin gold awards at the ASMI andNational SIT conventions.

Environmentally friendly new Blasting Chamber.

Well-equipped machinery workshop facilities.

Lowering of the new bedplate for Venus Glory.

maximising cost effectiveness andtimeliness in a technically safe manner.The team completed the project in arecord time of 55 days.

During the year, Sembawang Shipyardreceived the "Partners in CruiseServices" award conferred by PSACorporation during the SingaporeCruise Centre's 10th AnniversaryCelebrations. The award, which waspresented in November 2001,recognised the shipyard for its excellenttrack record in the ref i t andrefurbishment of cruise ships and its

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Training continued to be an essentialpart of the enforcement of safetyand developments. Re-training wasconducted for employees who wereinvolved in accidents. This was basedon a risk matrix, to ensure thatemployees received the trainingthey needed. The shipyard alsos ta r ted t ra in ing i t s s ta f f onimplementing Behaviour-Based Safety,

which would lead to more effectiveresults in the long term.

Care was also taken to ensure that itssubcontractors practiced high safetystandards. A consultant was engagedto assist them in implementing theSafety Management System. Cashawards were also given to those withthe best monthly safety record.

Balancing machine

6

5

4

3

2

1

4.30

3.10

4.104.30

1997 1998 1999 2000 2001

4.7

Per million man-hours

Frequency Rates