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JURONGSHIPYARD

From left to right: Allan Yau (Assistant General Manager), Wee Keng Kwee (Deputy General Manager),Wong Weng Sun (Executive Director) and Lee Yeok Hoon (General Manager Production).

The environmentally friendly new blasting chambers.

Shipyard Operations Review

Jurong Shipyard provides a one-stoptotal service in ship repair, shipconvers ion and mod i f ica t ion ,shipbuilding and offshore structures andengineering in Singapore. It occupies65 hectares of land and operates fourgraving docks with a total capacity of1,100,000 dwt and 2,728 metresberthing quays, supported by design,engineering, fabrication and cranagefacilities, machinery and hull workshopsand warehouses.

The year in review was busy for JurongShipyard, achieving an average dockutilisation rate of 76 per cent (based ondwt days) and 7.55 million manhoursfor the year. With some high value-addprojects in the orderbook, the shipyardachieved a steel throughput of 20,000tonnes. Some of its notable projects forthe year were:

MV8 Langsa VentureThe contract to convert the 35,000 dwttanker to a floating production-storage-offloading (FPSO) unit was awarded byModec Inc of Japan. The unit was

renamed MV8 Langsa Venture andchartered to Matrix Oil (Langsa) Ltd tobe deployed at the Langsa Field in theStraits of Malacca. It was designed witha processing capacity of 15,000 barrelsof oil per day and an oil storage capacityof 272,400 barrels.

Sultana Del EsteThe contract awarded by Wartsila NSDof Finland involved the conversion of abare barge into the world's largestpower barge capable of transmitting

148.6MW of electricity directly to theDominican Republic's national grid.Completed within seven months, workdone on the plant included the erectionof a pre-fabricated power house andthe installation of nine 18V46 engines,an engine pipe system, a 45-radiatorcooling system, a switch yard and ahigh voltage power supply of 138KV.

Sendje CeibaThis FPSO, which was converted froma 275,000 dwt Very Large Crude Carrier(VLCC) turbine tanker, boasts a storagecapacity of 2 million barrels of crude oil,a higher production capacity of 160,000barrels of oil per day and a waterinjection capacity of 135,000 barrelsper day. The conversion project wasthe second from Bergessen DY OffshoreAS of Norway. Chartered to TritonEnergy, a subsidiary of the American-based global integrated energycompany, Amerada Hess Corporation,the Sendje Ceiba would be deployedat the Ceiba oil field off EquatorialGuinea, West Africa.

Ocean SovereignThe contract awarded by DiamondOffshore Drilling involved major repairs,steel renewal, leg/derrick/tanks blastingand painting, quarters refurbishmentand electrical renewal. A total of 550tons of steel was renewed in this project.

Trident 9The jack-up drilling unit undertaken forTransocean Sedco Forex involved thereplacement of the drill floor, cantileverand all major equipment on the drillingpackage.

Pac AntliaThe 1078 TEU container vessel of16,794 dwt was designed in-house andconstructed at the shipyard in strictcompliance with the latest IMO rulesand regulations. It is single screw, dieselengine driven with bulbous bow,transom stern and 4 box-shaped cargoholds that can be used to transportcontainers in holds with cell guides andon deck with lashing. It has a servicespeed of 19.5 knots and measures 154metres by 25 metres by 13.6 metreswith the ability to accommodate up to200 FEU of reefer containers, with 124FEU on deck and 76 FEU in hold.

To enhance its facilities to servecustomers better, Jurong Shipyard tooksteps to provide additional steelfabrication space and blasting facilitiesin 2001. Four enclosed blastingchambers, each measuring 20 metresby 24 metres, were constructed at theshipyard's Tanjong Kling location.

The new blasting facilities wouldenab le b last ing and pa in t ingprocesses to be car r ied outsimultaneously without being affectedby weather conditions. The blastingchambers were designed to beenvironmental ly f r iendly as i ts

enclosure minimised dust andpaint fumes from pollut ing thesurrounding areas.

Due to an increase in workload anddemands for additional steel fabricationspace, the shipyard also constructedfour mobile steel fabrication workshops,each measuring about 24 metres by 35metres. To meet the additional storagearea for owner supply equipment andmaterial, the shipyard would beconstructing an additional warehouse of800 square metres and a new enclosedstorage area of 20,000 square metres.

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Further emphasis was placed on safetytraining. In November 2001, JurongShipyard embarked on the Behaviour-Based Safety (BBS) managementprogramme. Employees were taughthow to observe and feedback on critical"at risk" behaviour on the job. Thishelped them to achieve a betterunderstanding of how they could beputting themselves and others aroundthem at risk. Consequently this wouldlead to more effective and practicableresults.

Safety training was also extended tothe subcontractors. They would nowhave to appoint safety supervisors whowould be given proper training and

regular briefing on the new legislationrequired by the Ministry of Manpower.In turn, they would have to train theirworkers to meet the safety standards.

Additionally, the shipyard recognisedthe need to review and ensurecompliance to the safety managementsystem. Safety audits were carried outin 2001, both by external and internalparties. At the trade level, a safety tradecommittee made up of representativesfrom the six main trade groups metregularly to look into and revise safetypolicies. On the ground level, safety taskforces were mobilised regularly to ensuresafety compliance.

6

5

4

3

2

1

Frequency Rates

5.19

3.88

3.15

2.70

2.90

1997 1998 1999 2000 2001

Employees taught how to observe and feedback oncritical “at risk” behaviour on the job.

Comprehensive machinery workshop facilities.

On-the-job training.

Auto pipe-cutting machine.

Course No. Trained

Safety Instruction Course for Repair Managers 6

Safety Instruction Course for Direct Employees (SIC) 215

Safety Officers Training Course (SOTC) 3

Shipyard Supervisor Safety Course (SSSC) 72

Shipyard Safety Assessors Course (Hot Work Certification) 8

Shipyard Safety Assessors Course

(Confined Spaces Certification) 8

Total 312

Ministry of Manpower Safety Registered Courses

Course No. Trained

Behaviour-Based Safety (BBS) 224

In-house Fire Watchman/Fire Fighting Course 92

Marine Signalmen/Rigger Course 294

Safety Orientation Course (SOC) for New Contractor Workers 966

Safety Improvement Team 10

Lifting Supervisor Course 15

Marine Metal Scaffolding Supervisor Course 6

Safety Legislation Workshop 6

Fire & Rescue Training (SSPL) 7

Total 1620

Others Safety Courses

Ever mindful of the need to conserveenergy, Jurong Shipyard started on anenergy campaign in December 2001.During this campaign, the shipyard wouldmonitor and control the usage of allenergy sources including electricity, water,compressed air, gas and fuel.

As safety measures continued to beupheld, Jurong Shipyard recorded anaccident frequency rate of 2.90 permillion man-hours worked in 2001 whilethe frequency rate target set by theAdvisory Committee on OccupationalSafety and Health for the Shipbuildingand Ship Repairing Industry for 2001was 3.4 per million man-hours worked.

Per million man-hours

Safety Inspection.

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Additional steel fabrication workshop.

To encourage employees to participateactively in safety programmes, sectionsthat achieved zero accident rates weregiven monetary rewards during regularreviews. Since the launch of thisprogramme in 2001, accident rateswere reduced dramatically in the thirdquarter. Safety achiever awards werealso given to employees with a strongsense of safety awareness and havehelped in maintaining a safer workingenvironment.

Further promoting safety in theworkplace, the shipyard held an in-house Safety Improvement Teamconvention in July 2001. A total of eightteams participated in the convention.The winning team also took part in theAssociation of Singapore MarineIndustries SIT Convention in May 2001and received the Gold Medal Award. Atthe 7th National SIT Conventionorganised by the Ministry of Manpower,the same team won the Gold Medal.

Recognising the importance of goodhousekeeping at work, Jurong Shipyardreactivated the 5-S HousekeepingProgramme in 2001. With the fullimplementation of the system, theshipyard would be able to achieve higher

productivity with less wastage, betterequipment performance with lessdowntime, higher quality with lesshuman error and a better safety recordwith fewer accidents.

CNC Twin-Torch Plasma Cutting Machine.