Success of the Iwaki Platform Decommissioning

What’s Up
Social & Community
Climbing Fuji San
There is an ancient Japanese saying that it is a fool who does not climb Mt. Fuji but it
is a bigger fool that climbs her twice. If this is true then I am surely one of the fortunate
who can count themselves to exist within this happy limbo.
When the idea first came to me, I decided to make it worthwhile by making this a sponsored
event for charity. As my family had recently lost my mother to cancer, the charity which immediately
came to mind was Cancer Research UK as they perform important and life-saving work in investigating
this devastating disease.
Having limited time due to the vessel’s movements and the short official climbing season, I promptly made
use of our vessel’s internet facilities to set up a webpage for online donations
(www.justgiving.com/Daniel-Chinn) so that I was able to accept donations from friends at home.
Encouraged by the positive reaction which I received, I then decided to approach our company which I did by
writing to our CEO, C.J.D’Cort. At the time I was hoping for a gesture of support on behalf of SapuraAcergy,
basically an endorsement of my planned expedition and a small donation. I was therefore both delighted and very
pleasantly surprised when a few days later I received a response that our company wished to donate RM3000!
Spurred on by this official support, I redoubled my preparations in our excellent gym each day after the end of my
watch.
On the day of our departure from the vessel, I found myself both eager and apprehensive of the forthcoming
climb, as I set off to a small town called Gotenba in the Fuji Five Lakes national park. Arriving late in the
afternoon I packed my rucksack and settled into an early night’s sleep, ready for next day’s climb.
Rising early the next day, I took the longest trail in appreciation of the significant sponsorship I’d received
in such a short span of time. The bus dropped me off at the 5th station and from there; the summit
lay 5.8 miles away over fields of lava ash, rocks and boulders. Climbing in this terrain is difficult as
feet slip backwards due to the treacherous nature of the soil. After a few hours on the deserted
trail I noticed that the vegetation was becoming sparse and increasingly stunted whilst the air
became thinner and noticeably colder.
There are a number of mountain huts on each trail at various “stations”. I was
counting on these to replenish my water supply as although I had set off carrying
two litres, the exertion was draining this reserve with alarming speed. The only
horizon and the summit was as bleak and
noise that accompanied me was the wind whistling through the rocks and
barren a place as could be imagined. An unreal
my own laboured breathing as my lungs struggled to strip the oxygen
vista of vicious rock teeth, sharpened by the
from the thin air. Passing the seventh station, I was feeling very weary
elements ringed the crater which seemingly
and a real effort of self-motivation was required to resume walking
plummeted hundreds of feet within the mountain. It was
after each breather. Boots seemingly heavier than at the base,
strange to realise that somewhere beneath the layer of
pack bearing more achingly upon my back I am still unsure
snow and frozen rock, Fuji still bore a fiery heart.
what was more difficult: overcoming the physical fatigue or
the mental urge to stop and rest longer. However, my
The highest point is actually the site of a meteorological station and
arrival at the eighth station brought relief to my
as the wind whistled unhindered by I could understand why: nothing
dwindling water supplies and I drank greedily and
could be more exposed. I was alone on the highest point in Japan.The
gratefully once there.
temperature had now plummeted so I broke out my cold weather gear and
walked around the crater’s rim to where I had planned to start my descent.
Eventually, as I trudged onwards I was
greeted by the welcome sight of a
After some time, I began to encounter other climbers on this shorter trail.
wooden Torii gate marking the last few
Technically, I had begun my ascent on the first day of the climbing season and these
yards of the trail to the summit.
were people who were going to overnight in the mountain huts and complete their climb
Gratefully, I forced the last few
the next day. Eventually, I found myself walking through woodland and a distant lightening
steps from my weary legs and
of the sky heralded twighlight and the coming dawn. As the glow in the east grew, birdsong
arrived, finally, at the
began to fill the trees. Finally, after 18 hours trekking, I reached journey’s end, heaved off my
summit after eight and a
pack and bought myself a coffee, gratefully relieving the weight from blistered feet. I sat back, put
half hours of trudging.
my feet up and relaxed as I lounged in the growing light watching the sun break over the clouds and
lesser peaks.
The sun was
about to dip
Distance covered: 10.2 miles, Summit altitude: 3776m, Time taken: 18 hrs (including breaks)
below the
Money raised: £1600 and counting, Pain level: Immense!
Wester n
Thanks to the generosity of all my sponsors, especially colleagues and SapuraAcergy itself, this event has been a
resounding success; so much so if fact, that I have been inspired to plan a similar climb but this time of Mt Kinabalu, the
highest point between the Himalayas and Papua New Guinea. This should fit in conveniently with the movements of
Sapura 3000, our floating home from home.I am therefore leaving open my charity webpage at
www.justgiving.com/Daniel-Chinn should anyone wish to contribute (obviously I am not asking for anything other than moral
support from those who sponsored my last climb!).
My thanks go out to everyone who got behind me and gave me a metaphorical push up the slopes: your support gave me the motivation
I needed to get to the top!
Tea Party with Sapura Community
OurWorld
As the saying goes, a little help goes a long way. As all
of you know, one of our campbosses, Jayan anak Jawa,
has been facing a hard time since his son was diagnosed
with leukemia. SapuraAcergy had successfully collected
over RM 23,300 to help ease Jayan’s burden.
However, during the recent Sapura 3000 Expedition, a
member of the Sapura Group who had followed the
Expedition was touched by Jayan’s plight as well as
SapuraAcergy’s efforts in collecting funds. He had
appealed to the Sapura Community and they had in
turn managed to match our donation of RM 23,300.
To show our heartfelt appreciation, SapuraAcergy had
organised a ‘ThankYou Tea Party’ for the Sapura
Community with Datuk Shahril, Datin Yazreen and En
Syariman as our guests of Honor. We flew Jayan in from
East Malaysia, giving him the chance to personally
thank the committee and all involved.
During the tea party, both Datuk Shahril and En
Syariman pledged to top-up the remaining amount
needed for Jayan’s son’s treatment and operation.
Another First for SapuraAcergy
SapuraAcergy proudly welcomes the first differentlyabled member of our team; Ms. Gurmit Singh. Gurmit,
who joins us as our receptionist is partially blind and
has worked in multiple organisations prior to joining
SapuraAcergy. She is also a member of MAB – the
Malaysian Association for the blind.
In order to help staff better understand the condition,
we invited representatives from MAB to give us an
awareness talk on how to treat and help differentlyabled people, should the need arise. Besides the
awareness talk, members of MAB also serenaded us
with a medley of classic tunes.
Vol. 2/2010 (Issue 2)
Though rendered speechless, Jayan was very much
grateful and presented some tokens of appreciation
that he had brought with him from Sarawak. We at
SapuraAcergy would like to thank Datuk Shahril, Datin
Yazreen, En Syariman and the whole of the Sapura
Community for their efforts and contribution to help
ease Jayan’s pain and hardship. May you be blessed for
your generosity! Thank you!
Success of the
Iwaki Platform
Decommissioning
Project
SapuraAcergy was subcontracted by Nippon Steel Engineering
Co. Ltd. for the decommissioning of the topsides, jacket and
associated section of 12” gas export pipeline of the Iwaki
platform.
The Iwaki platform, which was installed in 1983 at a water depth
of 154m, is located approximately 40km east of Nahara Cho in
Fukushima prefecture of Japan. SapuraAcergy’s client for the
Iwaki Platform Decommissioning Project was Offshore Iwaki
Petroleum Co., Ltd.
Led by Stig Adolfsen, the project management team was based
in Kuala Lumpur, with a Japan Branch Office (JBO) team based in
Onahama led by Mohd Ruzaihizal Bin. Zakaria. The Technical
team was led by Tom O’Malley with the support of Phoon Kok
Huei, Kyu Sik Son and their engineering teams who successfully
completed the technical work scope. The subsea cutting package
was headed up by Kingsley Wood with the assistance of Emma
Killip.
We welcome Gurmit and hope that she will have a
long and prosperous career with us!
First Aid Training
SapuraAcergy sees it as imperative that our employees
are provided a safe and secure environment to work in
at all times. As such, a two-day First Aid Training
session was held on the 8th and 9th July 2010 at the
VIP Room, Sapura@Mines.
The capabilities of the Sapura 3000 were fully exploited in
performing a multitude of tasks in this project, including the
following heavy lifts:
• 16 modular lifts ranging between 100MT to 1100MT removal
of topside facilities and Module Support Frame
• Cutting the jacket into two pieces at approximately EL-92m
• Lifting the upper section of jacket (2625MT), and lowering it
to the seabed
MAY-JULY
KDN No. PQ/PP1505(16900)
• Toppling of the upper section through 90 deg. adjacent to
original location
• Cutting and stabilising the remaining export pipeline
The Sapura 3000 commenced her mobilisation in Johor Baru on
the 19th April 2010, where all project equipment was mobilised
onto the vessel over a period of 3 days. Considering the large
quantity of equipment required for this project, the layout on the
Sapura 3000’s deck was a project in itself. The vessel departed
from Johor Baru with Onahama, Japan as its destination on
22nd April 2010.
The Sapura 3000 arrived in Onahama, Japan 7th May 2010, after
approximately 14 days of transit. During her port call to
Onahama, the Sapura 3000 received all custom & immigration
clearances in less than 1 day prior to departing for a short transit
to the field.
As soon as the vessel arrived at the platform location and tried
setting up, it became obvious that problems lay in store with
adverse vessel and crane tip motion caused by a long confused
bi-directional swell. Transfer of equipment, personnel and any
lifting operations became a challenge. Subsequently several
changes to the sequence of work and execution methodologies
needed to be engineered.
Once topside preparations were completed, and the vessel
motion was within limits, the topside modules and the MSF were
removed and placed upon four cargo barges. These cargo barges
were subsequently towed to port in Japan for the modules to be
stripped and scrapped as required.
Eight sections of 100m long piles were then removed, each
weighing in excess of 220MT. The removal of piles was again
very weather sensitive and required the vessel to set up at a range
of headings. This was a very restrictive operation, however, it was
performed successfully.
The Jacket removal operations required each of the eight jacket
legs to be sealed with the use of large pressure caps, four of
these caps had integral lifting padeyes to be used for the jacket
The training session which saw about 20 employees
participating is conducted to ensure that each department will have their own ‘first-aiders’ in case of
emergency. Participants are required to sit for theory
and practical assessment, which includes multiplechoice questions, skill demonstrations and mock-drills
(scenario based).
Once they have completed and passed the assessment,
they will receive a Completion Card which is valid for 2
years.
Strength and Depth
I am proud to say that a total of 92 days of the Sapura3000 was utilised to perform the Iwaki Platform Decommissioning Project,
With approximately 276,500 manhours onboard, without a lost time incident and only one number of first aid case.
continued on page 3...
- Stig Adolfsen
CEO’s Update
It is clear that our shareholders are more than pleased with our
progress and performance, but this also presents the challenge
of coming up with a balanced commercial progression between
Acergy, TLO and SapuraAcergy for the next 3 to 5 years.
There has been no indication of need for a change in the name
“SapuraAcergy” and it is my view that we should retain the
name as I believe that our branding is paying dividends and our
reputation is gaining traction within the Asia Pacific region.
Therefore the possibility of registering the name SapuraAcergy
as a separate trademark is very much existent.
Project & Operations updates
1. Completion of Iwaki Platform Decommissioning Project
Decommissioning projects are notorious for their execution
challenges but the Iwaki Platform Project has been a
wonderful success story for SapuraAcergy from start to finish
from a technical, commercial and client relationship point of
view. The project team and all the support divisions have
done a tremendous job. If the Kikeh and MHSRP II projects
were not enough to convince the regional market of our
potential, then I am sure that the outcome of the Iwaki
Platform Decommissioning project will have the desired
effect.
HSSEQ - Safe Operations
1. Safety measures throughout the Iwaki Project.
We definitely had some HSE challenges on the Iwaki project,
but after all was said and done, the client was very impressed
with our commitment to HSE at all levels in the company
throughout the project. Our safety management team and
our system functioned well under
sometimes testing circumstances
and a third party safety audit
by Acergy during the project
confirmed that SapuraAcergy
is on the right HSE track.
However, safety is an area
where we can never allow
ourselves
to
become
complacent and therefore we
need to continue to drive
ourselves towards HSE
excellence everyday
and everywhere.
2. Mobilization of Sapura 3000 for the Gumusut-Kakap
Once the jacket rigging was removed, the water within the jacket
legs was further pumped out, replacing it with air; making the
jacket approximately 450MT in weight. The vessel’s A&R line was
connected to rigging on the jacket top. The vessel then moved
500m clear of the jacket site and on the evening of the 3rd July
2010 the jacket was pulled over and toppled onto the seabed.
This completed the work scope of the project.
All infield operations were completed on the 5th July 2010. The
planned duration to complete removal works was 51.58 days
(including weather downtime) while the actual duration for
offshore works was 59.32 days.
The Sapura 3000 was the ideal tool for the decommissioning
scope, the vessel’s crane had significant capacity to perform the
topside lifting operations. In parallel with this, the fully integrated
ACV’s on the vessel completed the subsea cutting operations.
The vessel’s crane also had the redundancy required to complete
the jacket lift and land operation. The vessel’s A&R winch
(integrated into the pipelay system) was used for the toppling
operations. The Sapura 3000 completed the entire
decommissioning work scope without the support of any 3rd
party construction vessel.
Highlights
3rd – 6th May 2010
4th May 2010
6th May 2010
7th May 2010
7th May 2010
29th May 2010
16th June 2010
24th June 2010
June 2010
29th June 2010
July 2010
5th July 2010
8th – 9th July 2010
19th July 2010
20th July 2010
22nd July 2010
27th July 2010
Acergy/SapuraAcergy participates in OTC Houston
Commencement of 2nd Cycle of SIGMUS inspections
Main Uddin’s heroic efforts in saving his co-worker’s life has him dubbed Gumusut’s “Goal Zero Hero”
Jayan’s ‘Appreciation Tea-Party’ with the Sapura Community
Sapura 3000 arrives in Onahama, Japan
Sponsorship of the ‘SapuraAcergy – OGAS Cup’
1st Town Hall Meeting FYE2010/2011
Malaysian Association of the Blind (MAB) Awareness Talk
OHSAS Surveillance Audit
Completion of the English Language Classes
Mt Fuji Charity Climb by Dan Chin (Sapura 3000 crew member)
Successfully completed the Iwaki Decommissioning project
First Aid Training course
Shahar Bin Hashim joins SapuraAcergy as Deputy Director HSSEQ - Corporate
Sapura 3000 arrives in Labuan from Japan
2nd Board of Directors’ Meeting FYE2010/2011
Commencement of Gumusut-Kakap project
What’s Up
Long Service
Awards Ceremony
SapuraAcergy held a Long-Service Awards ceremony at our 2nd
Quarter Town Hall meeting on 6th June 2010 in recognition of
continuous service with the company.
Congratulations to the following employees:
“How did he come about working for Sapura Acergy?,” we muse out loud. Hilmy replies, “A friend asked me
for my resume to submit it to Brooke International, and after it was passed around a bit, it came to SapuraAcergy. I hadn’t heard of SapuraAcergy but had heard of the established Sapura organisation and was
interested in the offer.” He goes on to say “What sealed the deal was the lure of offshore
work and the opportunity to start from scratch with a new company.”
The highlight of Hilmy’s daily routine is the toolbox talk he has with the crew. These are
essential as he discusses safety issues related to any safety bulletin here and reads out
the U-See U-Act submissions of the preceding day for affirmative action. When asked
what his greatest challenges are, working on the Sapura 3000, he replied “...to
educate people, especially the mid-level management on the importance of
HSE and that it is not just the responsibility of one person. HSE is for all!”
His advice to any who wish to become Safety Officers like himself, is
to always expect the unexpected and to be sure of the decisions one
makes as situations may arise between the company and the safety
acts/laws, “where you’ll have to be careful and stand by your
decision.” In parting Hilmy says with a smile “Good luck!”.
The crane experienced 1050MT during the lifting
operation, 1543MT of buoyancy was gained from 75%
of the leg length being filled with air.
Once at site, the project team was challenged with
re-engineering many of their solutions to reduce the use
of the main crane and maximise the use of the 40T
cranes along with manual handling and local rigging
methodologies to lift smaller items on the platform.
The supply of material and equipment from Japan was
kept to a minimum, however dealing with local
Japanese presented both language and cultural
challenges that needed to be overcome. With the aid of
local Japanese employees these challenges were
managed with ease.
Kong, Norhisham b Harun, Mohd Asri b Ariffin, Ang Kim Puay,
Daryl Leo Wakelin, David Ramoo, Yeo Cheng Kwan, Daniel
Carre, Gunawan, Zulkarnain b Saim, Nazlida bt Mohd Noor,
Fadzlina bt Tokiman, Iain Gray, Juliana bt Yahya, Nurman Harris,
Norwahida bt Ahmad, Azhar b Hasan, A. Gilbert D’Cruz,
Thomas Fontaine.
4 YEARS
C.J. D’Cort, Shawn Wong Chow Hong, Nurul Afiqah Kong bt
Abdullah, Syed Takhiruddin b Syed Abd Bari, Azizah bt Abu
Hassan.
3 YEARS
Frank Tilborg, Arizal b Abu Hassan Masri, Haznim bt Othman,
Mithlan b Mahyuddin, Zalifah bt Mustafa, Ameliza bt Abu Yazid,
Mohd Yusmi b Abd Mutalib, Alfred a/l G. Veeriah, Norhazita bt
Mohammed Nor, Aisyah bt Hj. Dzulfakar, Nurul Syariza bt
Ahmad Kamsuri, Lim Swee Lin, Tai Kien Hock, Riva Suliawan,
Phang Yoke Khim, Norliza bt Mohd Tajuddin, Nora ’Ain bt
Saharudin, Azmi b Ajman, Vincent Fromont, Laurent Rinaudo,
Rozita bt A. Rahman, Natasha Lee Sing Yee, Joel Sheng Kian
However, destiny had other things in store for him, and although this adventure seeker didn’t become a firefighter, he says
“I found my true calling in being an offshore safety officer”. Having been in the industry for twelve years, Hilmy’s first
posting was in Vastalux where he served as a safety officer for one year.
Jacket lift; the estimated overall jacket weight was well
in excess of the maximum lift capacity of the Sapura
3000 main crane. In order to achieve the lift, the legs of
the jacket needed to be sealed and used as buoyancy
chambers to reduce the lift weight.
Environmental conditions in the Pacific Ocean were the
biggest of the project challenges. The location of the site
presented the vessel with bi-directional swells. This
caused the vessel to roll continuously which reduced the
operational ability of the main crane.
Heeding His Calling
Hilmy Ishak is a self-professed happily married man with three children aged 11, 9 and 3 years. Describing himself as a serious worker,
yet happy-go-lucky otherwise, and a crowd-pleaser, this motor enthusiast originally aspired to be a fire fighter – joining the ‘Kadet
Bomba’ during his school days.
As there were so many unknowns, it is very difficult to
engineer the exact jacket weight, therefore to prevent
the jacket being buoyant, the jacket needed to be lifted
in stages, this allowed the jacket’s actual weight to be
established.
Once as-left surveys were completed the vessel transitted to
Onahama port, completed custom & immigration clearances and
set-sail for Malaysia on the 5th July 2010. After negotiating her
way past typhoon Conson, the vessel arrived in Labuan on the
20th July 2010 and completed the demobilisation of equipment
onto an awaiting cargo barge.
campaign
The Gumusut-Kakap mobilisation went reasonably well
despite some technical delays. The project team did a good
The decommissioning of offshore installations is the next part of
our industry. The successful completion of this work scope allows
SapuraAcergy together with the Sapura 3000, to be a market
leader in this field of operation.
Challenge 2
Although no dramatic changes to our company have been
foreseen, we have been in discussion with our shareholders for
the past 6 months in order to gain clarity on the commercial and
growth objectives of the company. We have also discussed the
possibility of acquiring a second vessel.
3. Devil Creek Development Project (DCDP) project progress
The DCDP project is largely on schedule with the offshore
pre-lay survey recently completed and the shallow water lay
barge, the Leighton Stealth, scheduled to commence
operations on xx September 2010. The Sapura 3000 will
proceed to mobilise for the DCDP immediately upon
completion of the Gumusut-Kakap campaign for 2010.
When the environmental conditions were right, the vessel’s
crane was connected to the jacket via 65m long 14” diameter
slings, and the water within the jacket legs was pumped out
making the jacket approximately 1000MT in weight. The jacket
was then lifted clear of the lower section and moved 80m to the
landing site. The jacket was then lowered to the seabed using a
series of crane moves and de-ballasting steps, and was set on the
seabed on the 3rd of July.
Challenge 3
One of our joint venture partners, Acergy, recently announced its
imminent merger with Subsea 7, a world leader in subsea
engineering and construction. The merger will be completed in 6
to 12 months’ time, until which time it will be business as usual
for SapuraAcergy.
job, keeping in mind that Shell is a technically demanding
client. The vessel is currently laying an 18” diameter pipeline
towards a 1200m water depth and early indications are that
the project and vessel are making good production progress.
From day one throughout the entire project cycle, the project
team worked together as one, with excellent team morale. The
challenges of working in a country in which no one had worked
before and successfully completing a decommissioning job is a
great achievement for us as a company as well as a personal
achievement for all team members.
Challenge 1
lifting operation. Prior to the jacket lift, a manifold of air lines
were arranged around the top deck of the structure, tested, and
connected to an air compressor spread located on the deck of
the vessel.
On the right track
On the merger:
Over A Cup Of Coffee
Continued from cover story...
HSEQ
Gumusut Goal Zero Hero
Safety is at the core of who Shell is, and delivering on our Goal Zero vision
requires everyone to constantly identify possible hazards and deal with them. A
safe environment is also synonymous with a tight-knit community, where people
look after each other and themselves. Nowhere is this more evident than on our
project sites around the world.
The story of Main Uddin, a general worker with a contractor firm on the Shell led GumusutKakap Project in Malaysia, shows how quick thinking and simple safety rules save lives. (The
Gumusut-Kakap field, also called “Gumusut”, is a field located in the Baram Delta Basin, offshore
north-west Sabah in water depths ranging from 850-1200m.)
On the morning of 6 may 2010, Main was assisting a Contractor Site Supervisor in routine bolting activity on
a J-Lay tower installation when something unexpected happened. When picking up a torque wrench, the supervisor suffered an electrical shock.
Main reacted immediately by first disconnecting the power connection before assisting his injured co-worker, effectively
saving his life. The victim was subsequently referred to the nearest hospital within 30 minutes where doctors confirmed him
to be okay.
Learning from this unfortunate incident is key and an investigations process was carried out. The incident has now been
properly documented, classified and the knowledge gained is being shared. As for Main, he was absolutely clear about
what needed to be done when the incident occurred. He knew the rules, applied them and by doing so, he saved the
life of his co-worker.
Shell’s commitment to relentlessly pursuing a goal of no harm to people and protecting the environment is a
mandatory requirement for all contractors, Shell companies and joint ventures under operational control.
Safe organisations are high-performing organisations, and delivering high performance across the board
is what success looks like.
Thanks to Main’s exemplary actions one of our co-workers was able to go home to his family,
and he has been dubbed Gumusut’s “Goal Zero Hero”.
Main Uddin is presented a certificate of recognition by
The SapuraAcergy employees who received Long Service Awards
Winfried Arens, VP Projects, UI East, at a large Safety Day