ISSUE 1 (13) 2014
Photo: Jakub Bogucki
in the heights
DFDS entrusted to us scrubbers
installation on-board it’s ships again
Key milestone on the FPF-1 project
achieved. Heavy equipment lifted up!
Over two million manhours
without accident on FPF-1 FPU project
Pages 3 - 5
Pages 17 - 18
It’s the final
3 We have a blitz
We assist DFDS in following
an innovative course to
meet the new sulphur rules
6 The Boskalis
During January 2015, new environmental regulations will come into
force which will be of crucial significance to the shipping industry in the
Baltic Sea, the North Sea, the English Channel and the entire northern-European transportation network.
Under these new environmental 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 expensive than oil with 1% sulphur, which
is commonly used today. Fuel prices will therefore become much
more expensive and subsequently
increase sea transport costs. This
could potentially lead to freight being forced onto European roads
and result in an increase in road
congestion and other environmental problems.
It means something very important 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 installation on-board the ships they operate, otherwise they may go out of
business. For this reason they probably stay awake long into the night,
since it’s a scene from their worst
But, there is nothing to be afraid
of. We have recognized the problem which these owners have faced
consulting them and suppliers of
marine equipment and marine environment protection systems as well
at a very early stage.
We are thus ready to assist owners 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 accomplish scrubber systems retrofitting jobs smoothly.
In July and August 2013 we installed Alfa Laval PureSOx exhaust
gas cleaning systems aboard four
DFDS Seaways ro-ro ships. That
operation was followed by another scrubbers installation in October 2013 on a large double – ended
car – passenger ferry operated by
Recently, DFDS has entrusted to
us scrubbers installation on-board
it’s seven further vessels (see details on pages 3 – 5). Some experienced European shipyards were
considered for this job, but eventually all the vessels have gone to
Remontowa. DFDS has trusted us
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 scrubbers! We have knowledge, experience, skilled workforce and facilities.
And we have the last minute offer,
however still available.
You can trust us, too.
Frequent visitor brings part
of its dredging fleet to us
We have a blitz on
There is a time when we
must keep our docks ready
12 We’ve breathed
new life into
Growing business in fishing
vessels and Eastern
14 We are a team!
Planning & Project Tracking
at Conversion Department
One of the most complex
17 Heavy lifts in
Key milestone on the FPF-1
Over two million manhours
without accident on FPF-1
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]
The content of the magazine (with the exception of photos) may by reproduced provided the source.
ISSUE 1(13) March 2014
We assist DFDS in following an innovative
course to meet the new sulphur rules
Remontowa Repair & Conversion is a quarterly customer magazine of Remontowa Shiprepair Yard, member of Remontowa Holding S.A.
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
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 ferry and ro-ro operators in Northern Europe. With a fleet of 42
passenger/car ferries and freight only ro-ro’s, the company delivers to over 8,000 customers high performance and superior
reliability through shipping & port terminal services, and transport & logistics solutions. For more than five million passengers, 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 strategy of transition to new sulphur rules.
And Remontowa largely contributes
to the process of getting DFDS ready
for new emission regulations.
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 Baltic Sea, the North Sea and the Channel, which are DFDS’ primary market
areas. According to recent DFDS Annual Report’s business environment
overview - the price of MGO (Marine
Gas Oil) with a content of 0.1% sulphur is currently 40-50 % higher than
1.0 % bunker fuel and this price difference is expected to continue in the
The DFDS’ transition strategy to
overcome the considerable financial
challenge of the new rules has three
� Installation of scrubbers on 21
ships by 2017
� Roadshows and meetings ongoing to prepare freight customers and
market for a cost increase
� Consolidation of routes.
Remontowa has already been assisting 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 installation is planned for another seven ships during 2014. At Remontowa
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 initially 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 involved in this year’s scrubber installation process.
The work is to be carried out during
the ships’ normal, scheduled drydocking 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
ISSUE 1(13) March 2014
which deserves consideration...
Actual and foreseen scrubber installations
at Remontowa in the coming years.
the 37,939 gross tonnage freight ferry Ficaria Seaways, was performed in Germany 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
Similar pattern, but with wider range of works - some piping and some further 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 engines, 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 Remontowa during 2014 comprises: two ro-pax vessels from Kiel-Klaipeda and
Karlshamn-Klaipeda routes - Victoria Seaways (built 2009, GT 25,518), Optima Seaways (built 1999, GT 25,206), adding to five freight ro-ro ships:
Britannia Seaways (2000, GT 24,196, Esbjerg - Immingham route), Suecia Seaways (1999 built, GT 24,196, Vlaardingen - Felixstowe route), Primula 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 operating 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!
Shipowners and operators will soon face hard reality 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 January 1st 2015.
Numerous countries and harbors attract the Owners with port and fairway fees incentives and “green
awards” dependent on vessels emission, encouraging 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 Environment 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 Emissions 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 contributing to acidification. The UE Directive regulates
the use of low sulphur fuel (below 0.1% sulphur content 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 directive allows for application of an alternative solution: 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 consumption 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 considering.
Victoria Seaways with the Alfa Laval’s scrubber system
installed at the end of March 2014.
Photo: Jerzy Uklejewski
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.
Trailing hopper suction dredger Crestway during its stay at Remontowa in January 2014.
ISSUE 1(13) March 2014
Royal Boskalis Westminster NV is
a leading global maritime services
company operating in the dredging,
ports, offshore energy and inland infra sectors. Its main clients include oil
companies, port operators, governments, shipping companies, international project developers, insurance
companies and mining companies.
Through Smit, Boskalis is also active
in towage and salvage. The company delivers innovative one-stop solutions to major maritime challenges.
Boskalis has 11,000 employees,
including its share in partner companies. The Netherlands based company operates in some 75 countries
across six continents. The versatile fleet of Boskalis consists of over
1,000 vessels and equipment. This
includes one of the largest fleets of
- As Boskalis is active also on
the Baltic, Remontowa, the leading
shiprepair yard in the region is a natural 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 advantages our yard is able to offer as
quality of service, flexibility and the
ability to mobilise assets and workforce on short notice – Piotr Kubicz,
Western European Market Commercial 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 hopper 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, remained at the yard for a wider range
of repair and maintenance works.
It was not the first time that Remontowa hosted and serviced Boskalis’ 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
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 replaced 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 maintenance 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, disassembly and then reassembly of shaft line cover (for the purpose of measurements of clearance / backlash and replacement of shaft sealings), replacement 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, machining of the cutter head bearing sleeve, works on keel (sea chest) coolers,
overhaul, repairs and measurements of the wheels of the stern trolley, overhaul of bottom sea chest valves and many items more.
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
There is a time when we must keep our docks
ready for them...
Season for ferries
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.
Dieppe Seaways during undocking.
ISSUE 1(13) March 2014
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 operating 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 Remontowa 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 Shipping Co. since 2007, spent 17-days (including 16 days in a dock) at Remontowa. 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 operator - serviced recently at Remontowa
was the 34 years old car and passenger 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 season. 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 (Germany) - Trelleborg (Sweden) route. The
ferry arrived to Gdansk for 2-year
class renewal, which meant reviewing and checking almost all machinery, 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 significant. Already in the process of repairs, additional work was commissioned by the Owner and widened
the scope or works to be done at
Cleaning and painting of the underwater hull (about 5200 sq m) or
the repairs and renovation of four exhaust gas boilers, as well as an auxiliary 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 Denmark’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 considerable and included, among oth-
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 replacement 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. Michel (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 maintenance of the hull with silicone paint application. Silicone paint offers better durability and lower surface friction at the same time, which facilitates fuel saving. 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 temperature. 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 recent years. One of the most visible result of this ferry’s recent stay at Remontowa 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
Refurbished Scandinavia departing from the shipyard.
Polish – operated Baltivia in the night...
Pont Aven leaving the yard after completion of repairs.
10 ISSUE 1(13) March 2014
Growing business in fishing vessels
and Eastern European sectors
new life into
Boris Syromiatnikov departing from Remontowa after completion of the conversion...
Photo: Jerzy Uklejewski
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 processing plant. But the range of upgrade was even wider. Remontowa
installed new main engines and several new, modern items of equipment
and systems that definitely enhance
the fishing and fish processing capabilities onboard Boris Syromiatnikov.
It is worth recalling that over the recent years is was not the first so extensive, thorough modernization of
12 ISSUE 1(13) March 2014
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 improved fishing and processing capabilities of Lira has been the main reason 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” offer 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-tuning 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 capabilities.
More often world’s leading manufacturers 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 calibration of shipboard machinery and
systems (just to mention top German
engine makers or manufacturers of
freezing equipment for fishing vessels). That proves the professionalism and renown, that Remontowa
trade mark enjoys - concludes Zygmunt 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 installing new items of equipment and
systems is a tedious work.
However, careful preparation of
conversion or upgrade design by
Remontowa Marine Design and Consulting Ltd., as well as proper coordination of repair, maintenance and
modification works, with supervision
from managers for production coordination, allows for successful completion 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 building entirely new fish processing factory, including numerous specialist
items of machinery, such as conveyors, fish processing equipment, sorters, 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 generators were overhauled, time-worn boiler was replaced with a new one supplied 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 replaced 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
Another deep-sea trawler - Lira - has recently undergone a wide range of
minor repair work. More significant items on the repair specification included: 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 Kurshskaya 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 fixing 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 systematic positive trend - seen over the recent few years - of revenue growth
and the number of vessels serviced by Eastern European Market Commercial Office of Remontowa.
The ship has also been entirely re-engined.
Photo: Jerzy Uklejewski
An entirely new fish processing factory was built onboard the ship.
Photo: Jerzy Uklejewski
One of the most complex projects nears
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
Planning & Project Tracking
at Conversion Department
Prosafe team during the undocking operation at Remontowa S.A.
Photo: Jakub Bogucki
We are a team!
Planning is critical to the
success of any project of
any size. Planning is a goaloriented, 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
Our specialist team every day analyzes
the progress in project execution.
14 ISSUE 1(13) March 2014
In Remontowa, on each step of the Project we pay a special attention to detailed project schedule. During the planning process it is necessary to define 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 resources 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 critical, 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 factors 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 Reflection, 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 special 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.
Key milestone on the FPF-1 project achieved
in the heights
Precise and difficult operation of
large structures and equipment
transport made for another milestone
for the project FPF -1.
Robert Hoefta (on the right), mechanical completion manager
at the shipyard’s conversion department.
Let us recall, that the Prosafe - operated semi-submersible accommodation and workshop unit Safe Scandinavia arrived to Remontowa S.A. late
November 2013, to undergo repairs,
maintenance and upgrade.
The focus and aims of the project are amongst others, to increase
her mooring capability (by replacing 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 floating 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 December 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-
16 ISSUE 1(13) March 2014
part from the yard immediately. During intensive finishing touches of the project 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
According to Robert Hoefta, mechanical completion manager, a special
team works on preparing full completion of the project to hand over the upgraded platform to the Owner. The team operates within a “conversion completion department” at Remontowa, focused on preparing and implementing 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 welding 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 documentation 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.
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
The scheduled several days operation 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 prepared 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 considered by the management of the
FPF-1 project as a milestone - key
stage point of the project - Krzysztof Dusiński, FPF-1 topsides project manager explains. Uglen floating 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 according to the plan drawn already three
months earlier, still at the stage of
docking (lift-up) of the submersible
The schedule has been completed just as foreseen. Our yard, along
with the subcontractors, had to provide pipe racks and supporting structures 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 separator and so called off-gas compressor. 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 meters and height of 10 m. The heaviest item weighed about 100 tons! In
total there were five such structures.
Precise logistics planning resulted
in collision-free and efficient completion of the entire operation. First talks
regarding the preparations, involving
our special task force team, took place
already half year earlier before the actual operation. It was then, when the
date of operation was set for January
16, 2014. Extensive phase of preparations commenced three months before actual operation.
18 ISSUE 1(13) March 2014
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
The whole plan of lift-up shipments of structures and equipment was dependent 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 shipments. Sometimes last-minute modifications of supporting structures have
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 operation began with the so-called “tool box talk”, or talk with the involved performers prior to the task. Every day there were also meetings with the Owners,
where the sequence of operations and potentially dangerous aspects operation 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, maintains a custom of awarding such spectacular achievements, and so did our shipyard
receive special award - occasional statuette.
Receiving an award for maintaining a
high level of health, safety and culture of
work is one of the highest forms of recognition. 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 professional 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 workers and subcontractors, members of task
force teams from Remontowa and Petrofac, fire-fighters, health and safety inspectors, designers, as well as representatives
of the shipyard’s management, led by CEO
Jarosław Flont and member of the board
for conversions Janusz Czajkowski. Representatives of the Owners were present
as well, with Marwan Chedid, Chief Executive ECOM, Rob Jewkes, COO IES and
Marwan Chedid, handing an award statuette to Jarosław Flont, expressed his
thanks for all activities so far, leading to excellent safety track record. He also emphasized 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 culture 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.