Laem Chabang Fabrication Yard Facilities

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FABRICATION YARD FACILITIES

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Laem Chabang Fabrication Yard Facilities

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FABRICATION YARD FACILITIES The centre of manufacturing for CUEL is located at the deep-sea port of Laem Chabang, 130 Km southeast of Bangkok on the eastern seaboard of the Gulf of Thailand, where CUEL operates the largest and most modern offshore fabrication facility in Thailand. CUELs 264,000 m2 (expandable to 318,000 m2) construction facility is located within the boundaries of Unithai Shipyard and Engineerings 560,000m2 ship repair facility. The facility has direct water front access to the Gulf of Thailand and is linked by excellent transport services, being adjacent to the Laem Chabang deep-water port, and major key road and rail links. The CUEL fabrication yard is located close to the Rayong/Mataphut petrochemical industrial area where a large number of skilled personnel and experienced fabrication subcontractors are available to supply any trade and quantity of skilled workers as required. The CUEL facility is fully self-contained with current production capacities of: Fabrication Facility Fabrication Area (m ) Man-hours per year Structural (tons per annum) Typical 4-leg wellhead platforms (circa 1,400T)
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264,000 318,000 (Year 2007) 4,500,000 6,000,000 30,000 40,000 8 - 12 simultaneously 18 - 24 per annum

1.

Yard Layout

The CUEL fabrication facility was purposely developed to cater for fabrication/construction of offshore oil and gas jackets and topsides. The material flow through the yard is one way from arrival at the material lay-down area progressively through the fabrication/painting, pre-assembly, final assembly and load-out processes. The yard assembly area has a 15T/m2 uniform bearing capacity allowing jacket and topside structures to be fabricated in any location and arrangement within the 128,000m2 final assembly area. The yard utilizes multi-wheeled transporters to move pre-assembled and assembled components through the production process providing maximum flexibility in yard layout and load-out sequences. Where possible the roll-up method of fabrication is used providing the most cost effective and efficient production process. The yard has the following key facilities: (refer to the yard layout on Page 10) 1.1 Material Lay-down Area This is a 45,000m2 area for materials lay-down and pre-fabrication automated shot blast and prime facility. Depending upon the project requirements, area is allocated for different materials such as for topsides, jacket legs, piles, tagged equipment items etc.
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Laem Chabang Fabrication Yard Facilities

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Within this area, around 8,000m2 is allocated for the blasting and priming of structural steel and plate material. The automatic blasting plant allows materials to be blasted then primed prior to fabrication where final painting is carried out on-site. 1.2 Warehouses and Material Storage Areas a) Open Storage of 140m x 200m used for the storage of: Structural steel plates, sections, tubular Process piping, valves (large size) Equipment, vessels and machinery

This area is equipped with 50T mobile cranes, trailers and forklifts. b) Indoor Storage 1. Piping and Materials Warehouse of 60m x 30m (expanding to 60m x 60m in 2007) facility for the storage of pipefitting and other miscellaneous items: Equipped with electrical hoist, forklifts. 2. E&I Warehouse of 72m x 20m facility for the storage of electrical and instrumentation items: Equipped with the forklifts. c) Covered Heated/Air-conditioned Storage consists of 7m x 5m area and is used as an E&I calibration shop and sensitive instrument storage facility. 1.3 Fabrication Halls (available through Unithai Shipyard and Engineering) There are two fabrication workshop halls, one for heavy and one for light material preparation. The dedicated workshops are equipped with overhead cranes, computercontrolled plasma cutting equipment, plate profile cutting machine, bending rolls, 1000 tonnes hydraulic presses, drills, guillotines and a wide range of manual, semi-automatic and automatic welding equipment. a) Heavy Fabrication Workshop consisting of 3,500m2 area, used for plate cutting, bending and rolling (11m H 25m wide). b) Light Fabrication Workshop consisting of 2,500m2 area, used for the pre-fabrication of miscellaneous item, such as casing guide, stairs, access platforms, pipe spools etc. This is an open-end covered workshop of the same height. 1.4 Fabrication Production Lines Components are pre-assembled in this area. Total area 30,000m2, which is divided into two parts: a) Jacket/Foundation Pre-assembly Area is allocated for the pre-fabrication of jacket legs, piles and heavy tubular members. It has following facilities: 4 x Semi-automatic submerged arc welding machine 1 x 110T rotators 2 x 20T rotators 2 x 30T rotator
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ESAB LCF1200 power sources + RC500 welding pods 2 x 120T gantry cranes 2 x 20T gantry cranes

b) Deck/Sub-sea Pipeline Pre-assembly Area is allocated for the prefabrication of platform deck structures, sub-sea pipeline assemblies, etc. This has following facilities: 5 x 10T gantry cranes CNC plate cutting machine 3m x 12m ESAB LCF1200 power sources + RC500 welding pods

c) Deck Assembly Shop 5 bays assembly shop with roof cover 25m 30m width x 70m length. Each bay is equipped with o 2 x 20T gantry cranes o 300 KVA electric power supply o Centralize supply line for O2, CO2, LPG and compressed air o DC welding machines and MIG welding machines. 1.5 Quay sides, Assembly/Erection Areas 128,000m2 area for jacket and deck assembly having 360meters quay frontage and a 30m x 30m load-out jetty. The area is equipped with: 3 x 150T crawler cranes 1 x 100T crawler crane 2 x 1000 KVA Electric power supply (underground distribution) ESAB LCF1200 power sources + RC500 welding pods Load out jetty rated for 4,500T integrated components

1.6 Dry dock facilities Two floating docks (available through Unithai Shipyard and Engineering): Loa: UNITHAI #1 282.2m 47m Keel: 250.2m 47m Capacity 140,000dwt UNITHAI #2 Loa: Keel: Capacity 191m 36m 169m 36m 75,000dwt

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1.7 Administration Block Administration block, with an area of approximately 10,000m2, consisting of multi story modern offices, accommodation and workforce canteen.

Yard Facilities: 1. Material Lay-down Area 2. Warehouses and Material Storage Areas i) Open Storage ii) Indoor Storage iii) Covered Air-conditioned/Heated Storage 3. Fabrication Halls 4. Fabrication Production Lines
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45,000 25,000 3,000 35 22,000 53,000

m m m m m m

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5. Quaysides, Assembly/Erection Areas 6. Dry dock Facilities i) Unithai #1 ii) Unithai #2 7. Administration Block 8. Development Area year 2006 2. Cranes and Heavy Equipment Capacity (Tonnes) 150 100 50 25 120 10 20 10 100 Lifting Height 128,000 140,000 75,000 10,000 52,000 m dwt dwt m m

Category Mobile

Type Crawler Rough Terrain

Gantry crane

Siced Demag A BUS A BUS Luffing

Floating

No. 3 1 2 3 2 3 12 4 1

Span

270m 30m 260m 20m 90m x 25m 260m x 20m 40m

18m 8m

Additional cranage is sourced on a rental basis up to 1,000 tonnes from local crane companies. Heavy haul multi wheel bogies are sourced from local (JV with international) transport haulage companies. 3. Welding Facilities Type Manual Description ESAB LCF 1200 Power source ESAB LCF 2400 Power source ESAB RC 500 Welding Pods LTN 200 Aristotig DC Inverter TIG M/C Welding M/C KHM 500PC Arcair gouging torch K4000 Automatic ESAB A6 Arcmaster submerged arc welder Additional welding equipment is managed locally on a rental basis as required PEA 1000 KVA, 22 KV/400V/50Hz Qty 11 units 1 units 120 units 22 units 6 units 24 units 3 units

Source of additional welding equipment Electric power source

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Welding procedures and welder qualification testing are in accordance with American Welding Society AWS D1.1 and ASME IX (latest revisions) welding standards. All welders are multi-coded qualified as 6G, or 6GR. 4. Miscellaneous 4.1 Mechanical & Fitting Shops Machinery S. No. Description 1.1.1.1.1

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

Farley Automatic (NC) Cutting Machine, 25mm thick Pinch Plate Roll Machine, 2in thick capacity Cincinnati Vertical Turning Lathe Forsdick Radial Arm Drill with 5ft. arm, 17in column Lodge & Shirley Centre Lathe Bullard Vertical Milling Machine Cincinnati Milling Machine ref. No. 260 Carlton Radial Arm Drill with 4ft. arm, 13in column Gray Planner, Martin Marietta Lucas 42860 Horizontal Milling Machine Victoria Universal Mill Portable Milling Enerpac Hydraulic Pipe Bender 1-1/4 to 4 Hydraulic Pipe Bending Machine 3/8 to 4 Bending Machine Pipe Threading Machine Lathe Machine Cutting Band Saw & Accessories Punching Machine Guillotine Shear Air Winch (Pneumatic) Model K6U Air Winch (Pneumatic) Model H5U Cap 1,361kgs Compressor Air Winch Type AH-36B Compressor Air Winch Type AH-22 Plate Stripping Machine, Koike, 4 parallel & 1 cross torch Tracer Shape Cutting Machine, Koike optical, 4 gas torches Ram Traveling Press, Mori 500T Hydraulic Guillotine, Atlas 3m long, 13mm thick Light Rolling Machine, 200T, 1.5m long Sunrise 60T Universal Ironworker
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1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 2 2 1 1 2 2 2 1 1 1 1 1 1

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S. No. Description 1.1.1.1.1

31. 32. 33. 34. 35. 36. 37. 38.

Profile Bending Machine Carter Water Cooling Tower Messer Grieheim 2 Head Profile Cutter Messer Grieheim 4 Head Profile Cutter Denco Miller Air Dryer Type 12W12 Hugh Smith HYD Shipyard Roll Press, capacity 1000T Press Brake, Cincinnati 1000T, 5m long Band Saw 280FLG

1 1 1 1 1 1 1 2

4.2 Non-Structural Capabilities and Capacity Pipe Shop Electrical Workshop Instrument Workshop Instrument & Electrical Lab/Test Shop Pre-Commissioning Subcontractors- Ultimate Technology Service Co., Ltd.-Expert team Co., Ltd.-Emco Subcontractor - Tri Progress In-house capabilities to carry out instrumentation, calibration, installation and pre-commissioning works. In-house capabilities to carry out E&I instrument testing and calibration. In-house capabilities to carry out pre-commissioning works coverings: Mechanical systems E&I systems Piping systems

4.3 Subcontracted Activities Plate Rolling Cutting & Edge Preparation Equipment Post Weld Heat Treatment Equipment Preheating and post heating Equipment Blasting, Painting & Finishing Equipment Fire Proofing & Insulation Services
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In-house and STP&I In-house and Unithai Shipyard & Engineering Uranus Thermal Engineers & Services Uranus Thermal Engineers & Services Profound Innovation (on site) Deborah Services (on site)

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Equipment for Non-Destructive Examination Laboratory Equipment (Destructive Tests) Weighing Equipment Loadout Multi-wheeled Trailers Thai NDT/OIS (on site) SIWA Destructive Testing Services Mammoet Mammoet

4.4 Training Facilities

Training facilities include: In-house welder training school In-house safety training team In-house HR team running and coordinating management, work skill and related courses. Other occupational training courses provided by outside facilities

4.5 Client Offices Adequate space- Available for office staff Facsimile - Available Telephone - Available Internet & e-mail services (high speed connection) available Secretarial help - Available Catering - Canteen on site Transportation - Local services available Accommodation - Hotel accommodation in Sri Racha (5km) and Pattaya (25km).

4.6 Security Services

Private security service around overall premises on a 24 hours basis.

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5. Load-out Capacity Yard has direct access to deep sea shipping channel via 30m 30m load-out quay with a total load capacity of 4,500 tonnes. Minimum water at low tide is 6m and normal tide variation is 2.32m. Assemblies are transferred from assembly yard to barges by multi-wheel transporters. Topside - no limit Jacket - no limit Maximum Weight Topside limit is based on transporter axle load (with present jetty design) Jacket limit is based on transporter axle loads. Method of Transfer Load out by Self Propelled Modular Trailer (SPMT) for topside and jacket at purposely built load out jetty (30mx30m, bearing capacity 10T/m2 tested up to 30T/m2). Engineering Based on 25m x 20m load bearing area distributed by SPMT, Calculation total bearing capacity is 5,000 metric tones. Maximum wheel load of SPMT is 36T/2.4m = 14T/m, bulk head jetty design capacity is 18.2T/m. Multi-wheeled trailers and Self-Propelled Multi-wheeled Trailer are available through specialist subcontractors for load-out purposes. Maximum Size

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