Case Studies

MatriX-EPS ensures steel fabrication & construction companies operate with maximum productivity

Unithai

Unithai expanded and modernised its major shipyard and advanced engineering facilities in Thailand in 2016. As part of this expansion the company selected MatriX-EPS to manage and ensure strict adherence to the company’s quality control procedures. The system is now also used to drive project management processes on all projects.

Unithai Shipyard and Engineering operates Thailand's largest shipyard, located within the country's main international deep sea port of Laem Chabang, which is at the heart of Thailand's chemical and oil tanker, container, dry bulk, car and offshore trade. The yard is developed on 688,000m2 of prime water frontage adjacent to the main port area accessible by protected deep water, rail link, and an excellent road system and only a short distance from the port and anchorage facilities of Ko Sichang, Map Ta Phut and Bangkok.

Core activities of this division of the Unithai Group are a complete range of ship repair, modification, conversion, shipbuilding, and offshore oil and gas fabrication work. With an extensive track record, Unithai has delivered many offshore and onshore structures worldwide, with major projects covering jackets, topside modules, jack up rigs, subsea stations, steel bridges and steel building structures, power plants and tank farms.

MatriX-EPS has helped Unithai Shipyard and Engineering successfully deliver a number of major steel fabrication and construction projects since 2016, including offshore modules and tug vessels.

MatriX-EPS helps steel fabrication & construction companies win major projects and ensures they are delivered on-time and within budget

Eversendai

When Eversendai opened its major new advanced fabrication facility in the Middle East in 2016, MatriX-EPS was selected to support all operational and project management information requirements. The company’s newest fabrication facility is in Ras Al Khaimah in the United Arab Emirates (UAE) and is one of the biggest in the region, having a land area of over 200,000m² with over 550m of exclusive quayside to specifically suit most onshore/offshore load out operations and is now considered to be the crown jewel of Eversendai.

Eversendai Offshore is an established Oil & Gas EPC contractor, specialising in complex fabrication projects, ranging from medium sized turnkey projects to large EPC projects covering the MENA, Asia Pacific, Australasia & European markets as well as the United States of America (USA) & South America. The company’s core focus is in the construction of New Build Jack-up Rigs including Upgrade/Refurbishment Rigs, EPC Fabrication Onshore/Offshore, Wellhead and Production Platforms, Offshore Structures & Foundation, Process Modules (including Early/Central Production Facilities, Separation, PWT, Compressors, Chemical Injection), Offshore Living Quarters, New Build Offshore Jack-up (Liftboats) as well as a range of Turnkey EPC Engineering services dedicated to the Oil & Gas sector.

MatriX-EPS has been used to support a number of major steel fabrication projects at Eversendai’s major UAE facility. These have included oil and gas projects, as well as civil engineering and vessel fabrication projects subcontracted to the RAK yard by the parent company. Eversendai Group is a leading global organisation delivering highly complex projects with innovative construction methodologies for high rise buildings, power & petrochemical plants as well as composite and reinforced concrete building structures in the Asian and Middle Eastern regions. Eversendai iconic high rise projects have included the Burj Khalifa and Burj Al Arab in Dubai, Capital District Towers in Abu Dhabi, Caltex Tower in Singapore, Crescent City in Azerbaijan and Petronas Twin Tower 2 in Kuala Lumpur.

In 2018, Eversendai’s Offshore new RAK yard was awarded a major contract to fabricate a number of offshore jackets for Saudi Aramco. This award followed accreditation with Saudi Aramco’s 9com certification, a stringent quality standard that is a pre-requisite for companies wishing to undertake projects in the Kingdom of Saudi Arabia. MatriX-EPS was instrumental in ensuring Eversendai secured this accreditation as the system ensures strict adherence to company quality standards, as well as maximising project profitability. MatriX-EPS also ensures optimum use and complete traceability of all materials including revisions. Nesting facilities are used to manage all pieces (from a few to hundreds) cut from plate as well as large diameter tubulars, this includes control of cut pieces returned to stock for subsequent re-use.

MatriX-EPS supports the world’s largest oil & gas subsea development

Heerema

When Heerema was awarded a major offshore subsea contract for their fabrication yard in Angola they selected MatriX-EPS to support this major project. Kaomba is the largest oil & gas SURF (subsea umbilicals, risers and flowlines) project world-wide to-date and is located in Block 32 offshore Angola in water depths up to 2,000 metres. Heerema Porto Amboim carried out fabrication and construction for the offshore Angola Kaombo project from 2014 to 2018.

This major EPCI project was undertaken by a consortium comprising Heerema and Technip and was awarded by major oil operator Total E&P Angola. The total contract value was approximately USD 3.5 billion and Heerema’s share was around 45%. Heerema’s scope included the riser systems, as well as the deeper and heavier pipe-in-pipe (18”/12”) production pipelines.

Award of the Kaombo contract required rapid expansion of Heerema’s fabrication yard together with overhaul of all systems and procedures. The MatriX-EPS team assisted with development of enhanced yard quality procedures as well as training and implementation of a comprehensive MatriX-EPS based material traceability quality control system.

On-site training on MatriX-EPS was provided in Angola for 30 system users. Technical support was then provided remotely by the MatriX-EPS team for the duration of the fabrication and construction project until completion in 2018.

MatriX-EPS facilitates steel fabrication company growth and ensures efficient and optimum use of all project resources

PAENAL

MatriX-EPS was instrumental in facilitating major expansion of PAENAL’s fabrication yard at Porto Amboim in Angola.

The PAENAL yard was created to provide fabrication facilities for topsides modules and FPSO integration in Angola for the oil and gas industry. PAENAL is owned by SBM Offshore, DSME (Daewoo Shipbuilding and Marine Engineering) and Sonangol. Major expansion of the yard included installation of the biggest crane in Africa, the HLC, capable of lifting a cargo of 2,500 tons in a radius of 36 metres and used to integrate modules for FPSO (floating production, storage and offloading) vessels.

Purchase of MatriX-EPS followed award of the largest project to-date to PAENAL, fabrication of water treatment module and associated FPSO construction and integration works for the CLOV FPSO for Total. MatriX-EPS was implemented to provide a comprehensive material traceability quality control system. The MatriX-EPS team also assisted the PAENAL project management team to implement streamlined work processes. Critical facilities provided by MatriX-EPS on this first major project included full tracking of all materials and components supplied to the Angolan yard from various sources.  The system provided advance information on deliveries that ensured optimum fabrication and construction scheduling and eliminated the possibility of costly delays.  Key features included the ability to optimise use of all plate and pipe and minimise waste.   

It was essential that on-site nesting and cutting followed the predefined plan exactly because large diameter tubulars had been nested in advance to minimise waste resulting in shipment of custom lengths to the PAENAL Yard. MatriX-EPS gave full control over this process by linking the specific lengths with the pieces to be cut.  Issue requests for Nesting Material ensured that the correct lengths were issued, and nesting reports provided details of the pieces to be cut. MatriX-EPS provided full traceability for individual lengths from receipt to completion of cutting on an ongoing basis throughout the project.

The hull section for the FPSO CLOV was built by DSME in South Korea and was the first FPSO to berth at a quay in Angola, the first module integration in an Angolan yard, and with the first naming ceremony in Angola.

The FPSO CLOV was completed in 2014 and MatriX-EPS was subsequently used to support fabrication of other major projects, the SBM / ENI N’Goma project that consisted of major modules and anchor piles and the CABGOC project for fabrication of 2 topside modules.

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