Presentation - ASTRON Meeting

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Safety Share

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Agenda

• 模块化的定义和操作

• 澳洲设计准则及规范

• 合格供应商的评定

• 数据包的管理

• 作
QA和QC工作

• 降低2000单元30%的费用

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Modularization
odu a a o

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Modularization Planning - Modularization Decision

Drivers Benefits
• Remote Location • Increased construction safety
• Extreme Weather • Reduced / flexible construction
• Experienced Work Force schedule
• Existing
E i ti IInfrastructure
f t t • Reduced
R d d overallll manpower /
• Major Contracting entities resources on site
• Strong Labour Union • Reduced risk of budget /
• High Labour
Labo r Cost sched le o
schedule overrun
err n
• Schedule • Reduced rework
• Safety • Quality Assurance
• Impact on Local Community • Earlier start
start-up
up / Return on
Investment

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Modularization Planning
• Understand the linkage between:
• Engineering
• Select module yard
• Procurement, Material delivery
• Module fabrication
• Transport
• Module Installation

• Avoid decision variations eg.: converting stick built to modular

at later stage

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Modularization Engineering – Design Criteria

• Land transportation limitations -
dimensions weight and COG
dimensions,

• Method of transportation for each module

• Method of installation of each module at

site

• Sequence of installation of the modules

• Hook-up
oo up access for
o ccranage,
a age, scaffolding
sca o d g
etc

• Practicality of modularisation of specific

scope

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Modularization Engineering - Studies

• Module Envelope Definition

• Land transport

• Sea transport

• Structural analysis - Land and

Sea transport and wind

• Prepare weight control reports

• Sea fastening analysis

• Lifting study
study, where applicable

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Modular Fabrication - Module Yard Selection COOEC

Qingdao Yard

• Pre-qualify
q y fabrication yyards

• Assessment areas
 Safety
 Facility
 Engineering Capability
 Construction Capability
 Contractual
 Financial

• China fabrication yard

 Good facilities
 Large pool of skilled labour
 Cost effective
 Cl
Close tto th
the llow costt
material supply base
 Aggressive top management

ZPMC
Changxin Yard 02/2012
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Module Fabrication - Sequence

Assembly of
beams & girders Installation of
to make a panel vertical columns
and bracing

Installation of
equipment, piping,
E&I then next
After painting, erect upper floor panel
panel on top of the
saddles

Panel byy
panel to the
top floor

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Module Fabrication - Extent of Fabrication

• Structure – Module structure, loose steels, sea fastening and etc.
• Piping – Piping fabrication & erection, tested, coated and
insulated

• Mechanical – Installation,
Installation alignment and pre-commission
pre commission

• E & I – Installed, tested, energized and pre-commissioned

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EPCM Company Functions - Quality Control

• Promote and reinforce the quality

• Conduct all kinds of inspections

• Qualify sub-contractors / suppliers

• SDI / NCR system / Punching

• Fabrication completion dossiers

Punch List

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Module Fabrication - Pre-Commission

Pre Commission
i/o check
• Prepare Test Pack subsets (“re-scope”) motor tests
• Accept hand-over from Construction equipment test
• Document punch items in detail run w water
– Contractual issues (Mod vs Final Site contractor) Temp
– Replacing defective parts (ship to Yard / Site) air

• Pre-Op Tests Temp

elec
– Instruments and i/o checks
– Electrical services
– Temporary Electrical and Air supply
Temp
water

P O Testing
Pre-Op T ti
Module Fabrication
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Module Fabrication - Cleaning and Quarantine

Concerns
• Soils
• Insects
• Seeds
• Food scraps
Mitigation:
• Build it clean and keep it clean
• Thorough clean on completion
• Early engagement from authority

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Module Fabrication - Preservation

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Project Example – Small Module (container size)

Electrical Module
Equipment Module

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Project Example – Koniambo Modular Yard

Project Summary May 27, 2009

Client Xstrata Nickel

Final New
Location Caledonia
EPCM HTJV (Hatch
Sep. 4, 2009
Company & Technip JV)
No. of
15
Modules
Weight
30s KT
(M-ton)
Site
60 members June 22
22, 2010
T
Team
Scope of Full module
Work fabrication
Module COOEC
Yard Qingdao Yard

During 26 Months

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Project Example – Koniambo Modular Yard

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Engineering
g ee g Capab
Capability
y

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Engineering - Qualification 21

Hatch Has a Class A Licence for Engineering

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Engineering - Functions and Capability 22

Provide engineering and design services in the following areas:

• Execution of China-based projects

• Execution of overseas projects together with other Hatch

offices (worksharing)

• Management of Chinese Design Institutes

• Engineering support for procurement in China

• Technical support for fabrication projects in China

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 Engineering – Design Codes 23

• Capable of designing to all major international codes – GB,

ASME, AS and etc.
• Suiting project needs
• Reinforce code Compliance via
• Project specification
• The right
g software p packages
g
• Material selection
• Engineering review of deliverables by local DI
• Technical review of fabrication by local vendor
• Engineering review of material substitution

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 Engineering – Recent Projects 24

• QSLIC Magnesium Smelter Project

• Huanghua Port Optimization Project
• Galaxy Lithium Carbonate Plant
• Koniambo Nickel Project
• Grosvenor Project
• GEMCo Eylandt Expansion Project

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Document Management
g System
y

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Hatch Core Systems - iPas

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What is iPas DM?

• H t h’ web-based
Hatch’s bb dDDocumentt M
Managementt S
System
t (DMS)

• Third p
party
y application
pp ((Open
p Text)) p
product called Content Server re-
named for use by Hatch

• All projects and proposals globally are to use iPas DM.

DM

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Who can use iPas DM?

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Procurement / VQS Capability

p y

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 China Procurement Organization 30

Global China
Procurement/ Procurement
Technical Support Manager

VQS Procurement & Procurement

Manager Strategic Sourcing Support

VQS Sr. Inspectors Senior Buyers Engineers

VQS
Q Inspectors
p Buyers Financial Controllers
VQS Jr. Inspectors E
Expeditors
dit Document Controllers
Logistics Officer Schedulers
Translators
Deliverables:
• Supplier
pp Prequalification
q
• Quality Management Deliverables: Deliverables:
• Quality Planning • PO & Contract Planning • Design & Detailing
• Technical review • Strategic sourcing • Vendor Data Review
• Review Supplier Quality • Vendor Recommendation • Financial Services
• Quality Surveillance • Tender Management • Database Management
• Performance Testing • Contract Negotiation • Filing
• Acceptance • Expediting • Scheduling
• Reporting • Logistics Coordination • Translation

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China Procurement Services

• EPCM Project Procurement Services

• Project China Sourcing Study
• Operational Components China Sourcing, Enquiry Handling
• Vendor Prequalification
• Contract Management
• Vendor Quality Surveillance
• Expediting

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 China Sourcing Value 32

• Approximately USD 1.1B

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China Sourcing by Project Location 33

BHP Billiton Rio Tinto OGI

BlueScope Steel Port Warratah Coal Alcoa
S
Severstal
t l North
N th AAmerica
i A l A
Anglo American
i Ch l
Chalco
Votorantim Metais Norsk Hydro Algoma
Glencore Wheeling Pittsburgh Steel Norilsk Nickel
TiWEST Brookfield Energy Windalco
E
Exxaro M d
Madawaska k Hydro
H d V l
Vale

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China Sourcing Challenges

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China Sourcing Risk Profile 35

Vendor Risks

China

Quality management
25
20
Engineering standards Planning and control
15
10
5
Communication 0 Employees qualification

Social responsibility Contractual obligations

Finance

Before mitigation After mitigation

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VQS Definition

Vendor Quality Surveillance –

Ongoing monitoring and surveillance of the Vendor compliance to
agreed client requirements.

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Vendor Prequalification 37

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 Risk Mitigation – Methods and Tools 38

• Vendor pre-qualification
• Pre-inspection alignment meetings
• A
Assess supply
l point
i t capability
bilit & capacity
it
Equipment
• Facilitate knowledge sharing workshops complexity rating
• Review vendor quality plans & procedures calculator

• Apply appropriate level of monitoring & surveillance

• Performance Testing

Manhour Calculate
Calculator Level of
Surveillance

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China
C a Sou
Sourcing
c g
Experience

July 2013

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Galaxy Resources, Jiangsu Australia / China

I t
Integrated
t d Hatch-Galaxy
H t hG l team
t
Asian fast track / western framework
Construction start 03/2010
03/2010, Opening Ceremony 03/2012

02/2012
 China
QSLIC Mg Smelter I
Imported
t d Technology
T h l From
F Western
W t
Construction completed in 2014
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China
QSLIC CaC2 Furnace W ld largest
World l t CaC2
C C2 Furnaces
F
Construction start August, 2013

02/2012
 Modules – Nickel Plant 43

Equipment: Modules, 15 modules with a

total weight 30
30,440
440 tonne

Client: Glencore

Project: Koniambo Project

Project Country: New Caledonia

Hatch Service: Contract management

including engineering support, vendor
quality surveillance and expediting

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 Modules - LNG 44

Equipment: Modules, 164 modules with a

total weight 39,000 tonnes

Client: Chevron

P j t Gorgon
Project: G Project
P j t

Project Country: Australia

Hatch Service: Contract management

including engineering support, vendor
quality surveillance and expediting

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 Modules – Process Plant 45

Equipment: Modules, 300 modules

Client: Eramet

P j t Maboumine
Project: M b i Project
P j t

Project Country: Gabon

Hatch Service: Engineering

and detail design

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Electricals

Equipment: 10MVA
10MVA, 500KVA and 3.3KVA
3 3KVA
Electrical Transformer, IEC standard

Client: BHPB

Project: Gemco Project

Project Country: Australia

Hatch Service: Contract management

including vendor quality surveillance and
expediting

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Drum Scrubber

Equipment: Drum Scrubber rubber lined,

45 x8
4.5m 8.4m
4

Client: BHPB

Project: Gemco Project

Project Country: Australia

Hatch Service: Contract management

including vendor quality surveillance and
expediting
p g

Inspector removing slack on girth gear teeth after

milling prior to dimensional check

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Metallic Piping

Equipment: ERW Line Pipe,

Pipe 600Km,
600Km up to
16”, API 5L

Client: Hamrin Oil

Project: N/A

Project Country: Iraq

Hatch Service: Vendor quality surveillance

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Pipe Spools

Equipment: Pipe Spool rubber lined up to

250” API standard
250”,

Client: BHPB

Project: Gemco Project

Project Country: Australia

Hatch Service: Contract management

including vendor quality surveillance and
expediting
p g

Pipe spools securely wrapped and strapped for

shipping to Australia

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Structural Steel

Equipment: Structure steel 1,350 tonne

with handrails and staircase
staircase, GB material

Client: Anglo Platinum

Project: RBMR Project

Project Country: South Africa

Hatch Service: Contract management

including vendor quality surveillance and
expediting

Chinese steel erected on Site in South Africa

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 Stackers and Reclaimers 51

Equipment: Stackers and reclaimers, 2

stackers and 2 reclaimers, capacity from
2,500 tph to 3,800 tph

Client: Anglo American Coal

Project: Grosvenor Project

Project Country: Australia

Hatch Service: Contract management

including design review,
review engineering
support, vendor quality surveillance and
expediting

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Shiploader 52

Equipment: 2,000t/h ship loader –

Delivered full assembled pre-
commissioned to QMM in Madagascar.

Client: Rio Tinto

Supplier: ZPMC

Project: QMM Project

Project Country: Madagascar

Hatch Service: Contract management

including vendor quality surveillance and
expediting

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 Material Handling Equipment 53

Anglo
g Sishen South – Stacker / Reclaimer
3000 tph Stacker / Reclaimer

Transnet Project – Gantry Cranes

58 sets of Gantry Cranes

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Ball Mill

Equipment: 2 Overflow Ball Mill, Φ4.11m ×

5 64
5.64m:

Client: Anglo American

Project: BVFR Project

Project Country: Brazil

Hatch Service: Vendor quality surveillance

and expediting

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Pressure Vessels & Tanks

Equipment: Tanks, 46 stainless steel and

mild
ild steel
t l tanks
t k and
d 4 solvent
l t extraction
t ti
cells

Client: QNI
Q

Project: YEP

Project Country:
Co ntr A Australia
stralia

Hatch Service: Contract management

including
g vendor quality
q y surveillance and
expediting

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Steel Pontoons

Equipment: Pontoons,
Pontoons 2000 tonne

Client: QIT

Project: N/A

Project Country: Madagascar

Hatch Service: Contract management

including vendor quality surveillance and
expediting

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Rail Equipment

Equipment: 160 Flat Rail Wagons, 4

R
Revolvers
l and
d 1,200
1 200 C
Containers
t i

Client: MMG

Project: Las Bambas Logistics Project

Project Country: Peru

Hatch Service: Vendor quality surveillance

and expediting

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