JURONG ISLAND SINGAPORE PETROCHEMICAL PROJECTS

JURONG ISLAND SINGAPORE PETROCHEMICAL PROJECTS

CASE STUDY JURONG ISLAND, SINGAPORE PETROCHEMICAL PROJECTS The Location Jurong Island is a man-made island located southwest of the main island of Singapore. The island was formed by extensive land reclamation efforts over many years, and is now a major petrochemical hub in the region, with a total land area of approximately 32 km². Jurong Island is home to many multinational companies, such as LANXESS, BASF, BP, Celanese, Evonik, ExxonMobil, DuPont, Mitsui Chemicals, Chevron Oronite, Shell, Singapore Petroleum Company and Sumitomo Chemical. Project Background/History Since deugro opened in Singapore in 1989, we have been involved in managing and executing large scale turnkey projects in Singapore and on Jurong Island, as well as the smaller neighboring islands, such as Pulau Ular. In recent years, deugro has transported well over 600,000 FRT of material and equipment to Jurong Island for renowned clients, such as Foster Wheeler, ABB, JGC, CB&I, Hyundai and Samsung. BUTYL RUBBER PLANT (BTR) PROJECT Project Data Name: Butyl Rubber Plant (BTR) Shipping period: Dec. 2010 to Dec. 2012 Volume: Approx. 50,000 FRT deugro had just completed a small petrochemical project for ExxonMobil (EPC: Foster Wheeler) on Jurong Island in 2009 when LANXESS first approached us with regards to its forthcoming investment in Singapore. Needless to say, deugro Singapore was delighted to have the opportunity to bid for this project, as this investment would be the largest in the history of LANXESS (at the time), aiming to build one of the most advanced synthetic rubber plants in the world and the largest of its kind in Asia. One and a half years later, the first shipments were well on their way from worldwide origins to their final destination in Singapore. Preparation of site entrance by installing a heavy-duty bridging system Main Shipments Unlike other remote areas and difficult environments where deugro works, Singapore is a developed country with excellent infrastructure and a mature transportation and logistics services market. As such, the challenges presented by this project were different than what we normally face. The main critical items were five lengthy and heavy columns originating from the fabricator KNM in Malacca, Malaysia. The measurements of the two largest columns were as follows: CD Reaction Column/80.00 x 6.00 x 5.06 m /247,430 kg MTBE Tailing Column/69.65 x 6.00 x 4.72 m /152,400 kg The columns were transported by two consecu tive barge voyages from Malacca to the Sakra Jetty on Jurong Island, Singapore. deugro s scope of work involved door-to-door transportation, including inland transport from factory to jetty, roll-on, barge voyage to Singapore, roll-off and on-carriage to the job site. The main challenge in Malaysia was the difficult route from the KNM factory to the nearby Tanjung Puteri Jetty, Malacca. Although the distance covered only 20 kilometers, there were seven very narrow turns to navigate. Major road improvements and civil works were needed, in addition to removing obstacles, before operations could begin. Extensive advance meetings with the respective authorities and town councils were necessary to ensure that all required permits were in place prior to commencement of the transportation. Because the route was so difficult, equipment could only be transported during daylight hours. We also needed many support vehicles, local police and third-party security to keep spectators at bay and allow for safe passage with no incidents. Roll-off operation at Sakra jetty, Jurong Island The jetty available for roll-on operations had not been used for quite some time and required extensive upgrades to ensure safety for this 2

critical operation. After a voyage of less than two days at sea, the barge arrived at the Sakra Jetty, Jurong Island with cargo ready to be delivered to site. Because the road infrastructure on Jurong Island is very well-developed, the five-kilometer distance from the jetty to the construction site was fairly easy to navigate. The more critical and demanding challenge involved the underlying bureau cratic procedures and obtaining permits/ approvals from the respective authorities to remove and reinstate a total of 18 trees, 29 traffic lights and light poles, as well as about 240 meters of road kerbs/dividers. Another big challenge was waiting about 100 meters away from the laydown/dressing area at the job site. The normal cargo entrance could not be used due to its limited turning radius, so deugro was assigned to construct a temporary access for the columns. After a detailed study of the available infrastructure and the site layout, taking into account the final plant location and crane set-up for erection works, a suitable location was identified. deugro organized the clearance of an area of vegetation measuring around 30 by 15 meters, leveling and compacting the ground and bridging the underground piping with a temporary, heavy-duty bridging system. Again, this involved intensive negotiations and dealings with the Singapore Land Authority and signing agreements for a temporary lease of the land involved. An 80-meter long CD reaction column maneuvering a tight turn en route in Malacca NEODYMIUM-BASED BUTADIENE RUBBER PLANT (NDBR) PROJECT Only a few month after successful completion of the BTR Project, LANXESS/Foster Wheeler awarded deugro Singapore the PBR NdBR Project. Although only about half the size of the BTR, the new project was not without its own challenges. Whereas the majority of the equipment for the BTR project originated from China and Malaysia, the client s sourcing strategy was different for the PBR NdBR project, with the main cargo coming out of India. In close cooperation with deugro India, about 8,000 FRT of processing equipment was shipped within approximately three months, from vendors such as Praj Industries, Godrej & Boyce and Novatech. A total of six part charters out of Mumbai, Kandal and Mundra were made on a last in / first out basis, ensuring the fastest transit time and earliest arrival in Singapore to meet the tight construction and erection schedule on site. Project Data Name: Neodymium-Based Butadiene Rubber Plant (NdBR) Shipping period: May 2013 to Aug. 2014 Volume: Approx. 25,000 FRT One of the many pieces of processing equipment being transferred to intermediate laydown area at Jurong Port after arrival 3

The most critical item in terms of size and weight was a 34-meter long and five-meter diameter hexane purification column with a unit weight of about 75 tons shipped out of the Port of Kandla. deugro made use of the same Singapore project team that was in charge of the BTR project for the PBR NdBR project. The experience gained and lessons learned in the previous effort helped to make the fast-track PBR NdBR project a great success, without any Lost Time Incident (LTI), and with all items delivered ahead of time. Discharging of 52-meter long distillation column at Jurong port, Singapore It is great when an EPC client and project owner entrusts you with three consecutive projects this is truly an achievement to be proud of, as it shows that the hard work and dedication that the entire project team has invested was recognized and has paid off. All in all, customer satisfaction is not just an empty phrase, but deugro s number one goal, which we strive to achieve, every single day! BTR I PLANT EXPANSION PROJECT Project Data Name: BTR I-Plant Expansion Shipping period: Dec. 2013 to Feb. 2014 Volume: Approx. 3,500 FRT Distillation column passing underneath the pipe rack at job site Halfway through the execution of the PBR NdBR Project, LANXESS approached us with a plan to simultaneously expand the BTR site, in particular, the I-Plant facility. The plan was to install a distillation column next to the other columns that deugro had transported two years before from KNM, Malacca during phase one of the BTR project. The obvious challenge was the size of the equipment, as well as the fact that the column would need to be transported within the live operating plant without shutting down the facility. This involved very narrow turns and maneuvers under existing pipe racks, as well as over culverts and underground pipes on site. Detailed studies were needed to work out a concept that could satisfy the client from both a technical and HSE perspective. Transporting heavy and long equipment in a live petrochemical compound always involves a great deal of HSE-related matters. At the end of the day, the transport concept worked out by deugro Singapore s project team convinced the client and we were awarded the project. The distillation column, measuring 52 meters in length and four meters in diameter with a weight of approximately 150 tons, was fabricated by Dipesh Engineering in India. The workshop was located about 140 kilometers away from Mumbai Port. The pre-carriage in India was coordinated by the deugro Mumbai project team, which managed to safely deliver the column after a six-day journey to the Mumbai Port. The heavylift vessel MV Annegret (two 320 SWL cranes) was chartered on a last in / first out basis to carry the cargo from Mumbai to Jurong Port, Singapore. Upon arrival in Jurong Port, the deugro Singapore project team handled direct delivery of the column onto two five-axle self-propelled modular transporters (SPMT) with bolster systems for the final journey to the site. Once at the site, the detailed planning and technical studies paid off the distillation column passed underneath the pipe rack into the final jack-down location with only a few centimeters to spare. 4

YOUR PARTNER FOR INDUSTRIAL PROJECTS IN SINGAPORE deugro (Singapore) Pte Ltd is a key provider for: Feasibility studies, route surveys and transport consultancy In-house Transport Engineering Department (TED) Approved Major Exporter Scheme (MES) customs clearance agent 5

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