SEA: Indonesia : PT. Gunanusa Utama Fabricators

PT GUNANUSA UTAMA FABRICATORS

What is PT Gunanusa Utama Fabricators?

PT Gunanusa Utama Fabricators is an Indonesian heavy engineering and fabrication company focusing on turnkey project in the growing lucrative Indonesian offshore oil and gas industry and other petrochemical and industrial plants.

Mr. Iman Taufik, an Indonesian entrepreneur and engineer, founded PT Gunanusa in 1980, with the intention of creating an indigenous company to support the growing oil and gas industry in Indonesia.

After more than 25 years, Gunanusa has successfully delivered turnkey projects in the oil and gas industry, for such client like TOTAL, BP, Hess, Petronas, Pertamina, ConocoPhilips, Chevron, PTTEP, ONGC, etc. Gunanusa is renowned as one of the leading offshore fabricator in the ASEAN region.

Services

In the spirit of the company’s mission to provide our clients with excellent products and services, we equip ourselves with integrated capabilities encompassing:

• project management
• engineering
• procurement
• fabrication and construction
• installation and hook-up
• testing and commissioning

Engineering

The core of our engineering department are a group of senior engineers from multiple disciplines (structural, mechanical, piping, electrical, instrumentation) with at least 10 years experiences in the fabrication and construction field.

Our engineers are also capable to design and to build pressure vessels and power boiler, according to ASME and BS standard. The design software for this activity are Caesar, SAP, PV Elite, Finglow. Gunanusa’s engineering department is also responsible for structures load out and sea fastening from our fabrication yard. Prior to load out and at each stage, our engineers analyze structurally the barge and calculate the water ballast to ensure that a side or a bulkhead will not buckle under the temporary overload.

In the engineering phase we have build an extensive library of multi-discipline CAD designs are using extensively CAD technology to speed up the design process and to avoid redundant design. Therefore, we can produce drawing, specification and data sheets much faster. Construction engineering also available at Gunanusa for the preparation of shop drawing for any design work required, and the AFC engineering document is used as the basis to perform the project execution.

Procurement

Our procurement activities start from inquiries, selection of vendors, purchasing, expediting, inspection, coordination, transport and materials receiving at our yard.

For importing material, our procurement department acquires material based on a government approved duty exempt master list, which reduces our material cost. When we export our platform, part of the material we imported is also duty exempt. To fulfil government requirement, we also procure the best quality local content available. We pass on our material cost saving to the customers.

We can acquire materials from all over the world, based on vendor list given by client, and world wide inspection company by reputable inspector like ITEX (USA), MOODY INT’L (Asia) DNV, LLOYD.

Fabrication and Construction

Gunanusa’s stellar reputation in the oil and gas field is built by years of fabricating experiences, years of delivering offshore structures to customers in Indonesia and around the world. Since our inception, we have delivered more than 100 structures.

Each structure build at our fabrication yard is unique, custom fabricated by dedicated engineers determine to do their best to fulfill the customer need and schedule. From material receiving to quality control, from shop drawing to structural works, from erection and assembly to pre-commissioning our engineer and technician are working hard to ensure that we deliver the best to our customers.
To ensure the quality of our work is on par with international standard, we have been certified in the following :

• ISO 9001 :
to provide a quality management systems.

• ISO 14001
to operate in a standardized environmental management systems

• OHSAS 18001
to establish an Occupational Health and Safety management system.

• ASME U, U2 and S
to manufacture of pressure vessels and power boilers.

Gunanusa fabrication yard, located 120 km west of Jakarta, occupies an area of 18 ha with an 800-meter water front to accommodate two jetties, each with 6000 tonnes structures load out capability.

The yard facilities are warehouses which include a bonded area and a temperature controlled warehouse, office spaces for client and for our engineering design work, blasting & painting area and heavy construction shop for fabrication, and assembly and erection area. Other yard amenities include a 24 hour on-site clinic with medical doctors and living quarters.

The yard is served by several kinds of heavy duty vehicles and equipments, crawler cranes capable of lifting from 40 to 450 ton of modules and equipments, overhead crane capable of lifting 40 ton. Gunanusa utilizes several arc welding techniques, among other the simple Shielded Metal Arc Welding (SMAW), the more versatile and smokeless Gas Tungsten Arc Welding (GTAW), the much faster Flux Core Arc Welding (FCAW) and the automated SAW (Submerged Arc welding).

As an offshore platform builder, we realize that our structures will face severe weather. To prevent water corrosion, to face sea water immersion, and to fight tidal change, Gunanusa uses a TSA Chamber to conduct Thermally Spray Aluminum (TSA) which will coat the material and extends the structure life.

Gunanusa instills and enforces safety and environmental awareness value to each individual working in the fabrication yard and projects. Our safety inspectors maintain vigil patrol on our site to monitor and to ensure that all of the safety procedures are followed. We perform regular drill in case industrial incident and natural disasters.

Our safety record is showcase by the many safety awards, for our zero-loss time accident, that we received from our clients and our leadership in the National Safety Board. Our quality controls trace materials from receiving to installation at clients. Each steps in the process; we verify and inspect the quality of the process.

Hook-up & Installation

Our experienced crews and field engineers are capable to perform on-site work hook up and installation, supported by versatile equipments, tools, consumable, utilities, and other resources required for site work hook-up, installation and completion.

For deck installation on shallow water or inland water, Gunanusa uses the float over method. The barge, with deck loaded, has to have transverse stability but be narrow enough to pass between the jacket legs. Stability and longitudinal strength must be adequate for both transport and at the critical stage when the deck is lifted above the barge. High capacity ballast and deballast pumps should be provided.

For installation in the open ocean, Gunanusa subcontract it the third party offshore installation company (OIC).

Through years of working at the customer sites, Gunanusa has become very adept in the hook up process. It is a very time critical process. Starting a new platform means there is a new cash flow source for the customers, but also during the hook up procedure, existence pipeline need to shut down to allow time for connection and the testing of the connection afterward.

To facilitate the hook up process, Gunanusa has its own fleet, the accommodation barge Mahakam, hook up barge (Guna 2 with 125 ton crane), and material barges (Guna 1).

Current Projects (2009-2011)

Bongkot QPS and FPS

PTT Exploration and Production Plc (PTTEP) operates the Greater Bongkot South (GBS) gas field in the Gulf of Thailand. For the Development Phase 4a of GBS, Gunanusa has won the right to fabricate and to install: QPS (Quarter Platform South) is a living quarter and utility platform with the capacity to accommodate 158-men. QPS is fully equipped to provide the necessary and amenities of life and also houses a 72 men dining area, galley, recreational room, and helideck. The deck weight is 2700 tonnes with a 750 tonnes jacket

FPS (Flare Platform South) has a deck weight of 700 tonnes with a 550 tonnes jacket. This project also include the fabrication and the hook up of bridges to connect to the nearby Production Platform South. The platforms will be installed at the water depth of 70 m.

ONGC - ICP-R PLATFORM

Oil and Natural Gas Corporation Limited (ONGC), India largest oil and gas company, awarded Gunanusa-AFCON Joint Venture to execute the ICP-R Process Platform Project in Mumbai High North, India.

The project scope of works is the Engineering, Procurement, Construction, Commissioning and Installation of the ICP-R platform, Flare Tripod and connecting bridge. The ICP-R platform consist Main Structural Frame, Building Module, Process Module, Turbo Generator and Compressor Module which has a weight of 7300 MT and the jacket weight is 3600 MT. The Flare Tripod topside weight is 90 MT and the jacket is 630 MT. The water depth is 75 m.

This is the first Gunanusa-AFCON Joint Venture project, and it will be completed on April, 2011.

HESS - Ujung Pangkah Central Processing Platform (CPP) and Accommodation & Utility Platform (AUP)

Hess operates the Ujung Pangkah area at East Java in shallow water at 10 m depth. Gunanusa has been awarded to perform Engineering, Construction, Hook Up and Commissioning of Central Processing Platform (CPP) and Auxiliary & Utility Platform (AUP).

CPP has a 2650 tonnes upper deck with an 260 tonnes jacket, the platform consists of processing module, gas/liquid separation, gas compression, liquids pumping and produced water handling, water treatment and disposal.

AUP has a topsides weight of 2080 tonnes with a 260 tonnes jacket. AUP will accommodate 35 persons and a Control Building located on the Cellar Deck which is comprised of the Motor Control Centre (MCC) room, Transformer Room, Local Equipment Room (LER) and workshops area. This project is scheduled for 26 months, with the expected installation on April 2011

Completed Projects

Total’s Tunu Field

Total E&P operates the Tunu gas and condensate field in East Kalimantan on the outer Margin of the Mahakam delta. Total has awarded Gunanusa to perform several phases of the field development.

Starting with latest one, phase 11, Total contracted Gunanusa to fabricate two platforms to accommodate the situation, South Manifold Platform (SMP) and South Compression Platform (SCP). SMP, weighing 2700 tonnes, consists of Deck, MP manifold with pig launcher and pig receiver, LP manifold, 2 slug catchers, and flare KO drums. SCP, weighing 4600 tonnes, consists of deck, inlet and discharge, air cooler, turbo-compressors, suction scrubbers for gas compressors, plant and instrument air systems, nitrogen production system, gas turbine power generator packages. SCP compressed the gas before delivery to Bontang LNG Plant. The project, which took 23 months, was awarded in December, 2006.

For Tunu Development Phase 7, Gunanusa fabricated and installed a 4900 tonnes Tunu Compression Platform, including dehydration unit, scrubbers, air cooler, gas compressor and power generators. The project entails implementation of a Middle Pressure manifold, and several trunk lines for the surrounding area connecting GTSs. The North Compression Platform for Tunu Development Phase 8, weighing at 5400 tonnes, is the largest platform Gunanusa ever fabricated to date. The NCP would allow the North Tunu area to operate in MP mode. The platform comprises of inlet slug catcher, air cooler, condensate export pumps and turbo-compressors.
At the North Tunu Field, Gunanusa fabricated and installed the 4200 tonnes North Processing Unit (NPU). The development works includes the necessary trunk lines and camp facilities.

Finally, Gunanusa also fabricated and installed the 700 tonnes Tunu Oily Water Treatment, with 800 tonnes piles.

The Peciko Field Development

Total E&P operates the Peciko gas and condensate field at the offshore of East Kalimantan, with a water depth from 30m to 50m, south of the Mahakam River Delta. Gunanusa has won several contracts for the Peciko Development Phases.

First, Peciko offshore Developments Phase 3, Gunanusa fabricated the new Satellite Wellhead Platform (SWP-G), the 20" sea line connection SWP-G and the existing MWP-A, and also the modification to existing facility (MWP-A). The plant design life is 20 years. The construction include the deck (1200 tonnes), jacket 800 tonnes, and a 4 km 108 tonnes duplex piping.

Second, Peciko Offshore Development Phase 4 EPSC 2 contract entails the fabrication of 2 more satellite wellhead platforms with 4 legs (SWP E & K), each weighing 1700 tonnes. The jacket for each deck is 800 tons. The contracts include one temporary drilling deck, and the offshore hook-up and modification of 4 other existing platforms. The project took 30 months, and was completed in 2004.

BP Tangguh Gas Production Facilities

The BP Indonesia’s Tangguh gas field in Berau Bay in the province of Irian Jaya, Indonesia. The natural gas field contains over 500 billion m³ (17 Tcf) of proven natural gas reserves, with estimates of potential reserves reaching over 800 billion m³ (28 Tcf). BP subcontracted Gunanusa to fabricate two Gas Production Facility (GPF) platforms (VR-A and VR-B), including their jackets and piles, totaling 10,900 tonnes.

The BP Tangguh facilities are especially coated with TSA (Thermally Spray Aluminum) to ensure maximum long term corrosion protection for 40 years.

Heat Recovery Steam Generators – Alstom Astoria Energy Project:

As part of a project to increase electricity supply to the City of New York, Alstom Power Inc contracted Gunanusa to fabricate two Heat Steams Recovery Generators (HRSG), each weighing 2500 tonnes. Both modules take the heat from an electrical producing turbine and feed a single steam turbine that turns another generator, yielding the full 540 MW. We completed this project in 8 months, and shipped it more than 12,000 mi. through the Panama Canal, across the Atlantic Ocean, and up the East River to the construction site.

Maharaja Lela Jamalulalam:

Elf Petroleum Asia operates the Maharaja Lela Jamalulalam offshore field in the coast of Brunei with a water depth of 60 m. Elf awarded Gunanusa the contract to fabricate, to deliver and to install two unmanned platforms. The first one is the Central Platform (CP), it comprises of the 1050 tonnes deck, a 950 tonnes four legged jacket, a 1100 tonnes piles and a 400 tonnes TDD.

Adjacent to the CP, Gunanusa also fabricated and installed a Satellite Wellhead Platform. The scope of work for the SWP were a 600 tonnes deck, a 910 tonnes jacket, and a 900 tonnes piles