Relocation Pres.General Rev.9

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Relocation Production Facilities

Business Line: Relocations

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Introduction

Reference Relocation projects

Reference Relocation feasibility studies

Feasibility study deliverables

Aspects of Relocations

Stork AMS, Projects approach

Questions

Contents

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Presenting experiences of Stork AMS, Projects with:

• Plant relocations

• Feasibility studies

• Relocation engineering and project management

Presenting Stork AMS, Projects approach and work methods

Introduction

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Needle Coker Plant – Shell Moerdijk(NL) to Argentina (1993/1994)

Melamine Plant – DSM Geleen(NL) to Indonesia (1994/1995)

Extruder Lines – DSM Geleen(NL) to Dupont Dordrecht(NL) (1995)

Reference Relocation Projects(1)

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Reference Relocation Projects(2)

Steel Plant – Hoogovens IJmuiden(NL) to Malaysia (1996)

Workshop machinery – Fokker Hoogeveen (NL) to Papendrecht(NL) (1998)

Complete Refinery – Mobil Worth (D) to India (1998/1999)

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Reference Relocation Projects(3)

TIP Unit /SWT Unit – Shell Stavanger (N) to BRC Antwerp(B) (2001/2004)

Test Modules – Philips Heerlen(NL) to China (2004)

Brewery Equipment – Grolsch Groenlo(NL) to Saudi Arabia (2004/2005)

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Reference Relocation Projects(4)

Extruders & Packing lines – Dupont Rozenburg(NL) to China (2005)

Extruders & Packing lines – Dupont Rozenburg(NL) to Argentina (2005)

Flight Simulator – Fokker Schiphol(NL) to Nieuw Vennep(NL) (2005)

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Reference Relocation Projects(5)

Production lines – H.J.Heinz Several locations (NL) to Utrecht(NL) (2006/2007)

Production lines – Paper Projects Dinxperlo(NL) to Doetichem(NL) (2007)

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Reference Relocation feasibility studies (1)

Shell International

• Relocation of Needle Coker Plant from The Netherlands to Argentina

Belgian Refining Corporation

• Relocation of HCU from England to Belgium

• Relocation of KERO Hydrotreater Plant from England to Belgium

• Relocation of TIP Unit from Norway to Belgium

Statoil

• Relocation of TIP Unit from England to Norway

Globe Foundries

• Relocation of Iron Casting facilities in The Netherlands

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Reference Relocation feasibility studies (2)

Kemira GrowHow

• Relocation of KEM Water Unit in The Netherlands

• Relocation of Storage Tank including facilities in Denmark

Vredestein

• Relocation of complete Tyre Plant from The Netherlands to Malaysia

Dekker Shipping

• Relocation of Suction Dredger Production Barge

Hexion

• Relocation of SALT Plant from England to Germany

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Feasibility study deliverables (1)

Determination of Dismantling and Re-assembling scope for:• Mechanical• Electrical and Automation• Civil• Packing • Transportation

Check status and availability of existing documentation

Prepare detailed list of assets to be relocated

Make detailed route survey

Determine scope for lifting and transportation requirements

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Feasibility study deliverables (2)

Prepare overall plan

Determine vendor involvement

Determine budgets for:• Dismantling• Transportation• Re-assembly

Check on environmental rules and regulations

List of applicable Assumptions / Conditions

List of Recommendations / Conclusions

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Modular:

Sections defined by equipment

Emphasis on heavy lifting and transport

Logistics is key factor for success

Piece small:

Sections defined by systems

Emphasis on coding and identifications

Traceability is key factor for success

Aspects of relocations

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Emphasis on partnership

Multi-disciplined

Relocation as one integrated proces (*2)

Total quality and safety management (*3)

The Project Management System – Prince (*4÷8)

Stork AMS, Projects approach (1)

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Relocation as one integrated process

Effectiveness• Project control system developed for combination of both activities

Economics• Cost saving because of less detailed documentation requirements

(no transfer)

Contractual• Avoiding conflicts of interest because Stork AMS, Projects has full

responsibility for the execution as a whole

Stork AMS, Projects approach (2)

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Total quality and safety management

Total Quality Management (TQM)

ISO 9001 Certified

ISO 10006 Certified - Project management

ARBO (Dutch legislation)

VCA** (Dutch safety certificate industrial contractors)

Stork AMS, Projects approach (3)

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The Project Management System - PRINCE

The structure

The capabilities

The advantages

Stork AMS, Projects approach (4)

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Stork AMS, Projects approach (5) PRINCE - The Structure

Drawing control

Bill Of Materials & connections

Work folder definition

Procurement

Man-hours calculation

Material control

What can be produced?

Prefabrication (incl. NDE)

Towards Client

Towards Subcontractor

Grit blasting & painting control

What can be installed?

Installation (incl. NDE)

Quality Control• registration• check• instructions

Production Control

Progress Registration

Earned Value Calculation

What can be hydro tested ??

Painting, insulation

Commissioning

Invoicing, Cost Sheets

Relocation Engineering Information

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Stork AMS, Projects approach (6) PRINCE - The Capabilities - Full Traceability

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Workfolder

Package

Part

Container

Part

Workfolder

Container

Package

(Sea)Transport

Dismantling Re-assembly

Barcodes linked to the Prince system providing

full traceability throughout

the entire process

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Stork AMS, Projects approach (7)PRINCE - The Capabilities - Planning Tool

• Weighting: Manhours per activity• Percentage complete calculation per activity

Network / ScheduleHistogram & S-curve

0102030405060708090

100

1 5 9 13 17 21 25 29 33 37 41

Week number

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050100150200250300350400

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ACTIVITIES like:•Piping complex =) 1• Column =) 234• Steelstructure =) abc• Area =) 5• Etc.

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Stork AMS, Projects approach (8)

PRINCE - The Advantages

To improve Contractor’s services to her Clients

To improve on efficiency in work preparation as well as in direct hours

To optimize the Electronic Data Interchange(EDI) possibilities between

Engineer, Contractor and Suppliers

To reduce doubling in Engineering and Contractors activities, staff and input

To provide the Project Team with the best possible tool and information in

order to CONTROL the project

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Questions

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