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BIG STUFF : Delivering The RAPID Project

Presentation by:
KC Low
Head, Corporate Strategy
& Business Development
Johor Port Berhad
Johor Port Berhad
A Multi Purpose Port with 24 dedicated Berths for different Cargo Types and hosts a total of 4.9 km of berthing space.
Handles Container, Edible and Non-Edible Liquid Bulk, Dry Bulk, Break Bulk and specialized Project Cargo.
Total area of 1,000 acres, 660 acres of which are designated as Free Zone.
Johor Port Water Limits

Provide Marine Services for all


vessel traffic going through the
Johor Port water limits including
Pilotage and Towage.
PETRONAS PIC / RAPID Project
RAPID in PIC is a fully integrated Petroleum Refinery and Petrochemical Complex
The Pengerang Integrated Complex (PIC) is
PETRONAS' largest investment in Malaysia,
located in Pengerang, Johor and forming part of
Johor State's ambitious Pengerang Integrated
Petroleum Complex (PIPC).

The PIC itself consists of the Refinery and


Petrochemical Integrated Development (RAPID)
and six Associated Facilities.

With an investment of USD27 billion covering an


area of 6,242 acres (2,526 hectares) and a start up
date of 1 Jan 2019, the PIC project is designed to
produce premium differentiated petrochemicals to
meet domestic demand for petroleum products.
PETRONAS PIC / RAPID Project
This project involves more than 40 major EPCC packages, 13 Licensors, > 200 Suppliers & Contractors

>40
EPC PACKAGES
>200
UIO SUBCONTRACTORS &
>60,000
MANPOWER
~350Million
PROJECT MANHOURS
PROCUREMENT PACKAGES AT PEAK
EXECUTED
CONCURRENTLY

>70 >16 >30 15,000


REGULATORY
TYPES OF PERMITS TO BE
ENGINEERING CENTRES REGULATORY BODIES TO
GLOBALLY BE MANAGED SUBMISSIONS
MANAGED

>140 ORGANISATIONS INVOLVED


PETRONAS PIC / RAPID Project
Plot Area Concrete
6,242 acres 1,800,000 m3

PIC / RAPID
x 3,500What are the QUICK
Football Fields
logistical
FACTS challenges
x9
for
PETRONAS Twin Towers

a project
Electrical & Instrumentation Cable
20,000 km
of this scale?
Structural Steel
North Pole 160,000 mt

South Pole x2 Second Penang Bridge


PETRONAS PIC / RAPID Project
Main figures
Construction Material 5,000,000 FT 505 Vessels for Break Bulk (incl. SHLO/HLO)
137 SHLO (> 250 tons) 633 Barges for Containers
& Logistics Overview 463 HLO (100-250 tons) 375 Barges for Break Bulk
85,461 TEUs 14,530 Trucks on the Road

TOTAL CARGO IN FT (Freight Ton)

384,550

1,000,000 351,307
SHLO

HLO

GENERAL CARGO BREAKBULK


652,829
GENERAL CARGO CONTAINERS

CAMP & FACILITIES


2,611,315
Connectivity to RAPID Site
By SEA Nautical Miles

Port Klang 225


Senai Airport PTP 62
E22
Jurong 33
Keppel 23
Johor Port 22

By RAIL (KM)

Port Klang Johor Port 434


PTP Johor Port 72

RAPID By ROAD (KM)


PTP Changi
Airport
Port Klang 454
KLIA 415
Keppel Terminal
Jurong Port PTP 146
R Sea Jurong 155
Rail Johor Port 72
Road
Senai 108
Changi 135
Road Challenges & Obstacles
Route distance is around 73 KM

Johor Port to
Pengerang
Overhead pipe rack at KM5. 5 Toll Plaza Cahaya Baru at KM8.5 / E22 Flyover at KM28.4 by land
(Jalan Pekeliling Pasir Gudang) Toll Plaza Penawar at KM50

Sg Johor Bridge at KM40 Electricity & Telekom hanging Small town, villages & schools along
cables at KM60 road to RAPID site at KM50 - KM70
Road Challenges & Obstacles
Route distance is around 144 KM

Via 2nd link / PTP


to Pengerang
by land
Exit from Singapore through Tuas Tuas Checkpoint special gate at Johor Checkpoint at KM5
Checkpoint. KM2.5

Skudai Flyover at KM17 Taman Perling flyover at KM25 Lima Kedai flyover at KM30
Overall Logistics Challenges
Logistics Risk Analysis

Total volume of cargo 5,000,000 FT


Restricted period of shipping operation 50 months
MOLF Tanjung Setapa availability M20
Number of EPCC packages 40 major packages / 200 suppliers & contractors

Identified Risks

Various places of origin / port of loading


Large number of vessels
Constraints at port of discharge / places of receipt
Congestion at ports, laydown & temporary storage areas
Different Brokers & Agents + numerous Forwarders & MTO Operators = uncoordinated Customs clearance

Misunderstandings Conflicting Operations Blocking Operations


Overall Logistics Challenges
Lessons Learnt
Road pressure &
Sg Johor Bridge limitations

HSSE issues
Breakdown of a Siemens cargo truck resulted in a 8 km traffic congestion
Main MOLF readiness

Peak Freight Period

Toyo Road Accident at Pasir Gudang Road enroute to RAPID Site

TOYO cargo weighing 101.75 ton / 70 m in length transported by low loader


4 days / speed of 20 km / hour = massive traffic congestion
Overall Logistics Challenges
Lessons Learnt HSSE issues ranging from fatal road accidents enroute to
RAPID Site and construction debris & dust polluting local homes
Road pressure &
Sg Johor Bridge limitations

HSSE issues

Main MOLF readiness

Peak Freight Period


Overall Logistics Challenges
Lessons Learnt
The logistical constraints and imminent social economic concerns
Road pressure & resulting from land haulage limitations, HSSE issues, pushback from
Sg Johor Bridge limitations local villagers and State Government necessitate the need to
accelerate the completion of the MOLF construction and the roll out
HSSE issues
of the Barging Services in order to ease pressure off the roads.
Main MOLF readiness

Peak Freight Period

MOLF Teluk Ramunia MOLF Tanjung Setapa


Overall Logistics Challenges
Lessons Learnt Changing cargo volume split to ensure no single transportation
channel (water & land) is oversubscribed during the peak year
Road pressure & with water transportation being the safest channel.
Sg Johor Bridge limitations
Scheduling regular Barging Services to reduce material trucks
HSSE issues by 66% during peak from 250 - 300 trucks/day to 80 - 100
trucks/day
Main MOLF readiness

Peak Freight Period


MOLF Operatorship
Johor Port has been appointed as the Operator for
both MOLFs at Tanjung Setapa and Teluk Ramunia with
the following scope:

Provision of Barging services from Johor Port (PGU) / PTP to


MOLF which includes the loading onto barge and the barging
voyage;

Operations and Management of both MOLFs including the


berthing and discharging of cargo;

Management of Storage / Laydown Yard covering the


movement of cargo to the MOLF Storage / Laydown Yard and
its subsequent management at the Yard; and

Last mile transportation for the transportation of cargo from the


Storage / Laydown Yard to the RAPID Construction Site.
MOLF Services
Handling Equipment available at MOLF
Port to Port Handling Activities
Services

650 T / 250 T / 100 T Cranes
Reachstackers
Overview On Dock / Off Dock


Prime Movers + Trailers
Forklift 15 tons / 10 tons
Gears

Feeder
Barge
PSA JPB MOLF
Ramunia

Vessel
------------- RAPID Site
MOLF
Vessel Setapa
PTP Barge Shipping Agent
Online transaction through Port System
Vessel (VCS and MSS) for:
Overseas On Dock / Off Dock Vessel Clearance
Berth Application

Forwarding Agent
Online transaction through Custom & Port
System (MPTS) for:
Cargo Clearance
Vessel / Barge Handling operation management
Site Area Plan

MOLF
Ramunia

MOLF
Setapa
MOLF Ramunia & MOLF Setapa

Designed for discharge of Containerized


cargo & General (Breakbulk) cargo of 400 MT
and less.
Designated for barges and vessels with
maximum draft of 5m.
Typical operations shall be for Lift On / Lift Off
by cranes or RORO and sent to the Storage /
Laydown Yard.

Designed for HLO, SHLO and RORO


operations .
Designated for vessels with a maximum LOA
of 170m and a maximum draft of 9.5m.
Typical operations shall be for HLO, SHLO and
RORO and sent directly to the RAPID
Construction Site upon discharged.
Whats next after RAPID?
The RAPID project is on schedule for its start up date of 1 Jan 2019.

MOLF Ramunia has ceased operations as of July 2017 and all Solid Product Jetty
Barges / RORO Barges / Vessels are now being redirected to MOLF
Setapa.

MOLF Setapa will be converted into a Solid Product Jetty to cater for
the future exportation of the petroleum products from the PIC /
RAPID.

Part of the MOLF Setapa facility will be retained to cater for


construction materials from:
Further expansion of the PIC / RAPID Project;
Replacement of RAPID major components due to breakdown;
and
Future development of the surrounding Pengerang Integrated
Petrochemical Complex (PIPC).
BIG STUFF : Delivering The RAPID Project

Presentation by:
Peter Roland
Managing Director
BBC Chartering Japan
RAPID BBC Chartering

How is BBC Chartering involved with


the RAPID Project?
History and Background
Main involvement with RAPID (and selected case study):
Toyo Engineering Corporation were awarded a contract for a
Steam Cracker Complex (SCC) project

A part of RAPID, contract value 240 Billion Yen

A special contract - BBC Chartering contracted directly with


TOYO Engineering Corporation Japan

Contract dated June, 2015

1 year development

Other involvement with RAPID:


As a positive indirect/direct side effect of the main contract BBC
Chartering has been involved in varies other packages for
RAPID
RAPID BBC Chartering

Facts & Figures for the case study?


Facts & Figures
Steam Cracker Complex
Total shipments to date : 53 shipments (still some shipments remain)
Shipped Volume (about) : 265000 F/T
Heavy lifts : up to 400mts

Cargo Type

18%

39%

30%

13%

Genaral Cargo Heavy Cargo Pipes Steel Structure


RAPID BBC Chartering

What kind logistical challenges did


the Steam Cracker Complex (SCC)
present?
Logistical challenges on the carriers side
Communication Stackability
Can represent the weakest link Cost cutting
Should be main focus? Priorities Transportation and packaging
Safety
Solution
Direct Communication
Solution
Identify main point of communication
Establish project teams (Local, regional, world-wide) Sufficient clauses
Back up Flexible loading terms deck option etc
Thinking out of the box loading
Short Notice and changing volume
No project is perfect Discharge port
Vendor Control Restrictions was concern
Construction Change Costs
Solution
Flexibility to adapt to the change Solution
Tool accessibility Open dialog with all parties involved

Heavy Lift
Range 85-400mts (Cold box 400mts)
No specific issue
RAPID BBC Chartering

What is the overall assessment of the


transportation of this project?
RAPID BBC Chartering

Conclusion
BIG STUFF : Delivering The RAPID Project

Presentation by:
Mike Schoofs
General Manager, Regional Project Division
deugro (Singapore) Pte Ltd
RAPID deugro group

What is deugros involvement with


the RAPID project?
RAPID deugro group
The deugro group has been involved with the RAPID Project since 2014

Initially supported the FEED stage with various transport and feasibility studies, as well as budgetary pricing

Awarded the first EPC contract for RAPID in 2015

Since then involved with various EPC packages within the project for Arabian, Japanese, Korean, Taiwanese
and Thai EPC contractors

Packages handled:
Steam Cracker Complex
Utilities for Steam Cracker Complex
Residue Fluid Catalytic Cracking-, LPG Treating-, Propylene Recovery and Caustic Neutralization Units
Amine Recovery, Sulfur Recovery, Sour Water Stripping, Liquid Sulfur Storage

Successfully executed shipments of more than 500000 FRT in total with Heavy Lifts up to 350 tons
RAPID deugro group

What case study are you going to


present today?
Case study deugro group
Rapid Package: P0001 RFCC, LTU AND PRU Units

Cargo : Hoppers, Drums, Pots and accessories

Volume: 57 Packages / 2813 tons / 25982 cbm / 3750 sqm

Heavy Lifts: 04 x Spent Catalyst Hoppers = L 45.02 x W 8.09 x H 8.72 m @ 348.0 tons each
02 x Fresh Catalyst Hoppers = L 40.37 x W 7.27 x H 7.87 m @ 185.9 tons each
03 x Drums up to = L 23.23 x W 7.89 x H 8.62 m @ 141.4 tons each
06 x Drums up to = L 19.85 x W 5.93 x H 7.97 m @ 87.0 tons each

Port of Loading: Gunsan, South Korea

Port of Destination: Tanjung Setapa, Malaysia = RAPID Project MOLF

Time of Shipment: September 2016


RAPID deugro group

What was special about this case?


The Challenge

Cargo readiness and project schedule made it necessary to ship all cargo on one vessel

+ 25000 FRT of cargo -> dedicated vessel


3730 sqm of which un-stackable -> vessel space
Heavy Lifts up to 350 tons -> lifting capacity of the vessel
Long units up to 45 meters length -> rigging and lifting
Tight stowage to accommodate all cargo -> vessel stability, efficient loading plan

Restrictions at Tanjung Setapa


Vessel LOA not to exceed 170 m
Draft restriction of 9.5 m
RAPID deugro group

How did you overcome this


challenge?
The Solution
deugro forwarding:
project management worked closely with supplier and client to update and finalize packing list
cargo readiness date
required on site date

d.chartering (deugros in-house chartering desk):


narrowed down potential vessel types matching the criteria for space and lifting capacity
selected vessels that would potentially fit the anticipated laycan window
approached carriers operating the pre-identified vessels with cargo details and schedule
negotiated highly competitive freight rates
selected vessel that offered the best fit for cargo, schedule and price

d.teq (deugros in-house transport engineering team):


worked with the client to identify, summarize and communicate to the carrier the technical requirements
reviewed and approved the carriers proposed method statement and transport manual
supervised operations and enforced adherence to the technical plan
The Solution
MV HAPPY BUCCANEER

Length overall: 146.00 m

Summer Draft: 8.24 m

Floor Space:
Weather Deck : 3067 sqm
Tween Deck : 2275 sqm
Tank Top : 1344 sqm

Crane Capacity: 2 x 700 ton SWL

Allowable Loads: 5.0 ton/sqm WD/TD


15.0 ton/sqm TT

Hatch Openings: 110.5 x 20.6 WD


67.0 x 20.0 TD
The Solution
The Solution
The Solution
The Solution
The Solution
The Solution
VISIT DEUGRO.COM/RAPID
BIG STUFF : Delivering The RAPID Project

THANK YOU!!!