The vessel site team comprises representatives of all the engineering disciplines involved in the design phases of the project.
The original PV150 design team forms the core of the Terra Nova ship design and shipyard site teams.
Vessel Construction
Construction of the Vessel Hull and Topsides commenced on 3rd August 1998. The lower turret was constructed by Noell Imac, in the Middle East and was delivered to Korea on 9 February 1999. The "topsides" construction is at three sites, 2 modules by Barmac in Scotland, 2 modules by PCL at Bull Arm, Newfoundland and the Upper Turret by Noell Imac in the Middle East.
Milestones. At the time of writing, the FPSO hull construction contract is in the final stages of mechanical completion and commissioning. Key dates for this contract are shown in Table 5.
The vessel was launched from the building dock on 22 May 1999 and was moored at C quay in the Daewoo shipyard. Mechanical completion programme continued until 22 November 1999 when the Vessel was moved to E quay to allow installation of the forward thrusters and to allow the commissioning programme to proceed. E quay has a dredged section with a minimum depth of 10.5 m.
Build Process. The Daewoo Heavy Industries shipyard fabrication processes and facilities are capable of producing an annual output of approximately 30 significant ships.
In simplistic terms this is achieved by a conveyor-belt approach to construction where the steel is cut and fabricated in "blocks" and "super blocks" in preparation for a slot in the shipbuilding dry dock. The preparation of large fabricated "blocks" is progressed to an advanced state and typically includes painting, services and outfitting. The Terra Nova hull steelweight of approximately 33,000 tonnes was fabricated in 230 blocks ranging from a couple of tonnes up to approximately 400 tonnes. Where the fabrication sequence and facilities allow these blocks are combined to produce super blocks. There are 50 super blocks ranging in weight up to approximately 620 tonnes. The largest single lift is the lower turret section (TS1) weighing 760 tonnes.
Given the size and weight of these "blocks" and "super blocks" the erection sequence in the dry dock is speedy and the vessel rapidly takes on a recognisable form and is transformed from a collection of assembled steel "blocks" to a floating structure resembling a vessel.
Status of Mechanical Completion and Commissioning. A common system of tracing completion of work is applied across the Terra Nova Alliance. This system is called PCS (Project Completions System).
PCS is a computerised project completion system for status of preservation, mechanical completion and commissioning by individual tag, Mechanical Completion package or commissioning package. PCS also contains engineering indexes such as master equipment list, line list, electrical consumer list, instrument index, computer point index and a document control system for MC documentation.
Status at 31St January 2000 is as follows (38 days to delivery). There are currently 43,145 Inspection Test Procedures (ITPs) in PCS. Completion currently stands as 91.9% complete. Function test Certifications (FTCs) are required for a total of 12,000 items. Status is currently 82.7% complete. After function testing of components systems and part systems are handed over to commissioning. Commissioning is currently 76.7% complete. There are 52 systems that are subdivided into approximately 270 part systems of which 225 are commissioned in Korea.
Commissioning at Sea Phase. Due to draft limitations at the commissioning quay it was planned to conduct an extended series of sea trials. The initial part of this programme was dynamic testing of systems. This programme included endurance testing of all thrusters, testing of cargo and ballasting systems, load sharing of generators, testing of emergency generator, fire system, compressed air system and inert gas generators.
Due to an error by the shipyard the three aft thruster caissons were flooded to above the motor height on the second day of this phase. All these motors were removed for refurbishment and have since been reinstalled in the Vessel. However as a result the work programme could not be completed and the Vessel had to return to quayside and a final series of tests planned.
Final Sea trials Programme. A period of Sea trails lasting approximately 10 days is scheduled before departure. The programme will include,
-Thruster endurance trial for aft thrusters
-Noise and vibration measurements
-Speed and manoeuvring trials
-Autopilot calibration
-Cargo tank offloading system function test with sea water. This is a limited test to confirm modification to hydraulic system pipe supports.
-Key Service generators paralleling (load test will be conduced quay side)
-Black start test
-Blackout and emergency generator start
-HPR test
-IGG performance test
-Speed log calibration
An inclining experiment will be conducted before sea trials. This will be witnessed by Transport Canada and Lloyd's register of shipping
Management Of Construction/Commissioning Phase
The management techniques used during construction are conventional. Extensive use of critical path analysis and look ahead has been used.
