An optimized process of series construction

To build 76 vessels in series in four years is an unprecedented challenge in the offshore oil and gas industry.

In order to successfully meet such an industrial challenge, close collaboration between BOURBON and its partners (designer and shipyard) was necessary from the very beginning of the project. Each party has its own point of view, and had to work intelligently with the others to obtain the best outcome.

It was in this spirit that each partner deployed its expertise and resources to meet the delivery schedules and ensure that the first vessels delivered offered satisfaction to clients from the moment they were commissioned.

With 3 objectives :

 

A series design for a vessel that is simple to build and operate

The series construction process significantly reduces costs and accelerates fabrication. Thus, the design was developed with an eye for simplicity in order to optimize construction as well as the maintenance and performance of the vessel in operation.

Designing vessels that are simple to operate and build, adapted to series production, by developing a methodology designed to simplify production and save time, while guaranteeing quality, reliability and ergonomics was the guiding spirit when BOURBON asked Guido Perla & Associates Inc. to create the Bourbon Liberty.

Guido Perla, president of Guido Perla & Associates Inc.

Working for American shipyards, Guido Perla & Associates Inc. has developed a methodology geared to simplifying production. This design firm, which also has solid experience in diesel-electric engines (Cummins / EPD), combined with Z Drive propulsion (Steerprop) and dynamic positioning system DP 2 (Beier), thus provided an excellent response to the BOURBON operating standards.

Optimization at all stages of construction, as well as throughout the entire life cycle of the vessel to facilitate maintenance, is what guarantees quality and reliability.
Bourbon Liberty 3D Modeling

In the design phase, 3D modeling simulates shapes and spaces. An analysis of fluid flow ensured optimized hull design. Using the methods of calculation by finished elements, redundancies have been optimized, and the structure lightened, by positioning the right materials at the right locations. Modern computer-assisted design technologies allowed the creation of standardized components or modules.

Standardized modules

 

In the hull preparation phase, the reduced number of standardized modules allowed us to anticipate the organization of the construction phases and ensure flexibility in planning the assembly lines and production sections.

 

As a result, at the Sinopacific Shipyards, only 9 days are necessary to assemble the modules that form the hull of the vessel, and the diesel-electric engine can then be simply installed on the main deck.
In the same way, the piping is pre-arranged in the hulls before final assembly, which is standardized and can be completed very rapidly.

Standardized modules

 

In addition to saving time, this series construction process allow large-scale standardization of the equipment, a not insignificant economic and industrial factor throughout the life cycle of the vessel.
 

Today, equipment availability is the greatest bottleneck in ship construction.

Thanks to the series effect, it is possible to secure delivery of the equipment:

  • azimuth thrusters (Steerprop),
  • EOS system (EPD),
  • gensets (Cummins)
  • control station

by optimizing the delivery format so that they can be installed rapidly and simply on the vessel.

Rigorous organization of production

The process of series construction requires a rigorous organization and ongoing quality control on site.

In coordination with the teams from the shipyards, BOURBON set up with the first orders placed with Sinopacific, a structure at the production sites that monitors, coordinates, and controls each vessel under construction.

Today, under the responsibility of the Director of New Construction, Bourbon Offshore – Production Section, based in Marseilles, the project head of the two Bourbon Liberty 100 and Bourbon Liberty 200 series has created, organized and manages a 40-person team in China under the direction of two former experienced captains who have been specifically detached for this mission.

These coordination teams (17 people in Dayang and 22 in Zhejiang), a real crucible of international expertise, are composed of Superintendents, expatriates of various nationalities, each responsible for 3 vessels, and Chinese Inspectors specialized by trade.

Resources equal to BOURBON's requirements

The industrial scope of such a project requires shipyards with leading-edge equipment and solid knowledge of series construction.

The Sinopacific design offices in Shanghai have CAD and innovative simulation tools to dialogue with designer Guido Perla (method of calculation by finished elements to optimize the structure, the Tribon system to direct fabrication in 3D…).

And the Dayang and Zhejiang yards in China are equipped with very powerful and high-performance handling equipment to manipulate very large units, latest-generation tools and facilities to cut the sheet metal, and leading-edge welding, sanding and painting tools.

In addition, the quality of the construction also depends on the skills and involvement of the employees on site.

Sinopacific emphasizes ongoing training for its employees through an integrated technical school, and participates in the improvement of working conditions. For example, air conditioning plants are installed during the construction of each unit to ensure the best working conditions for the operators in the shipyard when the outside temperature can reach 40 °C.

 

Bourbon Liberty: a long continuous collaboration

For BOURBON, Guido Perla Associates and Sinopacific, not everything began with the Bourbon Liberty.This collaboration began five years ago.

The foundations for the Bourbon Liberty series were laid as a continuation of this first profitable collaboration.

Read More