International experience key for Hertel on Pulau Ular

Hertel’s global expertise in industrial construction and maintenance services has been crucial in completing a new build project at the Ethylene Cracker Complex (ECC) project at the Shell Eastern Petrochemical Complex (SEPC).

Mega project

When it is fully operational the refinery will have an annual production capacity of 800,000 metric tons of ethylene, 450,000 metric tons of propylene, 230,000 metric tons of benzene, 155,000 metric tons of butadiene and 750,000 metric tons of mono-ethylene glycol.

The complex is Shell’s largest petrochemicals investment in Singapore, and employs over 15,000 workers. The SEPC will supply ethylene, propylene and mono-ethylene glycol to Asian markets - key raw materials for the textile and packaging industries. The large quantity of raw materials produced reinforces Shell’s position as the leading petrochemical company in the Asian market.

Coordination and collaboration

Hertel was awarded the contract for insulation, fireproofing, painting and scaffolding in the process areas and furnaces of the ECC in early 2009. The project was completed in June 2010.

Marius Nobel, Project Manager for Hertel at the Shell ECC project, said: “The successful completion of the ECC project has helped to underline our global credentials in industrial construction and maintenance services.”

“Hertel was working alongside Shell’s main engineering contractors CBI-Lummus and Toyo Engineering Corporation, so it was important we met regularly to coordinate activity. Meetings were scheduled on a daily basis to discuss the project openly, and share advice on best working practices at the site. It also helped to ensure the project was delivered on time.”

Always safety first

Richard Henfield, ECC Project Director for Shell Eastern Petroleum, said: “Hertel successfully completed the insulation and fireproofing contracts for their works on the ECC. Hertel’s commitment during the construction period was commendable, and they managed the project professionally, meeting our challenging schedule.

Richard continued: “As well as achieving one million man-hours without an LTI, Hertel was also awarded Shell’s Best Contractor of the Month award, which is recognition of its contribution to the success of the project.”

1,000,000 man hours LTI free

Marius said: “We were particularly pleased to have achieved one million hours without an LTI, which was part of Shell completing nearly 38 million man-hours without an LTI from January to November 2009.

“Safety was kept front of mind amongst all of our employees by implementing a number of safety techniques drawn from Hertel sites around the world. Daily ten-minute ‘Toolbox Talks’ were held at the start of each day to ensure that all staff were thinking about safety as they worked. Site managers also conducted regular site checks to make sure Personal Protection Equipment (PPE) was always worn.”

A global project

Hertel was able to draw upon the skills of colleagues throughout Europe, the Middle East and Asia. There were 60 senior site employees to oversee the project, comprising of 15 safety supervisors, 30 insulation supervisors, five QA-QC inspectors, and a number of administrators and site managers.

Marius said: “As the project moved forward, one of our greatest assets was being able to draw upon skilled workers from Hertel companies in Malaysia, India, China and Thailand to complete the project. At its peak we had 800 workers on site. Using Hertel’s experienced staff meant we know they would be fully aware of Hertel’s expectations on site safety and job requirements.”

A challenging project well delivered

“With limited space on the island of Pulau Ular, where the refinery is sited, it was important that the logistics for equipment storage were carefully planned to ensure minimum disruption. Equipment arrived by ferry and barge.

“The Shell ECC Project was a major project for Hertel, and with one of our biggest clients. As Hertel was also a new entrant to the local industrial construction market, it was incredibly important we made accurate forecasts about our capabilities and delivered the project safely and on time.”