Access all areas
The last few years have been challenging for KAEFER in Qatar. With a lack of new build projects, KAEFER in Qatar was mainly working on maintenances contracts. This helped build more experience both in the estimation and execution team.
But then, in early 2021, the team around Estimation Manager Bipin Badajena pitched for the annual maintenance contract for the Qatar Gas Operating Company. Thanks to Bipin’s extensive experience in the Qatari market and the support and vision provided by the team led by General Manager Christopher Selvaraj, they managed to win and will be providing services in just about all areas of the gas giant’s operations.
From insulation, scaffolding and painting to refractory and fire proofing, KAEFER in Qatar will spend the next five years helping the Qatar Gas Operating Company to keep its facilities running at the peak of their capabilities. That will also allow the client to progress with a major expansion of its LNG projects.
This project will be the first in Qatar to use the Layher Scaffolding System. It uses a combination of positive and non-positive connections in a bolt-free design with an automatic locking function, making it easier to forge connections that are right-angled, obtuse-angled and acute-angled. This modular scaffolding system is ideal for complex and difficult layouts, especially those with heightened safety requirements. On top of that, the entire project will make use of KAEFER’s new technology, such as the DPMS – The Order to Invoice Solution. Based on LEAN Site Management, DPMS is a central project management tool in which all resources, processes, capabilities and manpower are visualised and organised in real-time. This allows teams and project leaders to increase efficiency and places greater emphasis on transparency.
Laying the groundwork with LEAN
In addition to using innovative new technology and digital tools, the team has prepared for the major Qatar Gas Operating Company job by implementing a pre-execution LEAN project approach. This provides for an optimised and waste-free execution process and helps the team adopt a systematic work culture. In the spirit of continuous improvement, the team of up to 600 people working at peak times will collaborate and aim to eliminate unnecessary steps, whilst providing quality workmanship at every step of the way.
We are the Champions
It’s not just one of the largest intumescent fire proofing projects in the Middle East, it has also been crowned KAEFER LEAN Champion three times by outperforming key LEAN metrics, including LEAN turnover and the LEAN maturity score. The fireproofing & coating process executed at the Saudi ARAMCO-approved KAEFER Painting/Coating Yard in the Al-Jubail is a major endeavour. The facility covers an area of 25,000 m2 with 18 coating booths and hangers and has the capacity to handle daily production of 1,600 m² of coating. This project also manages the loading, unloading and transportation of 22,500 tonnes of coated steel structures and piping for erection at site by other mechanical contractors.
Success in the region and on this project has been achieved by maintaining the highest levels of productivity and material utilisation norms, enabling a significant increase in margins. A proactive marketing approach, utilising capacity fully and offering coating services at competitive prices has also helped a great deal. Furthermore, there has been successful implementation of on-the job training and full-time engagement of local Saudi tradesmen, who now make up approximately 10% of the workforce. They proudly work at the same levels as their expat colleagues with formal approval from ARAMCO.
This year, the team hopes to achieve 500,000 m² of overall coating orders at the yard. An ambitious target, but surely achievable by the LEAN Champions.
For all the ups and downs
358,410 cubic metres. That’s is the volume of scaffolding KAEFER in Oman has managed to successfully erect and dismantle since February 2020. Despite shortages of skilled labour, the team in Oman has continued to provide services for a one of its major clients: Vale Palletizing LLC. At the same time much progress has been made in the company’s Omanisation drive, with education and training provided for 12 Omani scaffolders, 3 administrative staff and 2 health and safety operatives. This bodes well for the future and KAEFER in Oman will continue to provide high quality service for complex access projects.