AVEVA World Magazine

Pipeline 2008 #1

AVEVA World Magazine | Technology insights and customer successes with AVEVA software

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Kalkavan Sedef shipyard implements AVEVA Marine to further increase productivity Magnus Feldt Communications Manager – Industry Solutions, AVEVA When we visited Kalkavan Sedef shipyard in Tuzla, Turkey, we found the site extremely busy. A new dry dock was under construction, a newly-built container ship was at the outfitting quay ready to be delivered in two weeks, and three container ships were being built simultaneously. The pace of progress is also high in the design office, where the design work had begun on a 180,000 dwt bulk carrier. This will be by far the largest bulk carrier ever built in Turkey. We met Cumhur Kuter, General Manager, who explained the changes the shipyard is carrying out to further increase productivity to meet the new challenges they are facing due to a very successful order intake. In the early 2000s, the shipyard's fabrication process was transformed into a workstation-oriented workshop production line with modern panel-line and assembly-line equipment. To support their fabrication process, Sedef implemented AVEVA's Tribon shipbuilding system for both their structural steel and their outfitting disciplines. A numerically controlled pipebending machine was also installed for the fabrication of pipe spools. The increased accuracy of production information has substantially reduced rework and saved man-hours as well as material costs. The shipyard has been able to reduce production time from first steel cutting to delivery from eleven months to eight months. Their first ship in a series of five container ships took 700,000 man-hours to build, while the fifth in the series required only 500,000 man-hours. Today, Sedef can build seven ships per year, compared to five similar ships before. Page 24 | AVEVA PIPELINE | 2008 Issue 1 In order to further increase the shipyard's production capacity and boost productivity, a huge investment programme is currently being undertaken. The shipyard is being extensively upgraded to allow the building of larger container ships of up to around 4,500 TEU, and bulk carriers of up to 180,000 dwt. The existing production facilities have recently been further extended by a new panel line supported by the AVEVA Marine solution. When the new, enlarged prefabrication area is completed, it will be possible to carry out all operations under cover. A 10,500 square metre dry dock is under construction, with an overhead gantry crane with a 500 tonne lifting capacity. A new pipe shop is also nearing completion. Near to this berth, and already in use, is a highly automated painting facility, providing environment-controlled, enclosed conditions where all blocks can be painted and finished. This facility has four halls, up to 18 metres high, and covers around 3,300 square metres. Using the AVEVA Marine system, the shipyard has now started the detailed design work on the first of the three 180,000 dwt bulk carriers. The basic design was undertaken by the Turkish engineering company, Delta Marine.

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