Congressman Randy Weber Visits Gulf Copper for MARAD Small Shipyard Grant

Congressman Randy Weber Visits Gulf Copper for MARAD Small Shipyard Grant

On Tuesday, October 23, 2018 at 3:00 p.m., Texas’ 14th Congressional District Congressman Randy Weber visited Gulf Copper Manufacturing Galveston Shipyard, 2920 Todd Rd., Galveston, TX 77554. Gulf Copper was recently awarded the MARAD Small Shipyard Grant.

The MARAD Small Shipyard Grant will help Gulf Copper cultivate efficiency, quality ship construction, and repairs at our Galveston Facilities:

  • Gulf Copper Dry Dock & Rig Repair was awarded a Small Shipyard Grant for the amount of $1,296,820.00. Gulf Copper will match the grant amount for the purpose of constructing a new Dry Dock with the capabilities of safely docking 4500-ton vessels efficiently.

 

  • This 4500-ton Dry Dock project will not replace any existing equipment. However, it will make major capital improvements to expand the use of two, U.S. built, 79 ft. x 116 ft. x 12 ft. Dry Dock pontoon sections that have been refurbished and are currently used for marine repair work.  It is the intent to join these two sections with a 10-foot transition piece to create a dry dock with dimensions of 216 ft. x 116 ft. x 12 ft. and a lift capacity of 4500 tons.  This will require building two new wing walls 27 ft. high and 8 ft. wide allowing a width between wing walls of 100 ft. The total cost of the project combined will be approximately $2,953,640.00 respectively.

 

  • By producing a Dry Dock of this size, Gulf Copper will create ample business opportunities in the shallow water market such as, Ferry Boats, Harbor Tugs and Inland barges. Along with additional work awarded comes more employment opportunities for our community.

Congressman Randy Weber said, “The work Gulf Copper contributes to the oil and gas, maritime transportation, refining, and petrochemical industries is critically important to the upper Texas Gulf Coast and our nation. With a view toward safety and efficiency, Gulf Copper is a terrific recipient for the MARAD Small Shipyard grant. Our local community and off-shore community benefit greatly from the services provided by Gulf Copper.”

“We pride ourselves in creating growth opportunities and working with the Galveston community to provide a brighter and sustaining future,” said Craig Marston, General Manager, Gulf Copper Galveston Shipyard.

 

 

For additional information or inquiries, please contact Craig Marston, Craig.Marston@GulfCopper.com.

Gulf Copper Will Be Attending OTC 2018 Monday April 30- May 3, 2018

Gulf Copper will be attending OTC this year. Our company is honored to have been a part of this conference for many years. As Gulf Copper is now celebrating its 75th anniversary in 2018, we are just as excited to see OTC celebrating 50 years! We look forward to celebrating many more productive years and visiting with all of our valued customers throughout the show.

Gulf Copper Celebrates 75 Years 2018

Gulf Copper was founded in 1948 and developed into a successful pipe fabrication company with a reputation for premium quality work installing copper piping on marine vessels. In 1979, the company was acquired by the Gulf Copper Group, and expanded services into full topside ship repair with the addition of a machining division. Over the years, Gulf Copper has continued to diversify, now servicing the commercial marine, offshore, shipping, oil and gas, petrochemical, power generation, construction and transportation industries. As we continue to grow and evolve we appreciate the loyalty and support of our customers, without you, this would not have been possible. 75 years and counting!

Seadrill Westvela Installation

GC Energy Services group (GCES) was contracted by Seadrill to perform the installation of the West Vela second BOP HPU

The Project was performed in two phases

Phase I involved cutting two access openings in HPU room to rig in the High Pressure Unit and the Accumulator bottles

These access openings were then reinstalled by the GCES Team

Phase II consisted of installing stainless steel piping rated for 6000 psi using a tig welding method and stainless steel tubing. GCES also performed the internal passivation of the stainless piping for further corrosive protection of the system

All work was performed safely and with good planning, resulting in on budget installation

Transocean Polar Pioneer

The scope included the removal of six (6) existing Panama chocks on the pontoons and installation of six (6) new Panama chocks which were fabricated by Gulf Copper and Manufacturing in their Port Arthur, Texas facility

Gulf Copper also performed the removal of 84 sea fasteners which had been welded to the underneath bottom plating of the pontoons for the heavy lift transit from SE Asia to Washington State

The work was performed in the ports of Port Angeles and Seattle, Washington. A smaller team remained onboard to perform various tasks in preparation for the upcoming drilling season in the Chukchi Sea

The Transocean Project Manager commented: “The team performed exceptionally well, the management responded promptly to our changing requirements. This was one of the best crews I have ever worked with.  From the design, fabrication, mobilization and demobilization, executions were above expectations.  Gulf Copper will be my contractor of choice in the future.”

The GC Energy Services team worked closely together with Transocean and Shell on a high focus job with the embedded safety culture and professionalism that has become expected in the industry

MV Ocean Constructor

Stabbert Maritime has completed the refurbishment of its newest vessel, the Multi-purpose Construction and Subsea Vessel Ocean Constructor, at the Gulf Copper Galveston shipyard. This is the second major refit of a Stabbert vessel performed at Gulf Copper. Work consisted of an accommodation upgrade, steel and piping renewals, mechanical overhaul of machinery, and coating of hull and superstructure. Numerous vessel components were renewed during the shipyard period.

While at Gulf Copper, the Ocean Constructor was drydocked and underwent a 5-Year Special Periodical Survey for Class Certification. The DP2 vessel, 126 meters in length, is equipped with accommodations for 200 people, a 300 ton pedestal crane, 25 ton auxiliary crane and dual ROV’s. Upon completion of the refurbishment, the Ocean Constructor is well suited for it’s mission of supporting offshore construction, cable lay, and subsea work.

Stabbert Maritime’s group of companies delivers a wide-range of innovative solutions and support services to offshore, science, subsea energy, and ship repair clients. The Ocean Services fleet serves science and research markets. Ocean Sub Sea Services (OS/3) serves the offshore oil and gas industry. SYS Ship Repair provides shipyard and repair services throughout North America. Stabbert clients rely on them to deliver timely solutions to complex projects in the most cost effective way, from mission design to refit and mobilizations to general vessel operation and mission completion. The company has experience operating in all of the world’s oceans, and currently is active in Mexico, Brazil and throughout North America.

Founded in 1948, Gulf Copper & Manufacturing Corporation is an employee-owned company that repairs and refurbishes marine vessels and offshore rigs and fabricates specialty components for the oil and gas market. The company operates strategically located shipyards, drydocks and fabrication facilities along the U.S. Gulf Coast. Gulf Copper serves the marine transportation, offshore construction and offshore drilling markets in addition to various United States government agencies.

Building ‘CALM buoys’ brings jobs to Port Arthur

Thanks to the manpower provided by Gulf Copper & Manufacturing, 7200 Hwy 87 East, three large freshly finished Catenary Anchor Leg Mooring (CALM) buoys are now fully operational and ready for delivery to Houston-based mooring company SOFEC Inc. at the end of the month.

Gulf Copper Keeps “Calm”

Gulf Copper’s Port Arthur facility earlier this year completed a unique 10-month project to build the three massive buoys for SOFEC, buoys which will be used to offload liquid product such as diesel or gasoline in places lacking deepwater ports.
In total Gulf Copper received two separate contracts to build a total of five CALM buoys (3 and 2), for SOFEC. The order is of particular interest from the yard’s view as it is a new line of business for the company.

The massive buoys pictured here are Catenary Anchor Leg Mooring System, or CALM buoys, and SOFEC is a global leader in the supply of CALM and SALM terminals globally. Each unit weighs in at 230 to 260 tons (depending on the number of heads) and the floating hull of the buoy is tethered to the ocean floor offshore of a storage or processing facility. “SOFEC Inc. has manufactured and delivered a total of 44 CALM buoys to date,” said Claude Signori, Project Manager, SOFEC, when Maritime Reporter checked in with him last month. “These have been delivered and installed evenly between Latin America, the Middle East and South East Asia. The demand for CALM buoys has been fairly steady since the early 80s and is expected to remain steady for the foreseeable future.  Prior to the arrival of the offshore terminal, vessels were obliged to moor to Jetties in a harbor/port.  This would mean the construction of Jetties, the addition of transfer hoses or mechanical loading arms and in most cases the expensive dredging and upkeep of channels to accept the medium to very large vessels used for the transport of liquid hydrocarbons.”

CALM

CALM refers to Catenary Anchor Leg Mooring, and the CALM Buoy is a floating hull with a rotating head to which vessels can moor. The CALM buoy falls under the category of a Single Point Mooring (SPM) typically with a turntable positioned above the geostationary hull mounted on a roller bearing. Flexible large bore rubber hoses are used to connect the subsea pipeline to the hull. Similar floating hoses are employed when connecting the buoy to a tanker prior to transferring liquid hydrocarbons. Central to the main bearing is a product swivel which allows fluid to transfer between the geostationary hull and rotating turntable while the moored vessel weathervanes. The primary benefit of a CALM Buoy over a SALM Buoy is ease of maintenance. The mechanical U-Joints of a SALM are removed, and the fluid swivel is located above the water surface. The vast majority of Marine Terminals installed since the mid 1990s have been CALM Buoys because of these design improvements.

While the technology is proven and accepted, demand can be tricky to gauge, according to Signori. “We have seen various increases and decreases that are very difficult to predict.  These marine terminals are not market followers since delivery from concept can be 24 months or more.  What we do see is a high demand for new refineries and power plants in remote regions where ports are not part of the local infrastructure.  It is much less costly to develop a system using a marine terminal than building a new port or harbor.”

One advantage of the CALM buoy for the operators is the ability to locate these terminals offshore in a suitable depth of water with an easy installation of the buoy connected to shore to via a pipeline.  Another advantage, the environmental signature of an offshore installation is considerably less than a shore side terminal.  These two factors, coupled with an expected operating life of 30 plus years will continue to drive the future market, according to Signori. “Also, as developing countries rely on importation of crude or refined product, we continue to see an increase in demand.  For instance, as India invests in relative remote areas with refineries for their internal needs, the supply of marine terminals to import the feedstock has increased.  The same will be true of power plants that rely on liquid hydrocarbons for operation.”

A Partner in Gulf Copper

The project was a first for Gulf Copper, and according to Eric Callarman, Gulf Copper & Manufacturing Corp., it presented its fair share of challenges along the way. But he credits SOFEC, their technical expertise, experience and willing to partner to resolve issues as they arose as helping the yard to build its best practices even further.

According to Callarman, challenges started with the schedule which demanded a 10-month production deadline. In addition, it was the biggest fabrication project to date for the Port Arthur facility, and construction far exceeded simple fabrication, involving electrical, mechanical, critical machining and FAT testing. “With the help of our client, we raised our level of quality to meet project requirements. We actually look forward to utilizing this new level of quality on projects moving forward.” For example, “we originally thought that the fabrication of the CALM Buoys was going to be the most difficult and time consuming portion of the project but as we started the mechanical and integration portion of this project, we quickly learned that this was actually the most difficult and time consuming.” The final challenge is one familiar to most any ship construction facility on every continent: the location and hiring of qualified craftsman to execute the contract. In total Gulf Copper added 50 positions for this project alone. But by the account of the client, all challenges were met.

“SOFEC is very pleased with Gulf Copper’s performance,” said Signori. “The quality is very good, and financial performance solid.  Some of the mentioned challenges appeared in the form of schedule challenges, but these were overcome with hard work and more than a couple long days.  Nonetheless, the project met both the Owner and SOFEC expectations.

“We were interested in contracting this work on the Texas Gulf Coast,” Signori said. “We were sure the proximity of SOFEC in Houston to a Gulf Coast fabricator would provide an advantage.  And given that the local fabrication would support the end user with regards to transportation and importation obligations at the final destination, it was an easy decision to try to work locally.  The difficulty would be to choose the right partner. SOFEC selected Gulf Copper based on their solid ship repair and fabrication experience,” Signori added. “SOFEC audited the yard and came away certain they could do the work.”

Two additional CALM buoys are currently being fabrication at Gulf Copper and will be delivered in December 2013.  “There is every reason to believe we will work with Gulf Copper on more projects in the future,” Signori concluded.

And while the business value of winning this contract and building these complex systems is self evident, Callarman sees a value to the project that will extend to and through the work of Gulf Copper. “The biggest lesson learned from this project is that we thought we were a very good fabricator, and we are, but this project exposed areas of needed improvement,” said Callarman. “Everyone at Gulf Copper, and on this project team, really got on board with this project and we made many improvements throughout this project. We are really excited by the improvements that we made and what this will do for Gulf Copper moving forward.”