Offering Solution to Pain Point
PT. Karimun Sembawang Shipyard, a wholly owned subsidiary of Sembcorp Marine, operates as a supporting yard on Karimun Island, Indonesia, driving the group’s strategic plan for offshore engineering solutions that encompass ship repair and conversion, fabrication and piping, as well as desludging and de-sloping services. Over the years, PT. Karimun Sembawang Shipyard has attracted projects from local and international clients due to its high-quality work and quick turnaround time, which complements Sembcorp Marine’s shipyards on the mainland in Singapore.
For operations to progress and a reputation to uphold, it is only right that the most reliable Denyo power generators are used to keep the operations running, because none of this will matter if there is no power to sustain the equipment and facilities. In general, a shipyard has various types of operations and may differ from day to day; hence, the loading profile is seemingly unpredictable, making a one-size-fits-all solution potentially ineffective and leading to either low loading or overloading of the generators. Identifying their pain points, Denyo recommended its SmartSync system, the most advanced synchronising system available in the market. This system is designed to automatically configure additional generators into synchronisation depending on the load required at that specific moment, due to its load-dependent start/stop functionality.
With the subsequent evaluations on PT. Karimun Sembawang Shipyard’s workflow requirements, two sets of Denyo DCA-800SPK integrated with the SmartSync system were supplied for installation, and benefits were felt immediately. As a result, their concerns were resolved. The entire process requires minimal manpower and also provides optimal fuel efficiency, leading to reduced operating expenses.
Unforeseen Situation Arise
On the evening of 16th October 2019, Denyo received an emergency call from the on-site project team in PT. Karimun Sembawang Shipyard – requesting technical assistance. Understood that the generators have failed to synchronise and the entire operational loads are currently carried by a single DCA-800SPK, at maximum capacity. The aforementioned can potentially lead to undesirable overloading on the single generator, tripping and putting operations into a complete halt. However, the cause could not be identified through calls. Knowing the impact and consequences, it must be handled promptly at all costs.
Delivering Exceptional Services
Recognising the extent and seriousness of the incident, two personnel from Denyo Singapore set off next daybreak to PT. Karimun Sembawang Shipyard, taking the first ferry, will assess the situation and conduct further investigations with the on-site team.
In the process of validating the root cause, our Denyo personnel matched the operations and the generator’s history log, inferring that the problem was a tripped external breaker due to unexpected earth fault leakage picked up by the switchboard. To substantiate the claim, several inspections were performed on-site and single line diagram analysis of the switchboard, along with incident recovery re-simulated corresponding with the history log, to confirm that the event of tripped external breaker has prevented the voltage from the first generator from reaching the second generator, hence synchronisation of the generators could not take place. After rectifying the fault, the loading profile of both generators was closely monitored for 2 hours, in addition to load-dependent start/stop operation, to ensure that the generators are back to their best working condition. Towards the end, our Denyo team presented incident findings to the on-site team to enhance their knowledge of dealing with similar occurrences in the future.
Denyo’s relations with the client do not end just after a successful project. With prompt response and value-added support demonstrated in this incident, the team from PT. Karimun Sembawang Shipyard was impressed and gratified by the excellence in services and customer dedication exhibited by the Denyo team.
