Hibernia GBS: Construction Schedule Recovery Applying Total Quality Management Principles

Abstract

Abstract Construction of the Hibernia Gravity Base Structure (GBS) commenced in fall 1992 in Bull Arm, Newfoundland. During early stages of construction the GBS project experienced serious delays. In 1994, as the base slab was completed, the NCNIPKS joint venture formed by Norwegian Contractors Newfoundland Inc. and Peter Kiewit Sons Co. Ltd. was awarded the Construction Management Contract to complete the construction and marine operations for the GBS. No previous offshore concrete structure has had such complex geometry in combination with very high rebar densities and strict tolerance requirements. Based on detailed studies and a full scale mock-up the limits for slipforming concrete structures were raised, and slipforming was implemented as the main construction method. Constructibility reviews were implemented to identify and resolve technical problems upfront, which has secured the schedule and improved project economics. Pulling together a new effective international construction team was achieved through application of the Total Quality Management philosophy being adapted for the project. Resulting from these efforts, the GBS project was turned around and the concrete works completed during fall 1996, on schedule and within budget. Introduction Construction of the Hibernia Gravity Base Structure (GBS) commenced in fall 1992 in Bull Arm, Newfoundland. In traditional manner, the lower part of the concrete structure was built in a Dry Dock, floated out, and moored at the Deepwater Site where the major portion of the structure was constructed. During 1993 the GBS project became increasingly delayed, and in the summer Hibernia Management & Development Company m C)ap proached Aker Norwegian Contractors (Aker NC) with partner Peter Kiewit Sons (PKS) to perform an evaluation of the Project. The first project performance study was carried out in September 1993 aiming to provide an evaluation of the overall project, its schedule and performance, identify critical areas, and propose remedial actions to recover the accumulating delays. Having identified the critical activities, a second study was completed early November 1993 with emphasis on finding means and methods to accelerate the near term construction activities to be performed in dry dock. The studies concluded that the existing project schedule was unrealistic and that the project would have to reconsider the planned platform installation in summer 1996. Major changes were recommended to be implemented to ensure that installation in summer 1997 was feasible. They included:Implement slipforming as the main construction method for building the walls.Introduce systematic constructibility review as an integrated part of the design and construction process.Strengthen the interface and communication between Engineering and Construction.Improve construction line management empowerment, commitment and accountability. In January 1994, personnel from Aker NC and PKS were integrated in key roles in the GBS project organization. The purpose was to v e d j the proposals made during the studies and confirm the revised schedule while continuing the construction activities. At that time the base slab was completed and the placement of rebar for the walls had just started.