PROJECT DESCRIPTION

Kirby was awarded the contract to install all electrical, LSS, communications, instrumentation and controls services associated with a wafer fabrication process conversion project.

The project contained a number of challenges, including fast track project nature, live plant environment containing potentially hazardous chemicals / gasses and management of a large number of directly employed trades peaking at 280. Physically large construction site also necessitated off-site material and plant storage and pre-fabrication.

Against this challenging environment, we delivered a high level of performance across the key project indicators of EHS, quality, schedule, commercial and innovation. Our leadership and management of EHS was particularly effective, demonstrated by ten awards for safety performance throughout the project. Kirby also received five awards for quality of installation and system handover approach.

A key component of our delivery model for this project involved the use of 3D BIM modelling techniques to design and construct the tool containment systems. We worked with other trade discipline contractors, using software packages such as AutoCAD, Revit and Total Station to produce a fully coordinated model of the congested sub-fab utility areas.

LEAN construction techniques were encouraged throughout the design and build process. Kirby fully subscribed to this initiative and were instrumental in developing off-site internet based training and induction programs; cloud based mobile technology at the work face; and early contractor engagement through integrated project delivery approaches. These techniques were key factors in the overall drive for optimum efficiency on this project.

SCOPE OF WORK

Kirby scope of works included the installation and commissioning of all electrical and instrumentation services.

The electrical and instrumentation systems installed by Kirby included:

• MV Distribution
• LV Distribution
• Generator
• UPS
• General & Emergency Lighting
• General Service Power
• Mechanical Plant Service Power
• Fire Detection & Alarm
• Access Control, Intruder & CCTV
• Earthing & Bonding
• Voice & Data Distribution
• Lightning Protection
• EMS
• Impulse Tubing
• DCS
• Profibus
• Scada
• Leak Detection
• BMS

Installed plant items included MV/LV switchboards, generators and transformers.

The total project meterage consisted of 1,055,000m of cable, 37,200m of containment, 2,300 number of instrument & loops, 275 number of calibrations, 1,300m of impulse piping.