Construction Australasia Oil & Gas and Minerals
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CLOUGH |
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FORGE1 |
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R MILLIONS* |
2012 |
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2011 |
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2012 |
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2011 |
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Revenue* |
8 484 |
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5 387 |
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6 204 |
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2 926 |
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Operating profit/(loss)* |
286 |
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269 |
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584 |
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396 |
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Segment assets* |
3 810 |
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2 056 |
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People |
4 785 |
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3 527 |
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LTIFR (Fatalities) |
0.1 (0) |
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0.2 (0) |
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Order Book* |
19 444 |
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11 467 |
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1 Reflected at 100%. Forge is equity accounted at 36% (2011:33%) within the consolidated results.
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KEVIN GALLAGHER
CHIEF EXECUTIVE, CLOUGH |
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Construction Australasia Oil & Gas AND MINERALS
A SOLID ALL-ROUND
PERFORMANCE RESULTED IN
TURNOVER RISING 58%
TO R8,5 BILLION. OPERATING
PROFIT FROM CONTINUING
OPERATIONS WAS R286 MILLION,
A 6% IMPROVEMENT
ON FY2011. |
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LEADERSHIP
Kevin Gallagher succeeded John Smith as CEO in November 2011.
Leadership and oversight were strengthened with the appointment of
executive and operating committees
PERFORMANCE
Clough’s drive to continuously improve safety paid dividends this year
with the overall lost time injury frequency rate (“LTIFR”) declining for
the fifth consecutive year, from 0.21 in FY2011 to 0.13. Notable
safety successes were achieved in Papua New Guinea where the
PNG LNG upstream infrastructure and EPC4 projects – both being
executed for ExxonMobil – respectively surpassed 12 million and
4 million hours worked without a lost time injury.
The company continues to lead the Australian oil and gas engineering
and infrastructure construction sectors on safety and its record in this
regard is an increasingly important differentiator for the company.
This will become particularly significant as Clough ramps up its
involvement in Australia’s mining and minerals sector where clients
look for suppliers that can replicate the oil and gas industry’s safety
standards.
Operating in a competitive high-cost environment, there is
considerable on-going pressure on suppliers, including Clough,
to constantly address their cost base. Restructuring initiatives this
year resulted in sustainable savings of more than R85 million a year.
Combined with a sharper company-wide focus on margins,
this achievement was reflected in a net profit after taxation of
R335 million.
Following an extensive evaluation of the company’s strengths and
opportunities for improvement undertaken by the new management, an internal restructuring exercise was carried out and is now well
embedded across Clough. This was considered necessary given the
company’s extensive range of services and the variety of work carried
out. Clough now has in place the appropriate management resources
to exploit its leadership in four well-defined business lines:
Engineering, Capital Projects, Jetties and Near-Shore Marine and
Commissioning and Asset Support.
Project execution highlights in the past year included the ExxonMobil
PNG LNG upstream infrastructure project in Papua New Guinea
which, at its peak, employed some 2 500 workers. This demanding,
large construction project is on track for completion in December
2012. Elsewhere in Papua New Guinea, work on ExxonMobil’s gas
conditioning plant (EPC4) was similarly on track with engineering
completed and piling and procurement largely finished by year-end.
Work on the downstream engineering, procurement and construction
management (“EPCM”) project at Chevron Australia’s giant Gorgon
LNG project progressed well with the first pipe-racks being received
on the island in June 2012. Clough now has over 700 employees
working in the Kellogg Joint Venture to execute the EPCM contract.
In February 2012 Clough was awarded the coveted AUD$350 million
hook-up and commissioning contract for Chevron’s Wheatstone
processing platform offshore of north-western Australia. Upon
appointment, Clough immediately began assembling the project
management team, appointing commissioning engineers and
undertaking preparatory tasks and planning ahead of the onshore
commissioning work. Project duration is some three years. (This year
Clough also won an AUD$400 million jetty-construction contract for
Wheatstone).
Other significant new business wins this year included EPC work
for CSBP’s nitric acid and ammonium nitrate plant number 3 at
Kwinana in Western Australia, worth some AUD$100 million, and
AUD$250 million integrated project management support contract
from INPEX for its Ichthys offshore project. Clough’s Jetties and
Near-Shore Marine business won a further two contracts for
the Ichthys LNG project later in the year, encompassing the Jetty
and Module Offloading Facility.
In Queensland, Clough entered the Coal Seam Gas industry and
secured its first significant win, the K128 contract for Santos’
Gladstone LNG project in Fairview. To be executed in joint-venture
with Downer Australia, the AUD$600 million contract entails the
construction of over 400 km of gas and water transmission pipelines,
two compression facilities and an 800-person camp.
The disposal of Clough’s Marine Construction business, effected in
December 2011, strengthened the company’s balance sheet which
at 30 June 2012 reflected cash holdings of R1 945 million. This will
provide Clough with the required flexibility to expand its business and
to take advantage of continuing strong investment in both the energy
and chemicals and mining and minerals sectors.
This year Clough increased its 33% shareholding in Forge to 36% as
this investment continued to deliver solid value. The Clough Forge
Joint Venture completed its work on Hancock Prospecting’s Roy Hill
Package 3 project, receiving a variation order in February for
approximately R130 million, an extension to its initial early contractor
involvement work.
PROSPECTS
Despite ongoing commodity price volatility, investment in the Australian
energy and resource sectors is set to continue testing record levels
over the medium term. This bodes well for Clough with its wealth of
experience and well-established brand and is reflected in an order
book which stood at R19,4 billion at the end of the year. Of this, some
R8,8 billion (excluding Forge) had been secured for FY2013. The order
book at year-end was up 82% compared to FY2011.
The business will remain focused on its foundation market sectors of
energy and chemicals and mining and minerals and target three
geographical regions: Western Australia and the Northern Territory;
Queensland and Papua New Guinea.
Current capital investment in Australian LNG projects amounts to
some AUD$170 billion. It is noteworthy however that this is confined
to no more than seven projects. While a large proportion of Clough’s
current revenue is today derived from capital projects, this revenue
stream will inevitably decline as projects are built and production
comes on stream. Over the medium term it is envisaged that such
work will account for no more than 30% of the company’s income.
To address this inevitable trend, Clough management has emphasised
commissioning and asset support, a field that will become a growing
source of business and that will demand more of Clough’s skills sets.
While such contracts tend to be lower risk and therefore generally
offer lower margins, they are typically of longer duration than
engineering and construction projects.
Continuing access to skills remains the single biggest challenge
facing Clough – and its competitors. The Australian oil and gas sector
has an estimated shortfall of some 30 000 to 40 000 employees. This
situation is being exacerbated by the strong growth of investment in
the minerals and mining sector and the relatively easy transferability of
skills between the sectors. During the past year Clough’s total
employment rose by more than 1 200 people to 4 785. To ensure a
continuous supply of talented engineers (the skills that are in the
greatest demand and that largely define the company’s value offering)
the Clough Scholarship Programme was reactivated this year.
While capital investment in Australian energy is set to peak over the
medium term, the country’s investment in mining and minerals
processing is approaching AUD$150 billion. Whereas energy spend
is concentrated among a few developers, there are more than
40 significant investors in new Australian resources developments.
In the new year a management priority will be to grow the Clough
brand across a range of resource segments, notably iron ore, coal,
precious and other metals projects. Clough has more than 30 years
of experience in mining and minerals and will aim to capitalise on its
reputation in the oil and gas space, most notably its enviable safety
record. Achieving a sustainable stream of EPC and EPCM mining
and minerals work will diversify earnings, mitigate risk and raise
overall margins.
Excluding Forge, management is confident of sustaining a minimum
Ebit margin of 5% in FY2013, increasing this to 7% over the
longer term.
Participating in an expected, significant increase in demand for EPC
oil and gas work in various regions of Africa will be prioritised. In
particular, Clough will identify opportunities to expand into Africa’s
burgeoning LNG sector by working with blue-chip Australasian clients
with whom the company has solid track records.
Sustained growth in recent years underscores the belief that Clough is
well placed to continue its leadership in engineering, procurement and
construction in the fields of energy and chemicals, water and mining
and minerals. Vision2017 focuses on giving shareholders superior
value and ensuring that the company can compete globally. This will
be achieved by consistently delivering excellence in project delivery,
improving cost efficiency, diversifying earnings and growing the
business by successfully and systematically implementing strategy.
12.3 MILLION HOURS
– NO LOST TIME
INJURIES
The numbers associated with the work that the Clough/Curtain Joint
Venture (“CCJV”) team are executing in Papua New Guinea are
mind-boggling: 1 500 employees, 200 kilometres of roads, ten bridges,
two wharves and eight work sites hundreds of kilometres apart.
But the statistic that everyone at Clough is most interested in, is
12,3 million. That is the number of hours the joint venture’s employees
have clocked up on Esso Highlands Ltd’s LNG Upstream Infrastructure
project since 2009 – without a single lost time injury (“LTI”).
The terrain the team members are working on is diverse and
challenging, stretching across various landowner boundaries. The
workforce is culturally as diverse as the landscape and the work is
often hazardous. Yet the fact that in June 2012 CCJV could celebrate
the magical mark of 10 million LTI-free hours, and continued this
performance to exceed 12 million, shows what can be achieved if
everyone takes safety to heart.
Joining the team for a celebration in June, Clough chief executive and
managing director Kevin Gallagher commented: “It is outstanding to
think we have achieved this safety milestone when we have people
ahead of the construction crews felling tall trees and clearing jungle,
people drilling and blasting as we cut our way through the mountains,
and then constructing roads. These are high risk activities; it is an
absolute credit to every team member that there have been no
lost-time injuries on this project. They have put in a world-class effort.”
This project entailed working from eight dispersed worksites, from the
River Port at Kopi in the Gulf of Papua New Guinea, through Gobe,
Kantobo, and Mendi, to Hides in the Southern Highlands of the country.
Recent project activities included construction of facilities and waste
management areas and approximately nine kilometres of the well pad
access road. Currently bulk earthworks for the Spineline Road and the
completion of the cellars are being carried out. A gradual demobilisation
is about to start as these activities conclude. The 650-person camp is
due to be handed over to Esso Highlands in December, with some
personnel remaining beyond to finish the last of the roadworks.
CCJV’s safety achievements reflect the disciplined safety culture that is
promoted at each of the worksites. It is the result of effective team
work, collaboration and communication between all employees to
complete the job safely.
Elsewhere in Papua New Guinea, CBI Clough’s EPC4 contract
to build the Hides Gas Conditioning Plant has achieved a similarly
impressive safety milestone: 4 million LTI-free hours.
As with CCJV, EPC4 has a culturally and linguistically diverse
workforce, one that has grown from fewer than 600 in January 2012
to more than 1 600 today. Every new employee takes part in a
rigorous safety induction programme complemented by cultural
awareness sessions that strengthen the “one team” approach. At site
incident review committee meetings workers and supervisors openly
discuss incidents while a stop work authority covers the whole
workforce. Visible supervision is strongly emphasised and potential
risks are identified and mitigated at fatal risk workshops conducted
with LNG project operator, Esso Highlands. |
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