bis facility presentation

BEMCO FOR INDUSTRIAL SERVICES (BIS)

Manufacturing Equipment, Piping & Structure

© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Introduction & Over View

Bemco for Industrial Services (BIS) operates from premises measuring a total of 90,000 SQM on a site next to the prestigious PP10 Power plant in Riyadh, Kingdom of Saudi Arabia, The factory was purposely built over last four years back to manufacture Pressure pipe spool prefabrication works, Pressure vessels, Steel plate works, Heavy structural steelwork and associated secondary steel work such as ladders, handrails and supports etc.

The emphasis has always been placed on having up to date modern equipment to ensure that high quality is achieved while maintaining good production levels in an excellent working environment


• Location

– Riyadh, Kingdom of Saudi Arabia

• Area

– Total Area: 90,000 sqm – Laydown Area: 35,000 sqm – Shop Floor: 22,900 sqm – Support Facilities: 5,200 sqm

• Employees

– 380 employees

• Capabilities – Prefab Piping Spools..... 500K DI/yr – HRSGs Non Pressure Parts...5K

Ton/yr – Steel Strcutures.......4K Ton/Yr – Manufacturing & Assembling of

Various type of Skids.

72%

5%

3%

3%

8%

4% 5%

Production

Engineering

Project Management

Procurment,Commercial & Proposal

Support Function toProduction

QA/QC

HR/Admin/Finance

Plant Capacity


Quality Policy & Accreditations “Quality a Tool for Success”

Accreditations

Quality Management System ISO 9001:2008

ASME Designators :

PP : Pressure Piping- Fabrication & Assembly

S: Power Boilers - Manufacturing & Assembly

U: Pressure Vessels- Manufacturing & Assembly

R: Repairs & Alterations

•Quality Policy BIS is committed to achieve and sustain excellence in Design Manufacturing and supply of Products and Services that shall meet Customer expectations by implementing the standards, Codes, Statutory and Regulatory requirements through continual improvement of performance and effective implementation of Quality management system through out the company


Company Accreditations


MAIN FABRICATION ACTIVITIES

PLATE FABRICATION STEEL STRUCTURE

PIPE SPOOLS FABRICATION SKID FABRICATION ASME PRESSURE

VESSELS


Organizational Chart

Factory Overview - Overall Plot Plan

Factory Overview - Piping Shops “Efficiency and Quality is our aim, Low costs to the customer ”

Shop Overview

HGG Pipe Cutting M/c CNC Band Saw NC Double Head Welding M/c

• 2 Bays each of 20 M Wide x 206 M Long

• Area: 8200 SQM

• Crane capacity: 5x10 T x 206 M (3 & 2 Cranes/Bay)

• Key Equipments

− CNC Band Saw − Semi Automatic Welding Machines − NC Beveling Machines − 10 Ton OH Cranes − HGG RBPC 660 Pipe Cutting Machine

(Remote control with PRO CAM Software) − NC MIG/SAW Welding Machines Quick − Pipe Spool Fit Up Station − Full Conveyor System For Production Line

PIPING WORKSHOP

Factory Overview - Piping Workshop

Bay 1 (20 M W x 206 M L)

4120 SQM

Simple & Complex Spool Area

CNC Band Saw Semi Automatic Welding Machines NC Beveling M/cs 10 Ton OH Cranes

1 10 2 2

1000 DI/Day/Shift (8 Hr)

Bay 2 (20 M W x 206 M L)

4120 SQM

Simple & Complex Spool Area

HGG RBPC 660 Pipe Cutting NC MIG/SAW Welding Machines Quick Pipe Spool Fit Up Station Full Conveyor System For Production Line Semi Automatic Mig Welding Machines 10 Ton Over head Cranes

1 2 2 1

10 2

1500 DI/Day/Shift (8 Hr)

Bay‐1

Bay‐2

Description Area Function Major Equipment Quantity Capacity

Factory Overview - Steel Plate Fabrication Shops

Shop Overview

CNC Plasma CNC Press Brake C& B System

• 3 Bays, Each Bay Spreads on Span 20 M Wide x 206 M Long

• Area: 12,300 SQM

• Crane capacity: 6 x10 T x 206 M (2 Cranes/Bay)

• Key Equipment‘s − 24 & 16 M CNC Plasma Plate Cutting

Machines (Remote control with Lentek Software)

− Plate Rolling Machines − CNC Press Brake − Profile Rolling Machine − 10 Ton OH Cranes − MIG/SAW Welding Machines − C&B Automatic Welding Stations

Plate Rolling Machine

Steel Fabrication Workshop

Bay 3 (20 M W x 206 M L)

4120 SQM

Set ups For Assembly For Initial Process like Cutting &

Bending

Guillotine Max Cut Semi Automatic Mig Welding M/cs Welding Rectifiers SMAW M/cs 10 Ton Over Head Cranes

1 10 10 2

Combine Capacity 3 Bays (3, 4 & 5) > 20

Tons/ Day/ Shift

Bay 4 (20 M W x 206 M L)

4120 SQM

Plate Fabrication For Duct &

Cylindrical Works

24 m Plasma & Oxy Gas CNC M/C 800 Ton Break Press Semi Automatic Mig Welding M/cs Welding Rectifiers SMAW M/cs 10 Ton Over Head Cranes

1 1

10 10 2

Bay 5 (20 M W x 206 M L)

4120 SQM

Plate Fabrication For Large Diameter Cylindrical Tanks &

Stacks

16 m Plasma & Oxy Gas CNC M/c NC Plate Rolling M/c 3m W x 50 mm Horizontal Profile Bending M/c Column & Boom Welding Stations Semi Automatic Mig Welding M/cs 10 Ton Over Head Cranes Submerged Arc Welding M/cs SMAW Welding M/cs Sweep Blasting Shop & Painting Shop

1 1 1 5

10 2

10 10 1

Factory Overview - Steel Plate Fabrication Workshops

Bay‐3 Bay‐4

Bay‐5


Factory Overview - Medium Steel Structural Shop

Shop Overview

Band Saw

• Area: 2400 sqm

• Crane capacity: 3x10t x 100 m

• Key Equipment's − Band Saw Machines − Guillotine Press − Magnetic Drill Machines − Semi Automatic MIG welding Machines − SMAW Welding Machines − 10 Ton Over Head Cranes

STRUCTURE SHOP

Structural Shop (24m W x 100 m L)

2400 SQM

Structural fabrication Facility

Band Saw M/cs Guillotine Press

Magnetic Drill M/cs Semi Automatic Mig welding M/cs

SMAW Welding M/cs 10 Ton Over Head Cranes

5 4 5

10 8 3

Structural Fabrication: 15 Tons/Day /Shift (400 Ton/month)

Factory Overview - Structure Workshop


Factory Overview - Surface Treatment Shop

Shop Overview

Blasting Machine

• Area: 2000 SQM

• Crane capacity: 1x 5 T x 76 M

• Capacity: 50 Tons/Day Surface Treatment

• Key Equipments − Surface Treatment Machine − Sand Blasting Machine − Painting Airless Spray System

Factory Overview - Power & Compressor House

Overview

Power & Compressor House

(14 M W x 57 M L)

800 SQM Power Facility Diesel Generators @ 560KW

Oil Fee Air Compressors: 292 [email protected] 5 2

Total Power: 2800 KW Total Comp Air: 584 cfm


Factory Overview - Welders Training Facility

Overview

Welders Training Facility (15 M W x 96 M L) 1488 SQM Training School

SMAW Welding Rectifier Machines 20 20 Welders Training at a Time


Factory Overview - Material Laydown & Storage

Overview

Raw Material Laydown Area

12,000 SQM

Lay Down Area 10130 SQM

Separate Raw material Area For Piping &Structural

Finished Product Lay DownArea

20,000 SQM Lay Down Area 14660 SQM

Separate Finished material Lay down AreaFor Piping & Structural

Central store Area 1,008 SQM Stores Storage Area For Consumable , Tools,Power Tool M/cs etc.

Description Area Function Capacity

ENGINEERING “ Excellence in Engineering offering the client the BEST SOLUTIONS” BIS Engineering department comprises of highly qualified personnel all

within the specific field of pipe design and operate from the main office. All personnel are fully experienced with pipe & Structure work design and manufacture and use the latest TEKLA, AUTOCAD, Pro CAM program including SMART PLANT 3D, Isometric and SPOOLGEN. The Piping engineering Team Design capabilities generically covers the following:- a. Generates detailed design shop drawings. b. Generates TAF, GPD & NC files for CNC cutting machines c. Generates documents for fabrication workshops covering:-

a. Material take offs (MTO) b. Weld map drawings c. Pipe cutting plans

ASME Design Validation for multiple projects using CAESAR-II

Presentation Presentation

Presentation

BEMCO for Industrial Services

Overall Project Management

20

BIS’s Major Contribution to various Projects

PP 10 Project 2012-2015

•Prefab Piping Spools- CS- 95,000 DI SS- 40,000 DI AS- 35,000 DI •Exhaust Stacks – 40 Sets- 2800 MT •Steel Structures – 2500 MT •BFP Skid frames – 210 MT

•Prefab Piping Spools- CS- 10,000 DI AS- 11,000 DI •Steel Structures –1100 MT • ASL Heaters Skid Assembly -12 Sets

PP 12 Project 2013-2015

•Piping Spools Erection- CS- 90,000 DI •Steel Structures Fabrication – 1500 MT

•Steel Structures Erection -5000 MT

QURRAYYAH CC Project 2012-2013

•Piping Spools Fabrication- CS- 22,000 DI •Blow Down Tanks with ASME Certification – 4 HRSG Units

HAIL CC Project 2015-2016

S . No. PROJECT/SCOPE DESCRIPTION ORDER ISSUED BY QTY UOM % of

Completion DELIVERY SCHEDULE AS PER

CONTRACT/SCHEDULE

START DATE END DATE

1 Piping Works

1.1 PP10 CCPP (Steam Blowing Piping) Arabian Bemco 3,000 DI 95 Nov‐2015 Feb‐2016

1.2 SSPP‐ BEP HYUNDAI Heavy Industries 98,000 DI 97 MaY‐2015 Feb‐ 2016

1.3 HAIL‐COMBINE CYCLE‐BEP Piping AMEC Foster Wheeler

22,000 DI 100 Oct‐2015 Jan‐2016

General Steel Structural Works

2 General Structure Works‐ PP 12CCPP BEMCO‐GS 150 Ton 90 15‐Sep‐14 Dec‐15

2.1 General Structure Works‐ PP 10CCPP

Arabian Bemco 40 Ton 95 ‐‐‐‐‐‐‐‐ Nov‐15

Bemco for Industrial Services Current Ongoing Projects (Piping & Structure)

I: POWER

S. NO. MACHINE DESCRIPTION CAPACITY QTY UOM FUNCTION/REMARKS

1 Diesel Generators Sets Power Rating/ 560kW 5 Nos. Utilization Capacity ‐ 3 MW 2 Air Compressor 250 cfm / 8.6 bar 2 Nos. For Utility Activity in Shop

II: PIPING FABRICATION

S. NO. MACHINE DESCRIPTION CAPACITY QTY UOM PROCESS REMARKS

1 CNC Pipe Profile Cutting Machine

Min. ‐ 48mm Max. ‐ 660mm Length ‐ 12000mm Accuracy ± 1.5mm Wall Thick ‐ Up to 50mm

1 No. Hot Plasma/Oxy Fuel for all Carbon Alloy Steel, SS

Cutting Speed 550mm/Min.

2 CNC Band Saw Machine Max. ‐ 660mm Wall Thick ‐ Up to 50 1 No. Cold Cutting ‐

3 N.C. Pipe Beveling Machine Min. ‐ 114mm Max. ‐ 610mm Thick ‐ 6‐180mm

2 Nos. For All Steels Beveling Cutting

4 N.C. Pipe Fit‐Up Machine Min. ‐ 168mm Max. ‐ 630mm Length ‐ 12000mm

2 Sets For All Pipe Fit‐Up Activities

5 CNC Pipe Welding Machine

Min. ‐ 168mm Max. ‐ 630mm Wall Thick ‐ 3‐60mm

2 Sets For Carbon, Alloy & SSMIG+SAW Process Efficiency ‐ 600 Inches/Shift

EQUIPMENT & MACHINERY SPECS & CAPABILITY

23

6 Manual Welding Machines Max. Weld Current 600A 28 Nos. For All Complex Spool SMAW

7 Welding Machine Max. Weld Current 500A 10 Nos. For All Complex Spool SMAW

8 Welding Machine Max. Weld Current 400A 20 Nos. For All Complex Spool SMAW

9 Material Handling OHT Cranes 10 MT 10 Nos. For Piping, Plate Shop Activities

10 Material Handling OHT Cranes 10 MT 3 Nos. For Structural Shop Activities

11 PWHT Equipment 125 KVA 2 Nos. For PWHT Activities of Piping 70 KVA 8 Nos.

III: SURFACE PREPARATION

12 Shot Blast Machine 160 MT/Hour 1 No. Shot Blasting before & after Fab. IV: STEEL FABRICATION SHOP

13 CNC Plasma Cutting Machine 3 Mtr x 24 Mtr up to 80mmt 1 No. Hot Plasma / Oxy Fuel

for all type of steels

14 CNC Plasma Cutting Machine 2.5 Mtr X 12.0 Mtr up to 40mmt 1 No. Hot Plasma / Oxy Fuel

for all type of steels

15 Plate Rolling Machine 2.3 Mtr X 25mm Thick 1 No. Cold Rolling

16 Profile Bending Machine ‐ 1 No. Cold Profile Bending

17 Press Brake 6.1 Mtr (l) x 17mm (t) ‐ 8000 kV 1 No.

EQUIPMENT & MACHINERY SPECS & CAPABILITIES

24


HSE “BEMCO Follows 5 STAR SAFETY & HEALTH Management System”

Main Roles & Responsibilities

Define and Implement the HSE Plan for the construction and site activities

Set up Emergency Response Plan

Implement Security Plan

Carry out Safety Education, Training and Motivation Programs

Define and Implement the Constructional Environmental Plan

Define and Implement the Waste Management Program

Define and Implement the Pollution Contingency Plan

Implement Work permit System

Identification and Correction of Hazardous Scenarios

Monitor and Control Sub Contractors HSE Performance

Implement HSE Lessons Learned from Previous projects

•Safety Objective Prevent Human Injuries and Property Damage in the phase of Construction and Commissioning of the Plant in accordance with the defined HSE Plan.


HSE Safety and Health Training & Orientation

Address the Safety and Health Responsibilities of all Personnel

Incorporate it into Training and Job Performance /Practice

Employees must Understand the hazards they may be exposed to and how to prevent harm to themselves and others from hazard exposure

Orientation Training Program to all Workers

Controlling the Hazards

To Prevent and Control hazards Engineering Controls

Administrative Controls

Personal Protective Equipment

Safe Work Practices Communicated via Training, Positive reinforcement,

Correction of unsafe Performance, and Execution


HSE Long Term Strategic Goals

Change Culture And Behavior- We are Building a leading culture of Personal Accountability for Safety And Operational Discipline

Provide Employees with Knowledge and Tools- Well Established and Maintained Well Defines Standards, Requirements and tools that Integrated Safety into all Phase of Activities

Creates Safety Work Place- To Provide Facilities and Reducing / Eliminating all Known Hazard

SAFETY GOALS

Constantly monitor & assess the effectiveness of the entire Safety Systems

Continuously improve the applications of the Safety Systems

Ensure a comprehensive coverage of Safety Training Programs

Integrate across the corporation one set of Priorities and Safety Management System Functions

Actively Promotes a Safety Culture

Recognize and reward good Safety leadership thru out the Company

www.arabianbemco.com

Thank you

bis facility presentation

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