Download - 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
© 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.
• 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
© 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.
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
© 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.
Company Accreditations
© 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.
MAIN FABRICATION ACTIVITIES
PLATE FABRICATION STEEL STRUCTURE
PIPE SPOOLS FABRICATION SKID FABRICATION ASME PRESSURE
VESSELS
© 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.
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
Description Area Function Major Equipment Quantity Capacity
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
Description Area Function Major Equipment Quantity Capacity
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
Description Area Function Major Equipment Quantity Capacity
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
Description Area Function Major Equipment Quantity Capacity
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
© 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.
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.
© 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.
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
© 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.
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
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