Download - Today & Tomorrow Jun 2014
AWI 106 Att. 8 Rev. 3 02 Jan. 2011
June 2014 / Rev. 0
Today & Tomorrow
June 2014
AWI 106 Att. 8 Rev. 3 02 Jan. 2011 June 2014 / Rev. 0 2
IPD EPC FM / O&M Construction Fabrication Instant Access (Dealership)
QTECH (Trading)
Service units
Departments
Calibration Laboratory
Sulaibiya Testing Laboratory
Projects Temporary Furniture Unit (PTFU)
Temporary Facilities (Office Cabins)
Fabrication Workshop Scaffolding Warehousing
Welders Training & Certification
Accommodation
Administration
Office Services
Business Development
Health, Safety & Environment
Proposals Contracts Procurement Engineering
Project Controls Services
Insurance
Quality Assurance/ Control Human Resources
Information Technology
Finance & Accounting Communications Equipment Assets
Equipment Operations
Operations
Organization structured to serve and support operations
Kharafi National General Overview
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Business lines Infrastructure Project
Development
Engineering, Procurement & Construction
Construction Facilities
Management Fabrication Services
§ Power § Power § Power § Power § Process Equipment
§ Water § Water § Desalination Plants
§ Refineries & Petrochemical Plants
§ Pressure Vessels
§ Wastewater § Infrastructure § Processing Plants § Water Distribution § Evaporators
§ District Cooling § District Cooling § Refineries § Sewage Treatment Plants § Separators
§ Renewable Energy
§ Renewable Energy § Gathering Centers § Pumping & Lifting
Stations § Modular Skids
§ Solid Waste Management
§ Building Services (MEP)
§ Petrochemical Plants
§ Industrial Complexes § Pressure Piping
§ Enhanced Oil Recovery
§ Social Infrastructure
§ Pipeline
§ Commercial Centers § Tanks
§ Mixed-use Development § Environmental § Enhanced Oil
Recovery § Residential
Complexes § Columns
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INFRASTRUCTURE PROJECT DEVELOPMENT
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Infrastructure Project Development Wastewater Treatment and Reclamation
District Cooling
Renewable Energy
Solid Waste Management
Enhanced Oil Recovery
Mixed-use Development
BOT (Build-Operate-Transfer) Schemes
BOO (Build-Own-Operate) Schemes
PPPs (Public-Private-Partnerships)
Joint Ventures and Consortia
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Infrastructure Project Development SULAIBIYA WATER AND WASTEWATER TREATMENT AND RECLAMATION PLANT, KUWAIT
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Infrastructure Project Development ABU DHABI SEWAGE TREATMENT PLANT - BOOT PROJECT / ADWEA
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Infrastructure Project Development ABU DHABI SEWAGE TREATMENT PLANT - BOOT PROJECT / ADWEA
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EPC - Engineering,
Procurement & Construction
§ Desalination Plants
§ Water Treatment
§ Pipeline & Pumping Stations
§ Water Distribution Networks
§ Power Stations
§ Gas Power Stations
§ Power Transmission & Distribution
§ Office & Residential
§ Commercial Centers
§ Educational Institutions
§ Hospitals
§ Hotels & Resorts
§ Sewage Treatment Plants
§ Solid Waste Management
§ Pumping & Lifting Stations
§ District Cooling
§ Industrial Complexes
§ Airports
§ Transportation
Engineering, Procurement & Construction
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EPC – Power OPEN CYCLE GAS FIRED PLANTS – 2,000 MW, AL SHABAB AND DAMIETTA, EGYPT
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EPC – Power OPEN CYCLE GAS FIRED PLANTS – 1,000 MW, AL SHABAB, EGYPT
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EPC – Power OPEN CYCLE GAS FIRED PLANTS – 1,000 MW, AL SHABAB, EGYPT
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EPC – Power OPEN CYCLE GAS FIRED PLANT – 500 MW, DAMIETTA, EGYPT
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EPC – Water
Ardiya Pumping Station, Kuwait Pumping & Lifting Station, Kuwait
Saadiyat STP2, Abu Dhabi, UAE
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EPC – Water
A7 Pumping Station – Riggai, Kuwait
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EPC – District Cooling AL SOWAH DISTRICT COOLING PLANT (50,000 TR)
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EPC – Central Utility Plants (CUP) SABAH AL SALEM UNIVERSITY PROJECT CENTRAL UTILITY PLANT (CUP 1 & 2), KUWAIT
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EPC – Infrast. & Environ.
Dubai International Airport, UAE
Marsa Alam International Airport, Egypt
Addis Ababa International Airport, Ethiopia
§ Kuwait International Airport
§ Dubai International Airport
§ Addis Ababa International Airport
§ Marsa Alam International Airport
§ Jebel Ali International Airport
AIRPORTS
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EPC – Infrast. & Environ. AIRPORTS - JEBEL ALI INTERNATIONAL AIRPORT, UAE
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EPC – Infrastructure INFRASTRUCTURE WORKS FOR ADNEC CAPITAL TOWER - UAE
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EPC – Building Services MEP WORKS - AL HAMRA TOWER, KUWAIT
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EPC – Building Services MEP WORKS - AL HAMRA TOWER, KUWAIT
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EPC – Building Services FOUR SEASONS HOTEL, LEBANON ADIA TOWER - ABU DHABI, UAE
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EPC – Building Services MEP WORKS
Central Bank of Kuwait HQ, Kuwait Al BabtainTower, Kuwait
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CONSTRUCTION
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Construction – Plants HABSHAN - 5 PROCESS PLANT, JGC-TECNIMONT / GASCO, UAE
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Construction – Plants HABSHAN - 5 PROCESS PLANT, JGC-TECNIMONT / GASCO, UAE
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Construction – Plants HABSHAN - 5 PROCESS PLANT, JGC-TECNIMONT / GASCO, UAE
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Construction – Plants HABSHAN - 5 PROCESS PLANT, JGC-TECNIMONT / GASCO, UAE
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Construction – Plants HABSHAN - 5 PROCESS PLANT, JGC-TECNIMONT / GASCO, UAE
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Construction – Plants HABSHAN - 5 PROCESS PLANT, JGC-TECNIMONT / GASCO, UAE
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Construction – Plants HABSHAN - 5 PROCESS PLANT, JGC-TECNIMONT / GASCO, UAE
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Construction – Plants AROMATIC COMPLEX, TECNIMONT / PIC, KUWAIT
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Construction – Plants AROMATIC COMPLEX, TECNIMONT / PIC, KUWAIT
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Construction – Plants POLYETHYLENE EXPANSION, OLEFINS – II / FLUOR, KUWAIT
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Construction – Plants LARGE SCALE STEAM FLOOD PILOT, JO (KGOC / CHEVRON), KUWAIT
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Construction – Plants ETHYLENE GLYCOL – II, OLEFINS - II, FLUOR, KUWAIT
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Construction – Plants FACILITY UPGRADE (AMALGAMATION PROJECT), KUWAIT
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Construction – Plants FUEL GAS PIPELINE PROJECT (PART A), KUWAIT
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FACILITIES MANAGEMENT /
INSTITUTIONAL & COMMERCIAL
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FM – Institutional & Commercial SEIF PALACE, KUWAIT
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FM – Institutional & Commercial BAYAN PALACE, KUWAIT
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FM – Institutional & Commercial ADMINISTRATION BUILDING AT BAYAN PALACE, KUWAIT
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FM – Institutional & Commercial ADMINISTRATION BUILDING AT BAYAN PALACE, KUWAIT
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FM – Institutional & Commercial LIBERATION TOWER, KUWAIT ADIA TOWER - ABU DHABI, UAE
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FM – Institutional & Commercial THE AVENUES, KUWAIT MARINA MALL, KUWAIT
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FM – Institutional & Commercial ARWA PRINTING PRESS, KUWAIT
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FM – Institutional & Commercial LEBANESE UNIVERSITY CAMPUS, BEIRUT
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FACILITIES MANAGEMENT /
INDUSTRIAL SERVICES
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§ Sewage Treatment Plants
§ Reclamation Plants
§ Pumping & Lifting Stations
§ Water Distribution Network
§ Storm Water Drain Network
§ Oil Fields
§ Gathering Centers
§ Booster Stations
§ Refineries
§ Petrochemical Plants
§ Pipelines & Well Heads
FM - Industrial Services
Operation
§ Power Plants
§ Diesel Power Plants
§ Water Desalination Plants
FM - Industrial Services Operation
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FM - Industrial Services Operation Kharafi National-Industrial Services is a leading “One Stop Shop for Industrial Maintenance & Value Added Services” in the region.
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FM – Industrial Services MAINTENANCE - OIL & GAS PLANTS
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FM – Industrial Services MAINTENANCE - OIL & GAS PLANTS
Tank Roof Replacement
Valve Maintenance
High pressure Piping Works Hydro jet Cleaning
Cable laying & Instr. Works De- Sludging Works
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FM - Upstream PRODUCTION FACILITIES MAINTENANCE, KUWAIT
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FM - Upstream PRODUCTION FACILITIES MAINTENANCE, KUWAIT
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FM - Downstream MINA AL AHMADI REFINERY STEAM FLOOD FACILITIES - JOINT OPERATIONS
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BOROUGE RUWAIS SHUTDOWN - 2012 FOR FACILITIES 1 & 2, UAE
FM – Industrial Services
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BOROUGE RUWAIS SHUTDOWN - 2012 FOR FACILITIES 1 & 2, UAE
FM – Industrial Services
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BOROUGE RUWAIS SHUTDOWN - 2012 FOR FACILITIES 1 & 2, UAE
FM – Industrial Services
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FM – Industrial Services SHUTDOWN WORKS - SHUAIBA REFINERY - GRTA, KUWAIT
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FM – Industrial Services O&M - POWER PLANTS
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FM – Industrial Services O&M - POWER PLANTS
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FM – Industrial Services O&M - POWER PLANTS
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FM – Industrial Services O&M - GIS SUBSTATIONS
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FM – Industrial Services OPERATION & MAINTENANCE OF PUMPING & LIFTING STATIONS
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FM – Industrial Services OPERATION & MAINTENANCE OF PUMPING & LIFTING STATIONS
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FM – Industrial Services OPERATION & MAINTENANCE OF SULAIBIYA WWTRP
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FM – Industrial Services OPERATION & MAINTENANCE OF ADWEA WWTP (WATHBA & SAAD), ABU DHABI
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Service Units & Departments
Health, Safety & Environment
Procurement & Material Control
Human Recourses
Equipment Operations
Quality Assurance / Control
Scaffolding Services
Project Control Services
Calibration Laboratory
Engineering Services
Camp Facilities
ABJ Engineering & Contracting Co. Kuwait
ABJ Industries PJSC UAE
Gulf National Insulation Systems Kuwait
Gulf National Insulation Systems UAE
Group Supporting Companies
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§ All employees undergo a Safety Induction Training course before they assume their responsibilities. Safety awareness is further intensified by:
• Safety Tool Box Talks • Pre-task safety briefing • Job Safety Analysis • Risk Assessments • Confined Space Entry
§ Rigging, Scaffolding and First Aid training are conducted by Third Party & certified.
§ With an objective to continual improvement, the safety management system elements are now certified by OHSAS 18001:2007 standard.
Health, Safety & Environment
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Health, Safety & Environment
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Human Resources Multinational Workforce is recruited through our existing agencies network world-wide.
Interviews and trade tests are conducted and supervised directly by our Project Staff.
Candidates are sourced ahead of time, based on project manpower projections.
Systematic re-certification of welders at work place to cope with new welding technology.
Continuous reassessment of qualification training and skill development programmes for all personnel.
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Human Resources Manpower Summary
Total Manpower: 29,579
Directors / Chief Dev. Officer / COO 15
Operations Managers / Project Director 11
Department Managers / Unit Managers / Unit Head 106
Manager of Projects / Snr. Project Managers 37
Projects Managers / Construction Managers 70
Services & Support Staff 1,897
Field Operations (Engineers / Supervisors) 1,189
Foremen 1,063
Skilled Craftsman 8,932
Plant / Equipment / Crane Operators / Drivers 2,031
Trade Helpers 2,046
Labourers 2,280
General Site Services & Warehouse Man 1,185
ABJ Engineering & Cont. Co. - Kuwait 5,548
Kharafi National – UAE 2,102
Kharafi National – Egypt 715
Kharafi National – Lebanon 352
Non Manual: 3,325 Subsidiaries: 8,717 Manual: 17,537
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Note: * We have deployed over 12,000 employees in Habshan-5 Process Plant Project, Abu Dhabi for GASCO, UAE in its peak and the Project has been completed in June, 2013
Human Resources Workforce Growth (2008-2013)
2008 2009 2010 2011 2012 2013 2014 Non-Manual 2,631 3,750 3,814 4,216 4,278 4,327 3,852 Manual 20,250 21,610 27,358 28,929 30,058 30,808 25,727 Total 22,881 25,360 31,172 33,145 34,336 35,135 29,579
0
5,000
10,000
15,000
20,000
25,000
30,000
35,000
40,000
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Quality Management System
Well established procedures in place for every part of the business and their continuous update with internal auditing to verify the implementation
Functional support of Quality Control to projects
Establishment of Welding Services Unit, to train welders and develop their skills in anticipation of shortage of trained welders in the region
Calibration and Testing Laboratories to ensure that calibration/ testing is done on time and that results of calibration/ testing are accurate
Six Sigma program implementation
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Quality Certifications - Organization Quality Management System
ISO Certification/ Accreditation:
ISO 9001:2008 Quality Management System
ISO 17025 General Requirements for the Competence of Testing and Calibration Laboratories.
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Quality Certifications - Fabrication Quality Management System
ASME & National Board’s Certification Stamps:
ASME Code : U Manufacture of Pressure Vessels – ASME Section VIII Division I
ASME Code : U2 Manufacture of Pressure Vessels – ASME Section VIII Division II
ASME Code : PP Fabrication and Assembly of Pressure Piping
ASME Code : S Manufacture of Power Boilers
National Board : R Repair/ Alteration of Pressure Vessels
National Board : NB Registered Boilers/ Pressure Vessels
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Quality Management System Quality Control - Overview
Quality Control
Technical Work Instructions for Piping, Pipeline, Tanks, Welding, Painting , Civil, Electrical and Instrumentation, Operation & Maintenance…..etc. Project Quality Plan, ITPs, and Method Statements Orientations and Trainings
QC Module in ERP Oracle Common database for fabrication and field activities
Welders Training School &
Certifications
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Quality Management System Calibration Laboratory (Calibration & Monitoring of Measuring Equipment)
Investment of over KD 2 million in Master Equipment & Instruments Number of Instruments – currently over 6000 Capabilities: Electrical, Mechanical, Linear, Mass, Pressure, Temperature Recent additions § Thermal Imaging Cameras § GPRS [Ground Penetration Radar System] § Moisture & Density Measurement in Soil using Radioactive Gamma rays
External Customers § M/s. Siemens, Equate, Schlumberger, Hempel Paints, Hyundai Engineering & Construction Co., SK Engineering…..etc.
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Quality Management System Sulaibiya Testing Laboratory
Investment of over KD 300,000/- Equipment
Testing Water, Waste water & Sludge samples
Checking ~ 87 chemical & microbiological parameters
Customer : Sulaibiya Sewage Treatment & Reclamation Plant
ISO 17025 accreditation by United Kingdom Accreditation Service - UKAS
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Projects Control Progress Monitoring is Carried out as Follows:
Actual returns for quantities installed and man-hours spent are collected daily.
Progress verification is carried weekly.
Productivity and performance indicators are reported on a weekly and monthly basis.
Key Factors to our Cost Control Approach are:
Forecast of quantities and man-hours.
Forecast of balance commitments for materials and subcontracts.
Forecast of staff and indirect costs.
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Engineering Services
§ Thermoflow § Aspentech § ETap
Specialist Design
§ X Steel § Spoolgen § Autocad,Civil,MEP § Aveva PDMS
Process Detail
Design
§ RIPAC § Candy
§ On Screen Take offs § Acad Take offs
Material Take Offs
§ Materials Data Base § ERP Modules § Primavera
Bills of Quantity
Tracking Commissioning Support
Post Award Detail Design & Engineering Support
Pre Award Tendering Support
FEED Packages
Concept Design
Technology Selection
ENGINEERING SOFTWARE EMPLOYED ENGINEERING SUPPORT SERVICES
§ Pipeflow § Ceasar II § Staad III § Robot
§ Elite § Hass § HVACOMP § HAP § Etab
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Kharafi National follows Integrated Procurement & Materials Management system in line with the ISO 9001 : 2008 requirement covering the following: § Procurement & Material
subcontract (Local & Overseas). § Logistics, expediting, Factory
Acceptance Test (FAT) & transportation.
§ Vendor Management (Supplier evaluation, Prequalification and performance measurement).
Multinational staff strength over 100 (including experienced Engineers, Supervisors and Buyers.)
Procurement
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Over US$ 750 Million worth of materials procured annually. In excess of 30,000 Material Requisition closed annually. Approved supplier strength of over 3,000 (one-third being overseas suppliers). KN adopts structured criteria for evaluating and re-evaluating suppliers based on their ability to supply products that meet the Organization's requirement and Periodic evaluation is conducted on the performance of the suppliers. KN conducts ‘Due Diligence’ on supplier premises as part of the supplier evaluation to enlist them as an approved vendor.
Procurement
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Extensive Knowledge of Local and International Markets. Purchase Orders / Subcontracts are awarded to Companies who supply quality products, competitive back to back basis and on time delivery. e-Procurement, utilization of B2B e-markets, Strategic Sourcing & Online negotiations with suppliers. Automated Procurement workflows through Oracle E-Business Suite ERP System. Compliance with the Purchase Order/ project schedule requirements are ensured through expediting/ inspection at manufacturer’s/ supplier’s premises in an orderly & systematic way for highlighting deviations, delay or damages if any, prior to shipment.
Procurement
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Procurement Trend Inline with the transformation of KN from a Traditional Contractor to an Operational Investor with EPC , Commissioning and FM capabilities, the Value of Procurement Increased Year on Year with increase in Turnover / Growth of KN
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Serving Warehousing requirements for More than 150 Projects / Cost Centers across diversified business lines in Middle East & Africa. Central Stores in Kuwait with 48,000 Sq Meters of area (Including 17,000 Sq Meters of Closed Stores, 31,000 Sq. Meters of Open Yard) having Heavy duty multi storied racking with State of art modern material handling facilities, Safety and Security systems. In excess of 160,000 items handled across various Projects and we adopt Efficient Codification & Standardization practices.
Material Control
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Over US$ 750 Million worth of KN Procured materials handled annually and Over US$ 1 Billion worth of Client Supplied Free Issue Materials handled annually.
Total Monthly Receiving Transactions over 5500 and Issues/Transfer Transactions over 4500.
Effective utilization of Oracle ERP Inventory Modules with Experienced resources to handle Computerized Transactions & Inventory Management.
Utilization of Temperature controlled Stores and importance for material storage & preservation as per manufacturers recommendations.
Utilization of Selective Inventory Control / Vendor Managed Inventory / Consigned Stock.
Material Control
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Equipment Operations Kharafi National own, manage and operate Equipment fleet in all countries where KN operates, keeping same policy, standard and discipline. Currently equipment in excess of 6,100 construction equipment/plant.
Currently more than 2,100 trained, experienced and qualified staff available at the equipment division.
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Equipment Operations
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Equipment Operations
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Equipment Operations
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Equipment Operations
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Scaffolding Services
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Scaffolding Services
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Scaffolding Services
Shuaiba Refinery – GRTA, KNPC, Kuwait
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Electrical Laboratory High Voltage Laboratory
Fluke Laboratory Pressure Laboratory
Capabilities Calibration Laboratory
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Balance Laboratory Chemical Laboratory
Temperature Laboratory Dimension & Vibration Laboratory
Calibration Laboratory Capabilities
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IR Thermography Inspection Power Quality Analysis
Validation of Welding Machines Cable / Pipe Detection
Calibration Laboratory Specialized Services
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INFRARED NORMAL
LV Fuse Carrier Problem
Problem in Pump Coupling
Problem in Busbar Termination
Calibration Laboratory Thermal imaging camera
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Camp Facilities in Kuwait & UAE
Shuaiba Capacity-10,000
Sulaibiya Capacity- 3,500
Mahboula Capacity- 2,400
Amghara Capacity- 500
Abdally Capacity- 1,000
Kuwait
Total = 17,400
Al Wathba Abu Dhabi Capacity- 2,200
Al Ain, Abu Dhabi Capacity- 525
Mussafah, Abu Dhabi Capacity- 750
Dubai Investment Park Capacity- 100
UAE
Total = 12,375
Saadiyat , Abu Dhabi Capacity- 700
Habshan-Abu Dhabi Capacity- 8,000
Madinet Zayed, Abu Dhabi
Capacity- 100
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Camp Facilities – Sulaibiya, Kuwait
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Camp Facilities – Sulaibiya, Kuwait
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Camp Facilities – Sulaibiya, Kuwait
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Camp Facilities – Shuaiba, Kuwait
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Camp Facilities - Habshan, UAE
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Camp Facilities - Habshan, UAE
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Camp Facilities - Habshan, UAE
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Aerial view of Mina Abdullah Facilities
ABJ Fabrication Facilities
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ABJ Fabrication Facilities
ABJ Engineering & Contracting Company fabricates a wide range of heavy industrial products for the oil and gas, petrochemical, chemical, fertilizer, power, water and related industrial sectors in Kuwait and beyond.
The Company designs, manufactures and installs pressure vessels, pressure piping, heavy structural steel works, tanks, modular skids, evaporators, separators and HRSG among a host of customized heavy duty products for large-scale projects in Kuwait and UAE.
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ABJ Fabrication Facilities
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ABJ Fabrication Facilities Strengths
Our current manpower is 2,027 skilled labor
Our current production covers the fabrication of the following:
§ Process Equipment
§ Vessels & Pressure Vessels
§ Evaporators for MSF Desalination Plants
§ Skids Mounted Process Modules
§ Pressure / Process Piping
§ Structural Steel
§ High Capacity 24 Hrs radiography vaults for NDT of pipe fabrication.
A large number of highly experienced staff in engineering design, production of fabrication drawings in accordance with international codes and standards.
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ABJ Fabrication Facilities
Electric Furnace – Temp – 800º C Transportation
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ABJ Fabrication Facilities DESALINATION UNITS
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ABJ Fabrication Facilities SEPARATORS / COLUMNS
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ABJ Fabrication Facilities PRESSURE PIPING
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ABJ Fabrication Facilities MODULAR SKIDS
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Jaber Al Ahmed International Stadium, Kuwait
Nelson Mandela Stadium, South Africa
ABJ Fabrication Facilities SPORT STADIUMS
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Gulf National Insulation Systems
Aromatics Complex Project
GNIS is a Specialized Insulation Company set up in 2006 between KN & Riva Mariani Group of Italy.
GNIS has a 5,500 m2 capacity set up with MAB Facility.
A 1,000 m2 State of the Art, Full Computerized Workshop.
Capacity up to 20,000 m2 / month of Fabricated Cladding Materials.
304 + 20 Strong Fully trained and experienced work force.
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Gulf National Insulation Systems
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Ethylene Glycol – 2, Kuwait Ethylene Glycol – 2, Kuwait
Gulf National Insulation Systems
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Main Clients References Ministry of Electricity & Water, Kuwait
Kuwait Petrochemical Industries Company
Ministry of Public Works, Kuwait Kuwait Gulf Oil Company
Kuwait National Petroleum Company Saudi Arabian Chevron Inc.
Kuwait Oil Company Ansaldo Industrial S.p.A.
Equate Petrochemicals, Kuwait International Bechtel Company, Ltd.
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Main Clients References Tecnimont S.p.A., Italy Fluor International Ltd., USA
Saipem S.p.A., Italy Kellogg Brown & Root – KBR, USA
Fisia, Italy Hyundai Engineering & Construction Co., South Korea
Technip, Italy Samsung Corporation, South Korea
Foster Wheeler, Italy SK Engineering & Contracting Company, South Korea
Petrofac International Ltd., UK Daelim Industrial Company Ltd., South Korea
Costain Oil & Gas - UK ABB Lummus Heat Transfer B.V., Netherlands
JGC Corporation, Japan Polimex Cekop, Poland
Mitsui Engineering & Shipbuilding Company, Japan Cegelec, France
