ABJ Presentation

AWI 106-ABJ Att. 5 Rev. 0 26 Jan. 2008 Rev. 1 23 Mar. 2008

Fabrication Facilities

2AWI 106-ABJ Att. 5 Rev. 0 26 Jan. 2008 Rev. 2 04 Feb. 2009

Parent Company : Kharafi National KSC (Closed)Operations : Kuwait, UAE, Bahrain, Egypt & Lebanon

Annual Turn over : US Dollars 1.0 BillionOperating Divisions & respective Portfolios

• ABJ (wholly owned subsidiary) : engaged in design/ manufacture / supply of Process Equipment Modules & Skids, Piping & Valve Skids, Pressure Vessels, Architectural Steel Structures, Pressurized & Atmospheric Storage Tanks, Pre-fabricated Piping Spools, Evaporators ……

• Infrastructure Projects Development : undertakes BOT, BOO & (BOOT) Plants in Water & Waste Water & Reclamation Projects and O&G Industrial Sector

Company profile


• EPCM : undertakes EPC Projects in Oil & Gas, Power, Water & Waste Water Sectors, Infrastructure Projects and associated core sector industries

• Construction (O&G) : engaged in site Construction – Civil, Mechanical, Electrical & Instrumentation - of projects in Oil & Gas, Power, Water and Infrastructure Projects

Company profile


• Facilities Management (FM) : offers Services Projects Development in Operation and Maintenance of Process Plants

• Trading Operations : Marketing and Agency representation of Products, Systems and Technology innovations

Company profile


IPD EPCM

Kharafi National KSC (Closed)(Kuwait, UAE, Bahrain,

Lebanon, Egypt)

ABJ Engineering & Contracting KSC

(Closed) –

Construction

Facilities Management

Trading

ABJ - MANUFACTURING HUB


Process Equipment Modules/Skids

Architectural Roof Structure - Stadiums

Pressure Vessels

Storage Tanks

ABJ - product portfolio


ABJ PORTFOLIO

Piping Spools Desalination Plant Equipment


• Oil & Gas sector

• Petrochemicals

• Water & Waste water and Reclamation projects

• Power plants

• Infrastructure projects

Industries catered


• Engineered PackagesProcess Equipment Modules & SkidsPiping & Valve SkidsIndustrial Steel Structure & Pipe Racks

• Pressure VesselsSeparators, Desalters, Glycol Regeneration / Dehydration Vessels, Reactors, Columns, Knock-out Drums …..

• Heat ExchangersShell & Tube Heat Exchangers

• Desalination PlantsPackaged Evaporators

• Architectural StructureStadiums, Malls, Amusement Parks ….. etc.

• Storage TanksPressurized and Atmospheric Shop Fabricated Storage Tanks

• Piping (Process & Pressure)Pressure Piping and Process Piping Spools

• Porta Cabins : Design, Built & Supply (As per Client’s requirements)• Corrosion Protection Services• Refurbishment/Conditioning of Static Equipment

Lines of business


Owners/End Users• Saudi Aramco

• SABIC

• ADCO

• BAPCO

• KOC

• KNPC

• PIC

• Equate

• Joint Operations (JO)

• Qatar Petroleum

• MEW (Kuwait)

• MPW (Kuwait)

• Indian Oil Corporation Ltd (IOCL)

• Cairn Energy

EPC Contractors/Consultants• Tecnimont

• Saipem

• Fluor

• Bechtel

• Linde

• Petrofac

• Tecnicas Reunidas

• Thermo Design Engineering

• Aker Process Systems

• Hamworthy

• SKEC

• Daelim

• JGC

• Petreco

• NATCO

• Siemens Water Technologies

• Fisia Italimpianti

• Sidem

• Birdair

Clients


• ISO 9001:2008 – Quality Management Systems

• ASME “U”STAMP – Pressure Vessels

• ASME “U2” STAMP – Pressure Vessels

• ASME “S” Stamp – Power Boilers

• ASME “PP” Stamp – Process / Pressure Piping

• NB – National Board Registration (Boilers & Pressure Vessels)

• NBIC – “R” – Repair of Pressure Vessels

Accreditations


Product Mechanical Design Code

Design Software Detailing Software

Pressure Vessels

ASME Section VIII Div 1 & Div 2

• PVEllite• COMPRESS

• AUTOCAD

Heat Exchangers

ASME Section VIII Div 1 & TEMA

• PVEllite • AUTOCAD

Pressurized Tanks

• API 650• API 620• UL 142

• TANK/E-TANK• E-TANK• E-TANK

• AUTOCAD

Atmospheric Tanks

• AISC • Staad Pro • Strucad• AUTOCAD• Tekla Structures

Steel Structure • AISC• BS 5950

• Staad Pro • Strucad• AUTOCAD• Tekla Structures

Design & Engineering capabilities


• ASME Sec VIII Div. 1& 2 - Pressure vessels

• ASME Sec 1 - Power Boilers

• ASME B 31.1 - Process / Pressure Piping

• ASME B 31.3 - Process Piping

• ASME B 31.4 - Pipeline Transportation Systems – Liquid Hydrocarbon

• ASME B 31.8 - Gas Transmission & Distribution Piping System

• ANSI/ NB-23 - National Board Inspection Code

• API – 1104 - Welding of Pipelines and Related Facilities

• API 650 - Welded Steel Tanks for Oil Storage

• AWS D1.1 - Structural Steel – Welding Code

Practicing construction codes


Shop Area• Mina Abdulla : 173,000 Sq. M• Shuaiba : 30,000 Sq. M

Shop Capacity

• Pressure Vessels : 500 TPM• Steel Structure : 500 TPM• Piping Spools : 2300 ID/D

Total Strength : 1700 to 2000

Shop facilities


FABRICATION SHOP (MAJOR EQUIPMENT)

• CNC Profile Plate Cutting Machine (Gas 200 mm thk

/ Plasma 50 thk)

• Plate Rolling Machine (100 mm thk & 20 thk)

• Bevelling Machine

• CNC Pipe Cutting Machine (1000mm Dia)

• CNC Pipe / Profile Bending Machine (12” Dia)

• Clad removing Machines

• Hydraulic Press (400 T)

• Press Brake (3 M (L) x 12 mm thk)

• Tube Expanders

Plate Rolling Machine - 100 mm thk

CNC Plate Profile Cutting Machine - 200 mm Thk

Shop facilities


FABRICATION SHOP (MAJOR EQUIPMENT)

• Shearing Machine 3 M (L) x 16 mm thk

• Circular SAW Machine (Beam Size 350 MM)

AUTOMATIC WELDING MACHINES

• Column & Boom SAW Welding Machine

• Column & Boom FCAW Welding Machine

• Bore Cladding Machine (2” minimum)

PWHT

• Oil Fired Stress Relieving Furnace

CNC Pipe Profile Cutting Machine - 1000mm dia

Stress Relieving Furnace – 7.5m x 7.5m x 40m

Shop facilities


NOZZLE CLADDING 2” & 24”.

Small Bore Mechanized Nozzle Cladding


MACHINE SHOP (MAJOR EQUIPMENT)

• CNC Deep Hole Drilling Machine (Multi Spindle – 4 m (W) x 6 M (L) x 200 thk.

• CNC Quick Mill Drilling Machine (120 x 120, Single Spindle – 3.5 M (W) x 3 M (L) x 200 thk

• CNC Quick Mill Drilling Machine (120 x 144, Single Spindle – 3 M (W) x 4 M (L) x 200 thk

• Vertical Milling Machine

CNC Quick Mill Drilling Machine (3 Nos.)

CNC Pipe / Profile Bending Machine (12” dia)

Shop facilities


MACHINE SHOP (MAJOR EQUIPMENT)(MAJOR EQUIPMENT)

• Horizontal CNC Floor Type Boring Machine

Table size (Rotary 360 Degrees) 2000 x 1800 mm 3 axis interpolation Longitudinal Travel X axis : 6000 mm Ram In/Out Y axis : 1080 mmVertical Travel (Head) Z axis : 2800 mmTable Load : 12,500 Kgs

• Radial Drilling Machines (63 Dia x 2.3 M (L) & 63 mm Dia x 800 mm (L)

• Table Milling Machine (Bed Length 2 M)

• Lathe Machines (1.6 M Dia x 4 M (L)

• Portable Milling Machines

Horizontal drilling machine

Shop facilities

Lathe machine – 1.6 M Dia x 4 M (L)


SURFACE PREPARATION

• Covered Blast Area : 1,200 Sq. M

• Covered Paint Area : 1,650 Sq. M

• Open Blast Area : 6,200 Sq. M

• Open Paint Area : 11,700 Sq. M

Shop facilities

Blasting Chambers - 25M (L)x14M (W) x12M (H)

Automatic Airless Blasting Machine - Window Size 2 M (W) x 1.5 M (H)


Lifting Capacity

• Shop EOT : 60T

• Tower Crane : 5T at 55 M radial span

• Gantry Crane : 20T

• Mobile Cranes : 25T, 50T, 80T, 100T,

120T, 180T, 200T,

300T & 350T

Shop facilities

350 T Mobile Crane


Level - I

Level - II

Level - III

Quality Assurance Manual(QAM)

Quality Manual establishes and states how we meet the requirements of ISO 9001

Administration Work Instructions (AWI)(Instructions for organization

wide application)

Department Work Instructions (DWI)(Instructions for department’s

application)

Technical Work Instructions (TWI)

(Instructions for technicalapplication in the projects)

Project Specific Work Instruction(PSWI)

(Instructions applicable to a specific project)

Quality Management System (ISO 9001:2000)


Level - I

Level - II

Level - III

Quality Control Manual(QCM)

Quality Manual establishes and states how we meet the requirements of ASME & NBIC

Technical Work Instructions (TWI)

(Instructions or technical application in the ASME & NBIC requirement)

Project Specific Work Instruction(PSWI)

(Instructions applicable to a specific job/ project)

Quality Management System (ASME & NBIC)


NON-DESTRUCTIVE EXAMINATION

In-house Facilities

• Dye Penetrant

• Magnetic Particle

• Thickness Measurement

• Ferrite Testing

• Hardness Testing

• Hydro Test

• Pneumatic Test

Third Party Facilities

• X-RAY .

• Gamma Rays

• Ultrasonic Testing

• Positive Material Identification

All Destructive Testing

Quality Control

RT Bunkers


MATERIALS• Carbon Steel & LTCS• Low Alloy Steels• Stainless Steel 304L,316L,321,347• Duplex Stainless Steel• Super Duplex Stainless Steel• Lean Duplex Stainless Steel• Cu-Ni• Titanium• Incoloy• Inconel• 6 mo Steels• Monel

PROCESSES• SMAW

• GTAW

• FCAW – (Machine & Semi Auto

• GMAW – (Machine & Semi Auto)

• SAW

• Stud Welding

• Bore Cladder using GMAW Process

CODES• As Per ASME Sec IX• As Per AWS D1.1• As Per API -1104

APPROVALS BY• LLOYDS • BUREAU VERITAS• GERMANISCHER LLOYD• HEARTFORD STEAM BOILERS• WELLUSEY• TUV

Welding processes & materials


WPS:• Carbon Steel – 78 Nos. • Stainless Steel – 32 Nos.• Low Alloy Steel – 02 Nos.• C.S – S. S – 15 Nos.• Nickel Alloy – 08 Nos.• S.S. Overlay – 10 Nos.• Nickel Alloy - Overlay – 11 Nos.• C.S – Nickel Alloy – 02 Nos.• Duplex Stainless Steel – 10 Nos.• S.S.-Nickel Alloy – 01 Nos.• C.S.-Nickel Alloy – 01 Nos.• C.S -Duplex Stainless Steel – 09 Nos• Duplex Stainless Steel - LDSS – 02 Nos• Copper Alloy – C.S – 03 Nos• Copper Alloy – D.S.S – 01 Nos• Copper Alloy – S.S – 01 Nos• S.S – D.S.S – 03 Nos• D.S.S – Overlay – 03 Nos• Copper Alloy – Overlay – 06 Nos• Copper Alloy – 01 Nos.• Total Numbers Of WPS : 199 Nos.

Maximum Thickness of WPS Qualified : 200 mm

PQR:• Carbon Steel – 55 Nos. • Stainless Steel – 22 Nos.• Low Alloy Steel – 03 Nos.• C.S – S. S – 17 Nos.• Nickel Alloy – 07 Nos.• S.S. Overlay – 11 Nos.• Nickel Alloy - Overlay – 08 Nos.• C.S – Nickel Alloy – 02 Nos.• Duplex Stainless Steel – 07 Nos.• S.S.-Nickel Alloy – 01 Nos.• C.S.-Nickel Alloy – 03 Nos.• C.S -Duplex Stainless Steel – 06 Nos• Duplex Stainless Steel - LDSS – 02 Nos• Copper Alloy – C.S – 01 Nos• Copper Alloy – D.S.S – 01 Nos• Copper Alloy – S.S – 01 Nos• S.S – D.S.S – 01 Nos• D.S.S – Overlay – 04 Nos• Copper Alloy – Overlay – 04 Nos• Copper Alloy – 01 Nos

• Total Numbers Of PQR : 157 Nos.

Summary - Welding procedures


• Document Register ( MS Access based program)

• Document Storage & Handling

• Issue of Controlled Copies

• Maintaining Master Copies

• Un Controlled Copies to Client

• Marking obsolete Copy when new revisions received

• Issue of documents through transmittals

• Documents/ Records Retention

• Electronic copies of Manufactures Record Book

Document Control System


• Body Harness (PPE)• Ensure periodic Calibration, Inspection &

Maintenance of lifting equipment• Reporting Near Misses, Incidents• Conduct Safety Training programs • Emergency Evacuation Drill• Fire Extinguisher Training • Posting Safety signboards, bulletins, posters • Hazard identification & Risk Assessment• Audit of PPE prior to commencement of

critical activity• Use of standard Scaffolding methods &

materials.• Promote safe working attitude through

incentives• Enforce disciplinary action for violating HSE

Policy

Health, Safety & Environment

Fire Fighting Training in ABJ


Dispensed Oil Expelling Unit (DOX) – 20 M (L) x 6 M (W) x 20 M (H) – 270 MTShipped to Saudi Kayan Petrochemical Co., KSA;

Logistics


Glycol Regeneration Modules 11 M (L) x 5 M (W) x 5 M (H) – 40 MTTransported to BAPCO, Bahrain

Logistics


Track Record….

Oil & Gas Petrochemicals


Dispensed Oil Expelling Unit (DOX); 20 M (L) x 6 M (W) x 20 M (H) – 270 MTProject : Ethylene Plant; Client : Tasnel Petrochemical Co., KSA; EPC Contractor : Linde, Germany / NATCO, USA

Process plant modules & Skids


Dispensed Oil Expelling Unit (DOX) – 20 M (L) x 6 M (W) x 20 M (H) – 270 MTProject : Olefins Plant; Client : Saudi Kayan Petrochemical Co., Al Jubail, KSA; EPC Contractor : KBR, Singapore / NATCO, USA



Glycol Regeneration Skids 11 M (L) x 5 M (W) x 5 M (H) – MT (7 Nos.) + Off-skid PipingProject : New Khuff Dehydration Unit, Khuff Development Program; Client : BAPCO, Bahrain EPC Contractor : Petreco Process Systems (Cameron), UAE



HP Discharge Scrubber : ID 3500 mm x (78+3) mm thk x 5500 mm T/T – SA 516 Gr. 70N + SS 316L Clad; Project : BS 160; Client : KOC, Kuwait; EPC Contractor : Saipem (Snamprogetti), Italy (Under Execution)

Pressure vessels

Rolling of 81mm thick SS Clad Plate in progress


Debutanizer, ID 4000 mm x 27mm thk x 38,700 mm T/T – SA 516 Gr. 70; 204 TProject : Aromatics Complex; Client : Kuwait Paraxylene Production Co., EPC Contractor : Tecnimont, Italy + SKEC, Korea JV Consortium

Pressure vessels


Separator Column, ID 6200 mm X 20 mmthk X 6700 MM T/T Project : Aromatics Complex; Client : Kuwait Paraxylene Production Co., (EQUATE),EPC Contractor : Tecnimont, Italy + SKEC, Korea JV Consortium

Pressure vessels


Pressure vessels

Stripper Column, ID 3500 mm X 17 mm thk X 27700 mm T/T Project : Aromatics Complex; Client : Kuwait Paraxylene Production Co., (EQUATE),EPC Contractor : Tecnimont, Italy + SKEC, Korea JV Consortium


Pressure vessels

Desalter / Degasing Vessels (12 NOS), ID 2200~3200 mm X 12~18 mm thk X 4500~10700 mm T/T ASME “U” Stamped, Project : Dehydration & Desalting Units; Client : South Oil Co., Iraq; EPC Contractor : Axia Howmar Limited.


Depentanizer, ID 1100 mm X 12 mm thk X 26350 mm T/T – SA 516 GR. 70Project : Aromatics Complex; Client : Kuwait Paraxylene Production CO., (EQUATE), EPC Contractor : Tecnimont, Italy + SKEC, Korea JV Consortium

Pressure vessels


Refurbishment : HP Gas Separator, ID 3125 mm X 35+2 mm thk X 8840 mm T/T – Carbon Steel Cladded with SS 321, Design as per ASME SEC VIII Div 2; Project : Up Gradation of GC 23; Client : Kuwait Oil Company; EPC Contractor : Petrofac

Pressure vessels


Pre-fabricated Piping Spools


SIGNATURE PROJECTS…

INFRASTRUCTURE SECTOR


Jaber Al Ahmed International Stadium – Kuwait, Aerial view : 285 M (L) x 260 M (W) x 40 M (H); Client : Ministry of Public Works; Main Contractor : M.A.Kharafi & Sons, Kuwait Membrane Design: Birdair, USA; Compression Ring fabricated by ABJ -– 2700T

Stadiums - Kuwait


Nelson Mandela Bay Multipurpose Stadium, Port Elizabeth, South Africa 256 M (L) x 196 M (W) x 32.3 M (H); Client : Nelson Mandela Petropolitan Munacipality, SA; Main Contractor : Grenekar / Interbeton LTA, SA; Membrane Design : Taiyo Birdair, USARoof Structure fabricated by ABJ -– 2500 T

Stadiums – South Africa


Green Point Stadium, South Africa - Section view from inside 265 M (L) x 245 M (W) x 54 M (H);Client : City of Cape Town, SA; ractor : Murray & Roberts; Membrane Design : Birdair, USA / PFEIFER, Germany. Compression Ring fabricated by ABJ - 1800T

Stadiums – South Africa


LANDMARKS…

WATER & WASTE WATER SECTOR


MBR Modules; 6.5 M (L) x 4.5 M (W) x 5.2 M (H) – 11 MT (12Nos)Project : Waste Water Treatment Plant; Client : Saudi Aramco, KSA; EPC Contractor : Siemens, USA

MBR Modules - KSA


ABJ Engineering & Contracting Co. KSC (Closed)

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