Unique expertise you can trust

Transcription

1 TURNKEY COMPETENCE FROM ONE SOURCE Solutions made by SMS Siemag

2 SMS SIEMAG Turnkey competence from one source TURNKEY SOLUTIONS made by SMS Siemag Unique expertise you can trust YOUR EXPECTATIONS Planning and building a new production plant or revamping existing facilities requires a broad range of knowledge, experience and reliable expertise. SMS Siemag offers you complete tailor-made turnkey solutions that include everything you want: best integration of buildings, infrastructure, logistics, and sub-systems all with cutting-edge technology. A sound basis for success given that demands woldwide are changing and growing fast - along with your expectations. We rise to the challenge by combining our leading metallurgical technology more rapidly, flexibly, and efficiently with our know-how in turnkey construction of integrated plants. All under one roof is our mission statement to create the synergies that produce innovative solutions for you. That s expertise from one source for even better performance. 2

3 OUR SOLUTIONS We offer you a choice of tailored turnkey models also covering EPC and EPCM services. Included in our full spectrum of services are highly skilled project management, configuration of project scope, basic and detail engineering, procurement and manufacturing, transportation to site, site start-up and management, construction, and/or installation services. All services in one hand minimises interface drawbacks. We are with you all the way. SMS Siemag takes control either as your general contractor or your leading partner in a national or international consortium. That means your plant is not just delivered, it's ready for operation! So you can concentrate on your core business: profitable production! 3

4 YOUR BENEFITS You can rely on our overall responsibility for planning and execution because we offer you a high degree of know-how, flexibility, and an excellent track. As a general contractor or leading partner in international consortiums, SMS Siemag draws on profound experience in implementing large-scale turnkey projects for the iron and steel as well as the nonferrous metals industries. Just as useful are our in-house technologies and the engineering expertise. Wherever your project is based, you benefit from our worldwide reach. It includes strategic partnerships covering the whole range of turnkey solutions for steelmaking and metal processing plants, including ancillary infrastructure. What brings you an added advantage is that SMS Siemag works with engineering offices, representatives, and local partners all over the globe. They ensure we are perfectly placed to handle all aspects of your project. 4

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6 SMS SIEMAG Turnkey competence from one source CONTRACT MODELS SMS Siemag provides you with three typical models for turnkey order execution: Self performing EPC (General Contractor) Engineering Procurement Construction Partnering EPC (Consortium) Engineering Procurement Construction General contractor Open consortium of technological and construction companies - Contract is signed solely between customer and general contractor - Selection of suppliers and subcontractors by general contractor with no input from customer - Contract is signed jointly by consortium with customer - Split of responsibilities within the consortium agreed upon in the cooperation agreement 6

7 Project management EPCM Engineering Procurement Construction Management Engineering company performs overall project management - Two separate contracts signed between customer and supplier: - Supply (EP) contract for the process plant - EPCM service contract for balance of plant (BoP) facilities TURNKEY BENEFITS - Tailored system solution from one source - Budget reliability - Deadline reliability - Optimized project completion - Single point of contact - Reduction of risks for the builder - Lower project organization expenditure - Lower expenditure for temporary hiring of experts - Single supply and warranty interface - Savings on project coordination 7

8 SMS SIEMAG Turnkey competence from one source EPC (GENERAL CONTRACTOR) Customer SMS (General Contractor) Overall project management Process plant Balance of plant (BoP) Process equipment Supplementary equipment and auxiliary plants Turnkey services Civil, structural steel and architectural works, building services, temporary site facilities, erection works for mechanical and electrical equipment, etc Contract Management/controlling Information flow REMARKS - Contract for the entire plant is negotiated and signed solely by you and SMS Siemag (as General Contractor) - SMS Siemag has full responsibility for time management, cost, and quality/performance - Overall project management and turnkey engineering as well as site management by SMS Siemag - Selection of suppliers and sub-contractors by SMS Siemag - Sub-contracts for equipment supply and on-site construction work are negotiated and signed solely between SMS Siemag (General Contractor) and the respective suppliers/sub-contractors 8

9 Reference plant Slab caster, Poland 9

10 SMS SIEMAG Turnkey competence from one source EPC (CONSORTIUM) Customer SMS (Consortium) Overall project management Process plant Balance of plant (BoP) Process equipment Supplementary equipment and auxiliary plants Turnkey services Civil, structural steel and architectural works, building services, temporary site facilities, erection works for mechanical and electrical equipment, etc Contract Management/controlling Information flow REMARKS - Contract for the entire plant is negotiated and signed jointly by the consortium partners (as General Contractor) and you (joint and several liability) - Each consortium partner bears the responsibility for time management, cost and quality/performance in its own part-project - Responsibility of process plant performance lies solely with SMS Siemag - Overall project management by the consortium leader - Split of responsibilities within the consortium for engineering, supply, and construction agreed upon in the cooperation agreement - Construction management by the consortium partner 10

11 Reference plant Steel complex (EAF + CCMs), Russia 11

12 SMS SIEMAG Turnkey competence from one source EPCM Customer SMS (EPCM Contractor) Overall project management Process plant Balance of plant (BoP) Process equipment Supplementary equipment and auxiliary plants Turnkey services Civil, structural steel and architectural works, building services, temporary site facilities, erection works for mechanical and electrical equipment, etc Contract Management/controlling Information flow REMARKS - 2 separate contracts negotiated and signed by you and SMS Siemag: - Supply (EP) contract for the process plant - EPCM service contract - SMS Siemag bears responsibility for time management, cost, and quality/performance for the process plant (EP contract) - Overall project management and BoP engineering as well as site management by SMS Siemag (as part of EPCM service contract) - You select suppliers and sub-contractors after recommendation by SMS Siemag (EPCM contractor) - Sub-contracts for equipment supply and on-site construction work are negotiated and signed by you after recommendation/assistance from SMS Siemag (EPCM contractor) 12

13 Reference plant SAF, Kazakhstan 13

14 SMS SIEMAG Turnkey competence from one source BALANCE OF PLANT Civil, architectural, and structural works Utility systems Building services and electrical coordination Energy systems Workshops Logistics systems Laboratories 14

15 CIVIL, ARCHITECTURAL, AND STRUCTURAL WORKS SERVICES - Consulting and design service, project planning and coordination of all aspects of structural work - Feasibility studies/analyses - Static stability analyses of structural steel construction - Basic and detail design for construction work - Calculation of quantities for all types of construction work - Specification of construction methods - Sourcing of construction contractors - Assistance in and supervision of construction projects up to acceptance ADVANTAGES - Structural engineering optimally adapted to SMS Siemag process equipment - Compliance with local regulations - Design and construction of all required process and auxiliary buildings - Design and construction of all ancillary infrastructure works - Identification and coordination management of interfaces between construction works and process-related auxiliary and supplementary plants - Assistance in and supervision of construction work by experienced specialists over the entire project duration 15

16 SMS SIEMAG Turnkey competence from one source BUILDING SERVICES AND ELECTRICAL COORDINATION SERVICES - Consulting and design service, project planning, coordination and execution of all aspects of building services including installations of air conditioning systems, heating and ventilation systems, fire detection and extinguishing systems, lighting, power outlets, escape route lighting equipment, and communication equipment such as telephone, industrial TV and intercom systems - Interface determination for media systems, power supply, and signals - Electrical equipment coordination - Planning of power supply for turnkey equipment - Planning layout of grounding and lightning protection systems ADVANTAGES - Optimally adapted building equipment - Compliance with local regulations - Planning and installation of all necessary building equipment for the construction project - Coordination of the interfaces between all equipment - Assistance in and supervision of building services by experienced specialists for the entire project duration 16

17 WORKSHOPS SERVICES - Selection of the necessary workshop equipment based on your requirements and the SMS Siemag equipment supplied - Concept and layout planning of the workshop equipment - Selection of the optimal equipment and tools for every individual requirement - Supply of equipment and tools - Assistance in and supervision of installation and commissioning, and training of operating personnel - Technical and operative assistance ADVANTAGES - Optimal coordination of dimensioning, layout planning, and selection of equipment and tools - Workshop equipment adapted to specific requirements and to your existing infrastructure - Compliance with local regulations - Coordination of the interfaces between all equipment (process engineering, civil works, structural steel engineering, electrical engineering, IT, etc.) - Selection and supervision of the suppliers by experienced specialists for the entire project duration 17

18 SMS SIEMAG Turnkey competence from one source LABORATORIES SERVICES - Selection of the analytical methods based on your requirements, product mix, and technological needs - Concept and layout planning of the laboratories required for the analytical methods - Selection of the necessary equipment for handling and preparation of samples (milling machines, grinding machines, pneumatic tube systems, etc.) - Selection of the optimal equipment and instruments for the individual requirements - Supply of equipment and instruments - Assistance in and supervision of installation and commissioning, and training for lab equipment operating personnel - Technical and operative assistance ADVANTAGES - Optimal coordination of dimensioning, layout planning and selection of equipment and instruments - Laboratory equipment suitable for the individual requirements - Compliance with local regulations - Coordination of the interfaces between all equipment (process engineering, civil works, structural steel engineering, electrical engineering, IT, etc.) - Selection and supervision of suppliers by experienced specialists for the entire project duration 18

19 LOGISTICS SYSTEMS SERVICES - Selection and specification of equipment based on technical performance requirements and the structural conditions for cranes and transport vehicles - Coordination between process requirements and logistics requirements - Layout planning of the logistics systems within the general layout - Capacity planning, specification of cranes and auxiliary hoists - Determination of transportation routes and store sizes - Planning of slab and coil transport equipment and packaging facilities plus integration in the general layout planning - Implementation of studies and analyses for storage and transportation capacities - Delivery of the equipment - Assistance in and supervision of installation and commissioning up to acceptance of the equipment as well as training of operating personnel ADVANTAGES - Dimensioning, layout planning, and selection of the equipment are optimally adapted to the process equipment on the basis of logistics aspects - Configuration of the cranes to individual requirements - Compliance with local regulations - Coordination of the interfaces between all equipment (process engineering, structural steel engineering, electrical engineering, IT, etc.) - Selection and supervision of the suppliers by experienced specialists over the entire project duration until the acceptance of the plant 19

20 SMS SIEMAG Turnkey competence from one source ENERGY SYSTEMS AND ENERGY MAIN DISTRIBUTION SERVICES - Efficient and safe dimensioning, layout planning and selection of the high-voltage/medium-highvoltage switchgear for distribution transformers, compensation and filter systems, emergency power generating sets, and UPS facilities to the low-voltage main distribution board and the asso - ciated emergency concepts on the basis of your requirements and the equipment supplied by SMS Siemag - Preparation of a power distribution concept in the form of a single-line diagram - Layout planning of the high-voltage/medium-voltage switchgear - Optimal dimensioning of all components from the overhead-line power supply to the mechanical positioning element - Dimensioning and specification of all energy distribution components and subsequent selection of global specialist companies - Progress and quality control - Assistance in installation, commissioning, and training up to equipment approval - Technical and operative support ADVANTAGES - Optimal coordination of dimensioning, layout planning and selection of the equipment - Compliance with local regulations - Consulting for the strategy for connection to the interconnected power system - Performance of network analyses - Coordination of the interfaces between all equipment (process engineering, civil works, structural steel engineering, electrical engineering, IT, etc.) - Selection and support of the suppliers by experienced specialists for the entire project duration 20

21 UTILITY SYSTEMS AND UTILITY MAIN DISTRIBUTION SERVICES - Dimensioning, layout design, and supply of auxiliary equipment such as water supply and treatment system, make-up water system, waste water treatment, potable water treatment, demineralization plant, and cold water systems for heating, ventilation, and air conditioning systems - Dimensioning, layout design and supply of auxiliary equipment for e.g. compressed air station, gas supply stations, air separation facilities, and hydrogen generating stations - Layout, design, and supply of interconnecting pipework between auxiliary equipment and production equipment - Optimization of auxiliary equipment and interfaces between the generating facilities and the points of consumption of the production equipment - Supervision of installation and commissioning, and training for the auxiliary equipment - Technical assistance in the drawing up of local approval documents ADVANTAGES - Dimensioning, layout design and supply of the equipment are optimally adapted to the specific performance requirements of the plant - Compliance with local regulations - Minimization of the number of interfaces between the equipment such as civil works, process engineering, structural steel engineering, and electrical engineering - Overall responsibility for the whole plant 21

22 SMS SIEMAG Turnkey competence from one source PRE-ENGINEERING STUDIES and INTEGRATED PLANT LAYOUTS Everything you want to know is within your reach whether it s about the latest plant technologies or the optimum process route. How? Because SMS Siemag not only gives you all the facts and figures, but also conducts pre-engineering studies in close cooperation with you. Together we identify substantial cost-cutting potentials in the very early stages of your project. You save a vast amount of time and money as a result of these in-depth surveys! Equally useful are our plant layouts for your integrated systems. That s because they hold the key to handling all interfaces or battery limits between various production stages, equipment, and disciplines. We continually update these plant layouts over the course of your project to deal with any hitches. Our advanced technology means many functions are automated from starting material and finished products handling to operating media supply as well as maintenance and storage. Moreover, there is a combined track and road system for direct transport to and from the buildings. To sum up, putting your project into one hand and reducing interfaces pays off in terms of highly effective plant integration plus short project times. There are several reasons for using our services from one source. First, you get the most cost-effective solution, because we optimize the interaction between single pieces of equipment and the surrounding steel structures. Second, planning the complete plant as one project gives you the scope to boost plant efficiency by analyzing bottlenecks and adjusting plant equipment across the process chain. So, from the initial investment idea to your successfully operating plant, we seamlessly integrate all your equipment to create a powerful, complete unit. 22

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24 SMS SIEMAG Turnkey competence from one source PROJECT MANAGEMENT What you need to succeed is project management based on experience. That s where our approach comes in and helps you achieve the results you want. Even more: we focus on turnkey elements to give you an overview of each single aspect that impacts on your project. Project development Including the complete spectrum of project development services from the preparation of technical and financial plans to the development of cost estimates and viability, to support for bankable feasibility studies Project implementation Including expertise across all disciplines, specifically project management itself, quality and safety management, contracting, procurement, construction, commissioning, and plant start-up as well as training of personnel for plant operation and maintenance, after-sales services, and plant operation assistance Logistics services Including trans-shipment, customs clearance, freight market analysis, and transport studies ASPECTS OF SMS SIEMAG PROJECT MANAGEMENT (PM) - Experience-based project management - Project-related authorization to act and sign - PM involved in all essential decisions concerning the contract - Clear nomination of skilled people for all functions within the project organization - Progress analysis in all contract stages with corrective action where required risk management - Quality monitoring and equipment supplyschedule monitoring - Regular meetings with your project team to discuss progress and reach decisions - Regular in-house meetings of key decisiontakers (project managers, key members, project managers of main suppliers) - Regular cost control - Open communication Commercial/financial services Including support for feasibility studies, assistance, consulting and coordination services for dealing with potential lending banks, off-takers, and export credit agencies during credit/project assessment, applications to export credit agencies, assistance with the negotiation of loan and off-take agreements with potential lenders and off-takers, coordination, review and discussion of financial models 24

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26 SMS SIEMAG Turnkey competence from one source PROJECT MANAGEMENT Typical Organisation Chart Client Project Management Time Schedule General Plant Layout Contract Management Cost Controlling Accounts Receivable Financial Services QA/QC Documentation Process Equipment Auxiliary Equipment Electrics + Automation Process + Auxiliary Equipment Process Process Equipment I Material Handling Dedusting Process Conception/ Hardware Automation Process Layout Process Equipment II Process Utility System Laboratory Equipment Power Distribution Erection (E) Cranes/Mobile Equipment Workshop 26

27 Off-site On-site Construction + Erection Work General Site Management Construction Work Erection Work (M) Site Administration Time Scheduling Infrastructure Work Contract Management HSE Building Service QA/QC Document Management Civil and Steel Structure Work Erection Management Construction Management Commissioning Management Site Logistics 13:42 27

28 SMS SIEMAG Turnkey competence from one source REFERENCES TO INSPIRE YOU You demand reliability we deliver it based on the profound expertise SMS Siemag has gained from integrated turnkey plants. To find out more details, simply see the references on the following pages. Together with our sister companies in the SMS group, we supply you with plants for the entire process chain clearly structured and arranged according to the materials you process. There are several options to choose from: As general contractors, leading partners in a consortium, or plant planning specialists, we offer you comprehensive know-how and a wide range of services starting from the planning and project phase, right up to handover of your turnkey plant. Or you can take advantage of our engineering for individual plant areas, and combine various units to form an optimally designed complete plant. Finally, to facilitate your investment, our services include financing on an international basis plus commercial and organizational services. Invaluable here is that we coordinate all activities in each phase of project planning and transaction. That ensures dependable performance of your contract. Read on for details of our world-class references. These are just a few examples plants we built to last and designed for top performance exceptional in every way, with proven effectiveness, for unparalleled results. 28

29 KARDEMIR A. S. Turkey Start-up date 2015 Plants / lines BOF steel melting plant with t converters, dedusting, control and electrical buildings, modification of existing bays Production capacity Upgrade to 3,000,000 tpy SCOPE OF SUPPLY AND SERVICES - EP for integrated plant (brownfield) incl. EP for process equipment and balance of plant (BoP), - Engineering and supply of electrical and automation system - Construction engineering, - Supervision of erection and commissioning, - Training of customer s personnel 29

30 SMS SIEMAG Turnkey competence from one source PCC BAKKISILICON HF Iceland Start-up date 2015 Plants / lines 2 submerged-arc furnaces (SAF / silicon metal) Production capacity 32,000 tpy SCOPE OF SUPPLY AND SERVICES - E for integrated plant consisting of pre-engineering for SAF plant complex, including process equipment and balance of plant (BoP) - Construction and equipment erection works 30

31 JSC TNK KAZCHROME Kazakhstan Start-up date 2014 Plants / lines 4 submerged-arc furnaces (SAF) for ferrochrome, balance of plant (BoP) Production capacity 440,000 tpy SCOPE OF SUPPLY AND SERVICES - EPCM for integrated plant (greenfield) incl. general project management - Engineering and supply of process equipment, engineering (incl. conversion to local standards), and tender engineering of balance of plant (BoP) - Engineering and supply of electrical and automation system - Construction and equipment erection works, construction management 31

32 SMS SIEMAG Turnkey competence from one source MAADEN MINING COMPANY (Joint Venture Maaden-Alcoa), Saudi Arabia Start-up date 2014 Plants / lines Single-stand aluminum cold rolling mill (SSCM) Continuous heat treatment and chemical treatment line (CHTCTL) Production capacity 190,000 tpy SCOPE OF SUPPLY AND SERVICES - EP for integrated plant (greenfield), supply of main equipment - Engineering and supply of electrical and automation system - Supervision of erection and commissioning, training of customer s personnel as option - Detail engineering for foundations CONFIDENTIAL CLIENT USA Engineered in 2013 Plants / lines Cold rolling mill (CRM) Production capacity 75,000 tpy SCOPE OF SUPPLY AND SERVICES - E for integrated plant consisting of pre-engineering study for a cold rolling mill (CRM) complex including process equipment, balance of plant (BoP), - Construction and equipment erection works 32

33 MAADEN MINING COMPANY (Joint Venture Maaden-Alcoa), Saudi Arabia Start-up date 2013 Plants / lines Aluminum hot strip rolling mill (1-stand hot reversing mill + 4-stand finishing mill), 2 shears, coil handling system, emulsion system Aluminum 4-stand tandem cold rolling mill, coil handling system, emulsion system Production capacity 650,000 tpy SCOPE OF SUPPLY AND SERVICES - EP for integrated plant (greenfield) incl. supply of process equipment - Engineering and supply of electrical and automation system - Super vision of erection and commissioning - Training of customer's personnel 33

34 SMS SIEMAG Turnkey competence from one source DRAGON STEEL CORPORATION Taiwan Start-up date 2012 Plants / lines Extension of BOF steel melting plant with t converter, extension to MH-system, gas cleaning and dedusting plant, gas export station, control and electrical buildings Production capacity Extension to 5,000,000 tpy SCOPE OF SUPPLY AND SERVICES - EP for integrated plant (greenfield) incl. EP for process equipment and balance of plant (BoP), engineering of construction works - Engineering and supply of electrical and automation system - Supervision of erection and commissioning - Training of customer's personnel 34

35 MAGHREB STEEL Morocco Start-up date 2012 Plants / lines Electric-arc furnace (EAF) Ladle furnace (LF) Continuous casting machine (CCM / slab) Production capacity 1,000,000 tpy SCOPE OF SUPPLY AND SERVICES - EP for integrated plant (greenfield) incl. EP process equipment - Project management - Engineering and supply of electrical and automation system - Supervision of erection and commissioning - Training of customer's personnel 35

36 SMS SIEMAG Turnkey competence from one source JSC PERVOURALSK Russia Start-up date 2012 Plants / lines Electric steel-making complex Electric-arc furnace (EAF) Ladle furnace (LF) 2 continuous casting machines (CCM / billet) Production capacity 1,100,000 tpy SCOPE OF SUPPLY AND SERVICES - EPC for integrated plant (greenfield) - General project management - Engineering and supply of process equipment - Engineering and supply of electrical and automation system including level 3 production planning system - Balance of plant (BoP) - Construction and equipment erection works - Construction management 36

37 SIDERÚRGICA NACIONAL Venezuela Start-up date 2012 Plants / lines Electric-arc furnace (EAF) Ladle furnace (LF) Vacuum degasser (VD) Continuous casting machine (slab) Twin Steckel mill Plate mill Production capacity 1,550,000 tpy SCOPE OF SUPPLY AND SERVICES - E for integrated plant (greenfield) consisting of detail civil engineering for technological steel structures for the steel making plant complex Start-up date 2011 Plants / lines Electric-arc furnace (EAF) Ladle furnace (LF) Vacuum degasser (VD) Continuous casting machine (slab) Twin Steckel mill Plate mill Production capacity 1,550,000 tpy SCOPE OF SUPPLY AND SERVICES - E for integrated plant (greenfield) consisting of detail engineering for equipment foundations and main buildings for the steel making plant complex 37

38 SMS SIEMAG Turnkey competence from one source CONFIDENTIAL CLIENT Europe Engineered in 2011 Plants / lines 1 submerged-arc furnace (SAF / silicon metal) Production capacity 8,000 tpy SCOPE OF SUPPLY AND SERVICES - E for integrated plant consisting of CAPEX estimation study for the engineering - Supply and erection of a submerged-arc furnace (SAF) complex including process equipment - Balance of plant (BoP), construction and equipment erection works DRAGON STEEL CORPORATION Taiwan Start-up date 2010 Plants / lines BOF steel melting plant with 2 (+1) 220-t converters, RH-plant, MH-system, gas cleaning and dedusting plant, gas export station, gasholder, control and electrical buildings, scrapyard, underground material-receiving bunker system Production capacity 2,500,000 tpy SCOPE OF SUPPLY AND SERVICES - EP for integrated plant (greenfield) incl. EP for process equipment and balance of plant (BoP) - Engineering construction works, delivery of steel structures - Engineering and supply of electrical and automation system - Supervision of erection and commissioning - Training of customer s personnel 38

39 SALZGITTER FLACHSTAHL GMBH Germany Start-up date 2010 Plants / lines Continuous slab casting plant with runout and discharge area, cooling water makeup and water treatment plant, scale pit, control and electrical building Production capacity 1,200,000 tpy SCOPE OF SUPPLY AND SERVICES - EPC for integrated plant (brownfield) - General project management - Engineering and supply of process equipment - Engineering and supply of electrical and automation system - Balance of plant (BoP) - Construction and equipment erection works - Construction management 39

40 SMS SIEMAG Turnkey competence from one source THYSSENKRUPP STEEL & STAINLESS LLC AND THYSSENKRUPP STAINLESS LLC, USA Start-up date 2011 Plants / lines Hot strip mill for carbon and stainless steel Pickling line with five-stand cold rolling mill Continuous pickling line 2 hot-dip galvanizing lines (GI / GA) 1 hot-dip galvanizing line (CAL) 1 hot-dip galvanizing line (FAL / GI / AGI) Skin pass mill Hot annealing and pickling line (stainless) Production capacity 5,300,000 tpy SCOPE OF SUPPLY AND SERVICES - EP for integrated plant (greenfield) incl. engineering and supply of process equipment - Tender engineering for mechanical and electrical equipment erection - Supply of erection material - Engineering and supply of electrical and automation system for HSM and SPM - Training of customer s personnel, coordination of all shops - Walking-beam furnace - Electrics and automation of several processing lines - Technical advice - Commissioning and optimization of several processing lines 40