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Fabrication Facilities

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


Company profile
Parent Company : Kharafi National KSC (Closed)
Operations : Kuwait, UAE, Bahrain, Egypt & Lebanon
Annual Turn over : US Dollars 1.0 Billion
Operating 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

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


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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

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


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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

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


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ABJ - MANUFACTURING HUB

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

IPD EPCM
ABJ Engineering
& Contracting KSC
(Closed) –

Trading Construction

Facilities
Management

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


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ABJ - product portfolio

Process Equipment Modules/Skids Pressure Vessels

Architectural Roof Structure - Stadiums Storage Tanks


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

Piping Spools Desalination Plant Equipment

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


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Industries catered

• Oil & Gas sector

• Petrochemicals

• Water & Waste water and Reclamation


projects

• Power plants

• Infrastructure projects

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


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Lines of business
• Engineered Packages
„ Process Equipment Modules & Skids
„ Piping & Valve Skids
„ Industrial Steel Structure & Pipe Racks
• Pressure Vessels
„ Separators, Desalters, Glycol Regeneration / Dehydration Vessels, Reactors,
Columns, Knock-out Drums …..
• Heat Exchangers
„ Shell & Tube Heat Exchangers
• Desalination Plants
„ Packaged Evaporators
• Architectural Structure
„ Stadiums, Malls, Amusement Parks ….. etc.
• Storage Tanks
„ Pressurized 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

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


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Clients
Owners/End Users EPC Contractors/Consultants
• Saudi Aramco • Tecnimont
• SABIC • Saipem
• ADCO • Fluor
• BAPCO • Bechtel
• KOC • Linde
• KNPC • Petrofac
• PIC • Tecnicas Reunidas
• Equate • Thermo Design Engineering
• Joint Operations (JO) • Aker Process Systems
• Qatar Petroleum • Hamworthy
• MEW (Kuwait) • SKEC
• MPW (Kuwait) • Daelim
• Indian Oil Corporation Ltd (IOCL) • JGC
• Cairn Energy • Petreco
• NATCO
• Siemens Water Technologies
• Fisia Italimpianti
• Sidem
• Birdair

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


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Accreditations
• 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

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


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Design & Engineering capabilities
Product Mechanical Design Design Software Detailing Software
Code
Pressure ASME Section VIII • PVEllite • AUTOCAD
Vessels Div 1 & Div 2 • COMPRESS

Heat ASME Section VIII Div • PVEllite • AUTOCAD


Exchangers 1 & TEMA

Pressurized • API 650 • TANK/E-TANK • AUTOCAD


Tanks • API 620 • E-TANK
• UL 142 • E-TANK
Atmospheric • AISC • Staad Pro • Strucad
Tanks • AUTOCAD
• Tekla Structures
Steel Structure • AISC • Staad Pro • Strucad
• BS 5950 • AUTOCAD
• Tekla Structures

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


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Practicing construction codes
• 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

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


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Shop facilities
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

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


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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 Plate Profile Cutting Machine - 200 mm Thk
• 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

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


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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 CNC Pipe Profile Cutting Machine - 1000mm dia

• Bore Cladding Machine (2” minimum)

PWHT

• Oil Fired Stress Relieving Furnace

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

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


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Small Bore Mechanized Nozzle Cladding

NOZZLE CLADDING 2” & 24”.

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


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Shop facilities
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 CNC Quick Mill Drilling Machine (3 Nos.)

• Vertical Milling Machine

CNC Pipe / Profile Bending Machine (12” dia)

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


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Shop facilities
MACHINE SHOP (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 mm
Vertical Travel (Head) Z axis : 2800 mm
Table Load : 12,500 Kgs
Horizontal drilling machine

• 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

Lathe machine – 1.6 M Dia x 4 M (L)

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


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Shop facilities

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


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

Automatic Airless Blasting Machine - Window


Size 2 M (W) x 1.5 M (H)
AWI 106-ABJ Att. 5 Rev. 0 26 Jan. 2008 Rev. 2 04 Feb. 2009
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Shop facilities

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

350 T Mobile Crane

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


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Quality Management System (ISO 9001:2000)

Level - I
Quality Assurance Manual
(QAM)
Quality Manual establishes and states how we meet the
requirements of ISO 9001

Level - II
Administration Work Department Work Technical Work
Instructions (AWI) Instructions (DWI) Instructions (TWI)
(Instructions for organization (Instructions for department’s (Instructions for technical
wide application) application) application in the projects)

Level - III Project Specific Work Instruction


(PSWI)
(Instructions applicable to a specific project)

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


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Quality Management System (ASME & NBIC)

Level - I
Quality Control Manual
(QCM)
Quality Manual establishes and states how we meet the
requirements of ASME & NBIC

Level - II
Technical Work
Instructions (TWI)
(Instructions or technical application in the ASME & NBIC requirement)

Level - III Project Specific Work Instruction


(PSWI)
(Instructions applicable to a specific job/ project)

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


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Quality Control
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


RT Bunkers
AWI 106-ABJ Att. 5 Rev. 0 26 Jan. 2008 Rev. 2 04 Feb. 2009
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Welding processes & materials
9 MATERIALS 9 PROCESSES
• Carbon Steel & LTCS
• SMAW
• Low Alloy Steels
• Stainless Steel 304L,316L,321,347 • GTAW
• Duplex Stainless Steel • FCAW – (Machine & Semi Auto
• Super Duplex Stainless Steel • GMAW – (Machine & Semi Auto)
• Lean Duplex Stainless Steel
• Cu-Ni • SAW
• Titanium • Stud Welding
• Incoloy • Bore Cladder using GMAW Process
• Inconel
• 6 mo Steels
• Monel
9 APPROVALS BY
9 CODES • LLOYDS
• As Per ASME Sec IX • BUREAU VERITAS
• As Per AWS D1.1 • GERMANISCHER LLOYD
• As Per API -1104 • HEARTFORD STEAM BOILERS
• WELLUSEY
• TUV

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


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Summary - Welding procedures
WPS: PQR:
• Carbon Steel – 78 Nos. • Carbon Steel – 55 Nos.
• Stainless Steel – 32 Nos. • Stainless Steel – 22 Nos.
• Low Alloy Steel – 02 Nos. • Low Alloy Steel – 03 Nos.
• C.S – S. S – 15 Nos. • C.S – S. S – 17 Nos.
• Nickel Alloy – 08 Nos. • Nickel Alloy – 07 Nos.
• S.S. Overlay – 10 Nos. • S.S. Overlay – 11 Nos.
• Nickel Alloy - Overlay – 11 Nos. • Nickel Alloy - Overlay – 08 Nos.
• C.S – Nickel Alloy – 02 Nos. • C.S – Nickel Alloy – 02 Nos.
• Duplex Stainless Steel – 10 Nos. • Duplex Stainless Steel – 07 Nos.
• S.S.-Nickel Alloy – 01 Nos. • S.S.-Nickel Alloy – 01 Nos.
• C.S.-Nickel Alloy – 01 Nos. • C.S.-Nickel Alloy – 03 Nos.
• C.S -Duplex Stainless Steel – 09 Nos • C.S -Duplex Stainless Steel – 06 Nos
• Duplex Stainless Steel - LDSS – 02 Nos • Duplex Stainless Steel - LDSS – 02 Nos
• Copper Alloy – C.S – 03 Nos • Copper Alloy – C.S – 01 Nos
• Copper Alloy – D.S.S – 01 Nos • Copper Alloy – D.S.S – 01 Nos
• Copper Alloy – S.S – 01 Nos • Copper Alloy – S.S – 01 Nos
• S.S – D.S.S – 03 Nos • S.S – D.S.S – 01 Nos
• D.S.S – Overlay – 03 Nos • D.S.S – Overlay – 04 Nos
• Copper Alloy – Overlay – 06 Nos • Copper Alloy – Overlay – 04 Nos
• Copper Alloy – 01 Nos • Copper Alloy – 01 Nos
.
• Total Numbers Of WPS : 199 Nos. • Total Numbers Of PQR : 157 Nos.

Maximum Thickness of WPS Qualified : 200 mm


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

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


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Health, Safety & Environment
• 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
Fire Fighting Training in ABJ

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


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Logistics

Dispensed Oil Expelling Unit (DOX) – 20 M (L) x 6 M (W) x 20 M (H) – 270 MT


Shipped to Saudi Kayan Petrochemical Co., KSA;

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


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Logistics

Glycol Regeneration Modules 11 M (L) x 5 M (W) x 5 M (H) – 40 MT


Transported to BAPCO, Bahrain

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


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Track Record….

Oil & Gas


Petrochemicals

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


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Process plant modules & Skids

Dispensed Oil Expelling Unit (DOX); 20 M (L) x 6 M (W) x 20 M (H) – 270 MT


Project : Ethylene Plant; Client : Tasnel Petrochemical Co., KSA;
EPC Contractor : Linde, Germany / NATCO, USA
AWI 106-ABJ Att. 5 Rev. 0 26 Jan. 2008 Rev. 2 04 Feb. 2009
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Process plant modules & Skids

Dispensed Oil Expelling Unit (DOX) – 20 M (L) x 6 M (W) x 20 M (H) – 270 MT


Project : Olefins Plant; Client : Saudi Kayan Petrochemical Co., Al Jubail, KSA;
EPC Contractor : KBR, Singapore / NATCO, USA
AWI 106-ABJ Att. 5 Rev. 0 26 Jan. 2008 Rev. 2 04 Feb. 2009
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Process plant modules & Skids

Glycol Regeneration Skids 11 M (L) x 5 M (W) x 5 M (H) – MT (7 Nos.) + Off-skid Piping


Project : New Khuff Dehydration Unit, Khuff Development Program; Client : BAPCO, Bahrain
EPC Contractor : Petreco Process Systems (Cameron), UAE
AWI 106-ABJ Att. 5 Rev. 0 26 Jan. 2008 Rev. 2 04 Feb. 2009
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Pressure vessels

Rolling of 81mm thick SS Clad Plate in progress

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

Debutanizer, ID 4000 mm x 27mm thk x 38,700 mm T/T – SA 516 Gr. 70; 204 T
Project : Aromatics Complex; Client : Kuwait Paraxylene Production Co.,
EPC Contractor : Tecnimont, Italy + SKEC, Korea JV Consortium
AWI 106-ABJ Att. 5 Rev. 0 26 Jan. 2008 Rev. 2 04 Feb. 2009
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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

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


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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

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


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

Depentanizer, ID 1100 mm X 12 mm thk X 26350 mm T/T – SA 516 GR. 70


Project : Aromatics Complex; Client : Kuwait Paraxylene Production CO., (EQUATE), EPC Contractor
: Tecnimont, Italy + SKEC, Korea JV Consortium

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


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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

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


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Pre-fabricated Piping Spools

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Pre-fabricated Piping Spools

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Pre-fabricated Piping Spools

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SIGNATURE PROJECTS…

INFRASTRUCTURE SECTOR

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Stadiums - Kuwait

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

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, USA
Roof Structure fabricated by ABJ -– 2500 T
AWI 106-ABJ Att. 5 Rev. 0 26 Jan. 2008 Rev. 2 04 Feb. 2009
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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
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LANDMARKS…

WATER & WASTE WATER


SECTOR

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MBR Modules - KSA

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
AWI 106-ABJ Att. 5 Rev. 0 26 Jan. 2008 Rev. 2 04 Feb. 2009
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ABJ Engineering & Contracting Co. KSC (Closed)
Resources to respond !

Thank You

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


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