Replacement of PG Cooler for Gulf Petrochemicals Industries Co. (GPIC)

Scope of Work:

• Remove existing Steam Drum & Ammonia Process Gas Cooler.
• Install new PG Cooler & reinstate existing Steam Drum.
• Perform all testing & assist Start-up.

Client: Gulf Petrochemicals Industries Co. (GPIC)
Location: GPIC Plant, Bahrain.

Project Highlights:

• Heavy Rigging of 110 Tonnes of PG Cooler and 77 Tonnes of Steam Drum
• Cutting & weld preparation of heavy schedule piping by in-situ machining
• Application of advanced NDT method of ToFD Ultrasonic Testing on heavy schedule butt welds
• 21 day shutdown execution programme was completed 3 days ahead of schedule.

Project Value: US $ 850, 000.00

Project Execution Duration: 18 Days (2005 April)

Manhours: 19, 103 (zero NLTA)

Anode Rodding, Butt Recycling & Rodded Anode Storage Building Civil & Structural Works

Scope of Work:

• Prepare Green Field site for building construction. Approx. 25, 000 M2
• Construct 3 large steel structure building, complete with roofing, ventilation, sidings, louvers & lighting.
• Construct & commission other integral service buildings such as Control, Hydraulic & Furnace Rooms.

Client / Owner: Bechtel / Aluminium Bahrain
Location: Alba Pot Line 5, Bahrain

Project Highlights:

• Heavy concrete foundations & grade slabs in excess of 10, 000 M3
• Fabrication and installation of more than 2000 Tonnes of Structural Steel
• Roofing and Cladding of Structural Steel Buildings of more than 20, 000 M2

Project Value: US $ 8, 545, 000.00
Project Execution Duration: 12 months (2004 – 05)
Manhours: 377, 453 (zero NLTA)

Aboveground and Underground Services

Scope of Work:

Design, procurement, installation, testing and commissioning of about 50 kms of aboveground and underground pipelines and a firewater tank. The pipeline network covers the entire area of Alba Line 5 Expansion project.

Client / Owner: Bechtel / Aluminium Bahrain
Location: Alba Line 5

Project Highlights:

• Surveyed, designed, procured, installed, tested and commissioned underground & aboveground pipelines (sizes 1” to 16” of different materials including Carbon steel, GRE, Brass and Stainless Steel with more than 50, 000 Inch dia.). Underground pipeline work includes all the civil construction activities.
• Designed, procured, constructed, tested and commissioned a Firewater Tank of size 11.0 m diameter x 11.3 m height. Work also included installation of pump station.

Project Value: US $ 3, 500, 000.00
Project Execution Duration: 14 months (2004-05)
Manhours: 347, 603 (zero NLTA)

Mechanical Work for Anode Bake Furnace & Anode Storage Building

Scope of Work:

• Installation of all the Mechanical Equipment for the Anode Bake Furnace and Anode Storage Building
• Associated works include piping and insulation
• Scope of work also include testing and commissioning of all the equipment units and piping systems

Client / Owner: Bechtel / Aluminium Bahrain
Location: Alba Line 5

Project Highlights:

• Installed, tested and commissioned 11 cranes
• Installed, tested and commissioned 4 systems of piping of various sizes and a total welding of 6000 Inch dia.
• Installed and tested 400 m of fume ducts of 1 m dia.
• Assembled, installed, aligned, and grouted 2 m dia. cross over ducts for the furnaces.
• Assembled and installed 500 m of Roller conveyors
• Fabricated and installed 50 Tonnes of Structural steel

Project Value: US $ 2, 300, 000.00

Project Execution Duration: 12 months (2004-05)

Manhours: 236, 383 (zero NLTA)

Construction of New Compressor Station No. 7 for Bahrain National Gas

Scope of Work:

• Prepare Green Field site for construction of new Gas Compressor Station
• Construct, install complete station inclusive of sub grade services, foundations, fabrication, equipment, structural, piping, E & I, fireproofing, roads, asphalt & control rooms.
• Fabricate & lay 50 kms of 2” – 24” pipeline to tie in the CS to the Gas Plant & other satellite stations.
• Testing & commissioning of all installation.

Client / Owner: JGC Corporation / Banagas
Location: Banagas

Project Highlights:

• More than 1000 M3 concrete work including Gas Turbine Foundation (210 M3).
• A total welding of 105, 000 inch dia. of pipeline and 23, 000 inch dia. of piping
• Installation of 17 heavy equipments in the new compressor station including 80 Tonnes Turbine
• Hot tapping at 12 locations

Project Value: US $ 5, 785, 000.00
Project Execution Duration: 16 months (2002 – 03)
Manhours: 749, 930

Kero-Merox Project for Bahrain Petroleum Company (BAPCO)

Scope of Work:

Construction of New Kero-Merox Plant including structural steel fabrication and erection, pipelines, piping, equipment erection, construction of cone roof tanks

Client / Owner: JGC Corporation / Bapco
Project Value: US $ 3, 950, 000.00
Project Execution Duration: 10 months (2000-01)
Manhours: 650, 000 (NLTA)
(Received Safety Award from JGC )

Project Highlights:

• Structural steel – 210 Tonnes
• Piping – 60, 516 Inch-dia. (Hydrotest - 159 systems)
• Heavy equipment erection - 15 Nos.
• Construction of cone roof tanks – 2 Nos.
• PWHT – 9, 912 Inch-dia.
• Radiography – 934 sheets without a single repair
• Handed over 2.5 months ahead of schedule.
  
  

Flue Gas Desulfurization Plant for Aluminium Bahrain (Alba)

Scope of Work:

• Fabrication and erection of steel work for absorber area, duct platforms, ladders, supporting structures for flue gas bypass ducts
• Steel plate construction, complete erection of flue gas and bypass ducts, dampers and expansion joints inclusive of holding fixtures
• Installation and alignment of pumps, fans and tanks
• Assembly and alignment of absorber/stack

Client/Owner: Babcock Borsig Power / Alba
Location: Alba Calciner Plant

Project Highlights:

• FRAP lines of 2 inch to 1.6 meter dia. were fabricated and installed on site
• Constructed 600 mm dia. suction and discharge FRAP lines from seawater circulation pumps
• New absorber and stack were erected using 400 Tonnes capacity crane

Project Value: US $ 1,060, 000.00
Project Execution Duration: 7 months (2002 – 03)
Manhours: 79, 927

FCCU Resid Processing Project for Bahrain Petroleum Company (Bapco)

Scope of Work:

• Demolition of existing structures, sheds, piping, equipment foundations
• Construction of new foundation sump pit and paving for new fresh catalyst hopper
• Fabricate, install structural steel
• Fabricate, install, test and commission piping systems
• Erection and alignment of new fresh catalyst hoppers and associated equipments
• Fabricate and install new stainless steel catalyst unloading line from Regenerator and repair existing catalyst and airline.

Client: Bapco
Location: Bapco Refinery

Project Highlights:

• Piping – 5, 890 inch dia. (4 systems)
• Structural steel – 36 Tonnes
• Blasting and Painting – 960 Sq. m
• Tie-ins during shutdown – 109
• Equipment installed - 10.

Project Value: US $ 950, 000.00
Project Duration: 5 months
Shutdown Period: One month
Manhours: 59, 380

ALBA Diversion of Bapco’s 6” Gas Line and 10” Water Line

Scope of Work:

Divert existing 6” gas line from BAPCO (US) to South ALBA Distribution Point (SADP) and the existing 10” irrigation water line from OKB to Riffa’a Golf Club to make way for the ALBA Line 5 Expansion Project

Client : Aluminium Bahrain
Location: Alba Line 5 Expansion Area

Project Highlights:

• Fabrication, installation, hydro testing of 2.5 km of 6” gas pipeline and 1.8 km of 10” water pipeline
• Installation of cathodic protection for the pipeline
• Third party inspection for all the pipeline materials
• Very tight project execution schedule of 17 weeks
• Project was executed within many constraints including coordinating with many parties including Bapco, Alba and Ministry Departments for work permits

Project Value: US $ 720, 000.00
Project Execution Duration: 5 months (2002 – 03)
Manhours: 32, 513 (zero NLTA)

Inline Blending Project for Bahrain Petroleum Company (BAPCO)

Scope of Work:

Construction of New In Lie Blending Plant including structural steel fabrication and erection, pipelines, piping, equipment erection and associated works

Client / Owner: JGC Corporation / Bapco
Project Value: US $ 4, 650, 000.00
Project Execution Duration: 12 months (1999 – 2000)

Project Highlights:

• Piping – 170, 000 inch-dia.
• Structural steel – 360 Tonnes (Painting – 4, 075 sq. mtrs)
• Fabricated and installed a piperack – 120 Tonnes
• Installation of 40 Heavy duty pumps
• Pressure testing of 620 piping systems