Djebel Ressas: A complete EPC and O&M project takes shape

Djebel Ressas: A complete EPC and O&M project takes shape Carthage Cement, one of North Africa s foremost cement manufacturers, commissioned FLSmidth to develop Djebel Ressas, Tunisia s largest and most
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Djebel Ressas: A complete EPC and O&M project takes shape Carthage Cement, one of North Africa s foremost cement manufacturers, commissioned FLSmidth to develop Djebel Ressas, Tunisia s largest and most technologically advanced cement plant. The client was extremely keen on having the best possible expertise for the project and agreed that FLSmidth would be responsible for a wide range of machine and equipment delivery, as well as for project co-ordination and operation and maintenance. 2 HIGHLIGHTS October 2011 Djebel Ressas: an EPC project begins Read more about FLSmidth solutions at PART 1 CONTACT SANDRA PIHL HEISE Expertise from the ground up HIGHLIGHTS October BIG NUMBERS THE ENTIRE PROJECT CALLED FOR 10,000 TONNES OF STEEL AND 100,000 CUBIC METRES OF CONCRETE. Creating the 5,800 tpd Djebel Ressas cement plant was an enormous undertaking. The project covers over 220 hectares in a southern suburb of the capital, Tunis, and adopts the latest energy-efficient technology. Its construction involved hundreds of highly specialised professionals and required thousands of hours of meticulous planning, precision engineering and labour. We paid particular attention to adopting the latest technology, high economy of energy consumption and great respect for the environment, said Mr Lazhar Sta, CEO of Carthage Cement. Djebel Ressas strategic location enables enable Carthage Cement to supply the greater Tunis area, representing 50% of the national demand, including export markets. It will also contribute significantly to economic and social development throughout the region by generating 400 to 500 direct jobs when the plant is operational, as well as additional jobs with subcontractors. One company one solution To complete the project, FLSmidth teamed up with the experienced Turkish contractor, EKON. The client selected FLSmidth as the supplier of machinery and engineering for the new plant and EKON was given responsibility for civil design, supply of structural steel and plate work, site preparation, civil works and plant erection. Throughout the project, FLSmidth made sure of consistently high standards, integration and, ultimately, substantial time and cost savings for Carthage Cement. The value associated with this One Source strategy and FLSmidth s successful track record were two important factors for Carthage Cement s shareholders. The successful introduction of Carthage Cement on the Tunis stock market revealed that these were also critical factors for other investors, as the Carthage Cement stock remained stable at a high valuation even during and after the unrest in Tunisia. The project also involved a complete operations and maintenance (O&M) contract, designed to facilitate an optimum transition from construction to production and guarantee high performance on a longterm basis at the lowest possible cost. Our O&M contracts are run by some of the best engineers in the industry and offer a fully sustainable model for a plant s ongoing success. They encompass every aspect of a plant s management to give customers complete peace of mind that their operations are being run as effectively and profitably as possible. Efficiency and transparency Right from the outset, FLSmidth was able to efficiently move the project ahead thanks to an approach to project management that centres on regular customer contact and open dialogue. FLSmidth project managers were involved from a very early stage even at initial customer sales meetings. As Sandra Pihl Heise, project manager for FLSmidth, points out: Once the sales process had been completed we brought together all the key points of contact in FLSmidth who would be coor dinating the different phases of the plant s 4 HIGHLIGHTS October 2011 ENGINEERING GENERAL ARRANGEMENT BASIC MAIN DET ENGINEERING Planning for the plant required between 12 and 15 thousand engineering drawings The cement mill shells weigh 152 tonnes each The big ge the raw mi 103 to FLSMIDTH PROJECT MANAGEMENT Kick-off meeting CONTRACT EFFECTIVE MAY 2010 PROJECT STAGES STAGE 1 LEVELLING Buildings Employees Machinery Utility Roads MOBILISATION CIVIL WORK EXCAVATION Just to level the area (exclusive of foundation work) cubic metres of 490,000 earth was moved 7 kilometres of roads have been built FORM WORK A total of 6 kilometres of water pipes The en 10, 100 HIGHLIGHTS October AILED PURCHASE MANUFACTURING ar for ll weighs nnes The storage area for parts and supplies measures m 2 - equivalent to the size of 6 soccer fields SHIPMENT STAGE 2 STAGE 3 ERECTION COMMISSIONING STEEL STRUCTURE CASTING REINFORCEMENT tire project calls for tonnes of 000 steel and cubic metres of concrete,000 The preheater tower will be metres high, the same 94 height as the Statue of Liberty Currently more than 700 workers are employed at the site, with about 25 more to be hired each week. At peak, there will be around 1,800 employees on site A dozen cranes of various types are available on site 6 HIGHLIGHTS October 2011 BIG NUMBERS THE PREHEATER TOWER BUILDING WILL BE 94 METRES HIGH, THE SAME HEIGHT AS THE STATUE OF LIBERTY; THE PREHEATER TO THE TOP OF THE CYCLONES IS 120 METRES HIGH. development. This meeting involved many different people from all departments and proved to be a highly effective way to outline targets, set responsibilities, agree upon timelines and begin detailed planning, including finance, logistics and HR functions. A following project meeting with Carthage Cement and their advisor PEG was set up where everything was carefully discussed and debated, and exact specifications were agreed to, with room for flexibility should anything unforeseen occur. Engineering, planning and civil work The planning stage of any project is always lengthy and detailed, Sandra continued. However for the Djebel Ressas plant there were an especially large number of factors to be considered, ranging from the macro (what capacities were appropriate, which equipment should be used) to the micro (how many filters and bolts were needed) and everything in between. Planning for the plant required between 12 and 15 thousand engineering drawings and several hundred different people contributed to the design, drawings and specification of machinery. The overall layout of the site and all civil work was also agreed upon in detail down to how many lamps were needed to light up the complex at night. This planning set the stage for actual site mobilisation and civil work on a scale one would normally associate with building a town, encompassing roads, utilities and preparation of the plant site. Worker housing (for around 1,000 employees at the peak of construction not including 800 more who will be bussed to the worksite), canteens, offices and warehouses were put up and plant equipment began to be shipped in and stored. A fleet of trucks worked day in and day out unloading equipment and supplies into a storage area equivalent to the size of six soccer fields. A total of 490,000 cubic metres of earth had to be removed just to level the area, exclusive of foundation work for the plant. Infrastructure was a major undertaking, including seven kilometres of roads and a total of six kilometres of water pipes. Next came preparation for construction of the plant, including excavation and form work, followed by reinforcement, casting the foundation and raising the plant building s steel structure. BIG NUMBERS THE GEAR FOR THE RAW MILL WEIGHS 103 TONNES, AND THE CEMENT MILL SHELLS WEIGH 152 TONNES EACH. Purchasing and manufacturing As part of the planning process, the managers of each department collaborated to create what was essentially a long shopping list that outlined everything that would eventually be needed to build the plant. This shopping list was handed to a specially appointed manager of FLSmidth s purchasing department, whose task was to ensure that the most appropriate, highest quality and best-priced components would be sourced from global vendors or, if possible, manufactured in FLSmidth s own proprietary workshops worldwide. HIGHLIGHTS October A TOTAL OF 490,000 CUBIC METRES OF EARTH HAD TO BE REMOVED JUST TO LEVEL THE AREA, EXCLUSIVE OF FOUNDATION WORK FOR THE PLANT. As a global group, FLSmidth was able to secure highly competitive prices from vendors in a variety of countries, including Germany, China, Finland, France, Poland, India and Brazil all on the basis of an agreed vendor list. Throughout the purchasing stage, Carthage Cement was kept fully up to date with monthly progress reviews. Even though there were thousands of individual components being assembled in many different workshops across the globe, FLSmidth performed regular inspections to ensure a consistently high standard was met. Carthage cement also participated in inspecting main items of equipment. Shipping and transportation Much of the plant consisted of extremely large, heavy and complicated parts (the raw mill alone weighs 600 tonnes and comprises of thousands of individual components), requiring experienced professionals who have specialised knowledge of both the equipment at hand and the methods of delivery. All transportation of equipment or materials from the vendors to the site was done by sea with equipment shipped from 20 different harbours. About 75 full shiploads bulk and 400 containers was needed for the complete plant. FLSmidth s shipping teams work meticulously to ensure that everything is delivered safely, securely and on schedule just a day s delay at one end of the supply chain can cause a series of setbacks further down the line. Carthage Cement was regularly updated with tracking reports, delivery times and confirmation of the safe arrival of key components. Constant contact A crucial element that supported the successful first stage of the Djebel Ressas project was FLSmidth s use of MyFLS TM, an intranet system that enabled everyone involved in the project to quickly and easily access any drawing, itinerary, plan or agenda. If changes were made to a document, no matter how large or small, the relevant people were instantly alerted via update reports. In addition, regular face-to-face meetings often on site and detailed monthly reports featuring photos of all progress enabled Carthage Cement to see the exact status of each part of the process. BIG NUMBERS THE PROJECT REQUIRED SEVEN KILOMETRES OF ROADS, SIX KILOMETRES OF WATER PIPES AND 800 KILOMETRES OF ELECTRICAL CABLES. 8 HIGHLIGHTS April 2012 Djebel Ressas: Installation begins In June 2011, just over a year after the contract with FLSmidth became effective, Stage Two began for Carthage Cement s new state-of-the-art cement plant in Tunis. Keeping track and making progress As construction began for the Djebel Ressas project, almost 500,000 cubic metres of soil had to be excavated and moved and steel structure and concrete made ready to support the many tonnes of equipment needed. The equipment was stored in a 42,000 m 2 storage area, which was secured and tightly controlled. As well as the huge pieces, such as the gears and mills, there were also many thousands of pieces that only weighed a few grams or kilos. Each had to be meticulously documented and organised as they each formed an important piece of the entire complex. FLSmidth design drawings Some of the larger pieces of equipment are being assembled on site, which means that the FLSmidth design drawings are being studied carefully every day to make sure everything is assembled and installed according to strict specifications. Nine tower cranes are needed to lift and assemble the machines. Balancing huge equipment and fine alignment Precision is key in plant construction and supervisors from EKON were on site to make sure the installation went as scheduled. PART 2 CONTACT SANDRA PIHL HEISE HIGHLIGHTS April BIG NUMBERS 13,500 TONNES OF MECHANICAL EQUIPMENT AND 7500 TONNES OF STRUCTURAL STEEL ARE BEING INSTALLED. Read more about FLSmidth solutions at There is little room for error as the engineers are often working with tolerances of less than 1mm. For example, the kiln supports are aligned within + / 0.2 mm. The balance between the huge equipment and the really fine alignment that is necessary is what makes plant installation exciting, explains Kent Almar, Chief Mechanical Supervisor at EKON, FLSmidth s partner in this project. Installing the kiln involves the very precise alignment of a really large, heavy machine. One kiln roller weighs 30 tonnes plus an additional 350 tonnes from load when in operation. During installation, the inclination of the kiln roller is adjusted with a tolerance of between 0 and 0.2%. This will ensure the smooth operation and long lifetime of the mechanical parts. exactly where each cable must be placed. There is a place designated for every individual cable in the FLSmidth design. Inspection and testing It is not only the large machines that are inspected and controlled the small machines, conveyors and filters are also inspected by the supervisors and the assembly must be signed off. At FLSmidth, as part of the Final Acceptance Test, all the control and communication systems are being assembled and the connections tested. Process and engineering experts from FLSmidth work together with the client to make very sure that any errors or shortcomings are corrected before the whole system is packed and sent to the site. Cable control The mechanical construction is a large, time-consuming job. But once this is done, the installation process is still only half complete. All the machines need to be connected to electricity, both to distribute power to the entire plant and also for the communication cables, so that all the equipment can be centrally controlled from the control room. Approximately 800 kilometres of electrical cable need to be pulled through underground corridors. FLSmidth supplied precise plans detailing which cable must be used for each machine and SCAN HERE FOR VIDEO ON DJEBEL RESSAS' DEVELOPMENTS SCAN HERE FOR PART 1 ARTICLE ON THE DJEBAL RESSAS PROJECT 10 HIGHLIGHTS April 2012 ENGINEERING GENERAL ARRANGEMENT All systems are inspected and tested by the customer together with FLSmidth inspectors Basic Main Detailed INSPECTION & TESTING FLSMIDTH PROJECT MANAGEMENT Kick-off meeting CONTRACT EFFECTIVE MAY 2010 PROJECT STAGES Shipment STAGE 1 STAGE 2 Stage 2 is well underway at Djebel Ressas. Based on FLSmidth engineering, a team of experts is managing the on-site fabrication and installation of this enormous plant and the mechanical, electrical and control and instrumentation works are being installed. STEEL STRUCTURE CASTING Equipment is stored in a 42,000 m 2 storage area, and tight control of the stock is crucial. Pre-assembly for mechanical installation started in June 2011 and is now around 15% complete. REINFORCEMENT FORM WORK EXCAVATION PRE-ASSEMBLY LEVELLING CIVIL WORK EQUIPMENT STORAGE INSTALLATION HIGHLIGHTS April STAGE 3 During installation, the inclination of the kiln roller is adjusted with a tolerance of between 0 and 0.2%. Of the 1,217 people on site, 528 are involved in mechanical installation. Approximately 800 kilometres of electrical cable will be pulled through underground corridors. COMMISSIONING ELECTRICAL INSTALLATION MECHANICAL INSTALLATION ALIGNMENT 12 HIGHLIGHTS October 2012 SITE REPORT Djebel Ressas: Preparing for O&M Our flexible operation and maintenance (O&M) contracts enable us to integrate world-class operations and management with our customers own capabilities to build high performing organisations focused on sustainability, quality and profitability. Guaranteed production How do cement plant owners ensure that their new plant gets up to specified production as quickly as possible? How do they attract, recruit and train the right personnel and manage it all effectively? What is the best way to effectively maintain the plant? These questions can be resolved by an O&M contract. Carthage Cement signed a contract with NLSupervision, part of the FLSmidth Group, for the O&M of Djebel Ressas, including a guaranteed production for five years. This O&M contract means that FLSmidth is committed to ensuring the efficient operation of Djebel Ressas and to maintain it in premium condition for five years. There is significant value in an O&M contract for the customer. Apart from the obvious benefit of a guaranteed production PART 3 CONTACT SAMIR IDRIS HIGHLIGHTS October capacity NLSupervision guarantees to meet 1.8 million tonnes of clinker per year at Djebel Ressas, including the very first year there are the additional benefits that come from the technical and commercial expertise that an experienced O&M company offers. This is particularly helpful in the case of Carthage Cement, a relative newcomer to the cement industry in Tunisia. Set up and implementation NLSupervision specialises in offering everything needed for the successful setup and implementation management, operation and maintenance of a cement plant. At Djebel Ressas, this means that the NLSupervision team is on site, carrying out preparatory setup and implementation work before the Provisional Acceptance Certificate (PAC) is signed. During this time, the contractual responsibility still lies with the project and commissioning team but once the PAC is signed after commissioning is complete, then NLSupervision will take over full responsibility for running the plant and the five year contract begins. The preparatory stage is very important; NLSupervision ensured that everything was in place before the PAC and ready for when the plant begins operation. Under the contract, NLSupervision is responsible for supplying everything required to operate a cement plant, including spare parts, consumables, safety clothes, and maintenance programmes as well as lots of other things, which will all help to guarantee maximum operational stability. Ground-breaking IT setup One of the first tasks for NLSupervision after the contract was signed was to set up a local subsidiary in Tunisia called NLSupervision Tunisia, which is owned by NLSupervision. This is the first NLSuper vision office of its kind to be fully integrated with the FLSmidth IT system. This setup essentially means that the IT infrastructure at NLSupervision Tunisia enjoys total compatibility with the IT facilities used at FLSmidth headquarters in Copenhagen. This has some great benefits: everything runs more smoothly due to the standardisation of equipment and software licenses, and workers in Tunisia receive the exact same IT support as if they were sitting in Denmark. This IT integration has also helped to give the employees at Djebel Ressas a sense of being part of the wider FLSmidth Group. The computerised maintenance system, Maximo, which is a key tool for the efficient running of the plant with all vendor documents stored in the system, informs the maintenance manager exactly when maintenance has to take place on all the equipment. Maximo also holds important information about the stock that needs to be in the warehouse and when and what needs to be purchased for the plant to run smoothly. 14 HIGHLIGHTS October 2012 ADMINISTRATIVE NLSupervision NLSupervision Tunisia creates two main administrative systems: Human Resources and Finance. Careful preparation ensures that all policies are in accordance with regulations in Tunisia. Local senior advisor hired with 35+ years of experience in the industry NLSupervision Tunisia local office is established in Tunisia The General Services Supervisor ensures all office fittings are in place Staff in Tunisia enjoy the same IT support and software as at HQ in Denmark All HR policies are in place, in line with Tunisian work regulations, including: - Payroll - Benefits - Training - Working environment HR manager recruited HUMAN RESOURCES TECHNOLOGY O&M contract - signed O&M DEVELOPMENT CONTRACT EFFECTIVE MAY 2010 LOCAL OFFICE SETUP & IMPLEMENTATION A key tool for maintenance, Maximo, is also fully integrated with HQ FLSmidth / EKON The NLSupe
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