Over 2014, Fives upgraded the two Gas Treatment Centers at the Alba Line 5 in Bahrain. This project was established as a major challenge for Fives’ teams, from the engineering studies in Franceto the turnkey implementation of the solutions on site.

As part of its Line 5 pot amperage increase,Alba has awarded Fives with a contract to modifythe two Gas Treatment Centers supplied in 2005,in order to comply with gas and alumina flow rate increase. The contract consisted of the supply and installation of one additional exhaust fan including existing duct modification, new airlifts installationand the replacement of the existing fan impellers. This project has been executed in collaboration

with Fives Middle East in Dubai andFives Services Gulf based in Bahrain,that provided assistance for the local sub-contracting and site construction.Among the major challenges faced, was the simultaneous deployment of over100 Fives’ sub-contracted personnel at the GTC yard area which is actually considered part of Alba potline 5. Alba expects zero tolerance in non-compliance on its safety standards; hence arranged intensive training on safety induction,on awareness of potroom hazards (DC hazards), on working in confined spaces as well as working at height for all Fives’ personnel. Alba‘s strict requirements on 100% compliance to usage of personnel protective equipment like HF masks, fire retardant clothing were fully met during the project execution.On the way ahead, another big challenge was executing the project when pots were in operation. Installing new equipment for the upgrade called for shutting down the whole GTC. Alba’s team and Fives’ site management team had to therefore call for well-planned and coordinated GTC shutdowns so as to achieve maximum installation work within short periods. Moreover, as the existing plant was ten years old, replacing a piece of equipment by another one was not as simple asit seems. Especially because the main pieces of ducts were 10 m long and had to be handled at a height of 20 m, between two potlines where space was congested and limited. Safety analysis,

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ALBA - GTC 3 & 4, A SUCCESSFUL PROJECT

I N T E R V I E W

Health, Safety and Environment are among the main objectives of the Group to focus on when executing projects all over the world. Today, Fives aims at moving towards a strong safety culture shared by each and everyone, and at continuing along path of progress achieved over the past five years. The presence of a HSE coordinator helps us to put HSE on top of our priorities. Audrey Duport has been working as HSE Coordinator for the Aluminium business line for two years. She answers three questions to explain her role within the organization.

What is the mission of the HSECoordinator at Fives?My role is to ensure that, at the end ofa working day, Fives’ employees and our contractors are as fit and healthy as when they started it. To reach this objective, we first need to comply with any applicable regulations, standards and best practicesand to ensure that we meet all our customers’ requirements. I work in collaboration withour Managers and staff in defining and implementing adequate control measuresfor the activities under their responsibilities. Our HSE management system has been completely revised by using the principlesof the OHSAS 18001 international safetystandard. In the past few years, many procedures have been reviewed to ensure better control of our site activities.For instance, a yearly audit planning has been set to make sure that regular HSE audits are carried out on all our projects. Practical actions have been taken: integrating HSE supervision for night shift personnelon site, implementing safety awards for

individuals on site and modifying the design of some pieces of equipment for safety purposes.Last year, we completely reviewed our standard construction HSE plan to be upto date with the latest best practices and to ensure a better control of site activities. This revised plan has been implemented on the GTC modification project for Alba 5.

Can you tell us more about Fives’ ambition in terms of safety?During the past few years, we have worked with clients renowned for their high HSE policy. Being in contact with these clientson a daily basis has been a very valuable experience for our teams. We have mettheir expectations and achieved excellent safety records. Our ambition is to become fully independent from our customersto reach equivalent standards, whatevertheir expectations are. Our zero-accident policy must not be an objective but rathera certainty whatever the context of the project is.

How is safety integrated in all phasesof a project?At the very early stage of the project, the commercial team takes into account safety requirements in its offers including forrevamping and expansion projects. Safetyis also one of the main criteria to select our construction and commissioning contractors. When the contract is awarded, Fives defines a project specific HSE construction plan that includes local statutory, existing constraints and client’s requirements. It draws up in details what the HSE organization will beon site.This construction HSE plan is then passedon to the Site Manager and HSE Manager before the construction phase starts, in order to ensure that they are both aware of their responsibilities and familiar with the rules and procedures to be applied, including the emergency protocol specific to the project. This plan will evolve as the project moves on. At the end of each project, Fives’ management team reviews the safety performance and feedbacks from the site team. This process is essential to ensure that all deficiencies will be corrected for the next projects and to identify what must be reproduced to reach optimal safety performance.HSE is a continuous improvement process.

SAFETy AT FIvES, A DrIvEr OF OPErATIOnAL ExCELLEnCE

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FIVES GOOD NEWS FOR YOU, the newsletter of Fives Solios SA – 25-27 boulevard de la Paix – 78100 Saint-Germain-en-Laye France – Phone: +33 (0)1 30 87 45 50 – Director of Publication: Hugues Vincent – Editor: Alain Périers – Editorial Committee: Thierry Allegrucci, Stephen Augostine, Bernard Cloutier, Bijan Cour – Writers: Hélène Bachellerie, Fabienne Virieux – Thanks for their collaboration: Lee Allen, Pasquale Calo, Mamak Chiron, Audrey Duport, Mathieu Frainais, Hien-Tin Huynh – Execution: Christophe Cocquet – Printing: TPI - 34, rue Jean-Lefèbvre - 95530 La Frette-sur-Seine – Registration of copyright and ISSN: 2109-280X. Printed in 500 exs.

EditorialAfter several years of primaryaluminium production overcapacity, the demand in 2014 has finally exceeded the supply, the stocks have decreased and the metal price has started to increase. This situation suggests some improvements in the 2015-2016 horizon and new investments may emerge. However, in 2014, the aluminium producers mainly focused on reaching full capacity in their new smelters oron improving overall efficiency in their existing installations. In this context, Fives mostly received contracts for equipment modifications and services. The revamping of GTC 3&4 at Alba 5,in Bahrain, was a successful project despite the challenge in terms of schedule and site conditions. Fiveswas also engaged in the final execution and commissioning of the Hindalcoand Vedanta smelters in India, while completing the Rusal Boguchany smelter construction. As a supplier of pioneering technologies, Fives has further enhanced and marketed Genios, its electromagnetic metal moving system. Fives’ commitment and strength to fully assist and proactively help its clients to maximize the performanceof their industrial plants in operation has been further demonstrated. As a key lever for the Group’s opera-tional excellence, Safety is at the heart of Fives’ corporate social responsibility and HSE management is becomingfully integrated into our project execution process. Lastly, in 2014, all companies of the Aluminium Division of Fives have been renamed and now present their offer under the Fives brand. Hugues Vincent, C.E.O. Fives Solios

newsletter - March 2015

Aluminium

What’s new in Aluminium?

Gas Treatment Center

13,000,000 man-hours without LTIrespectively at Ma’adenand Qatalum

Audrey DUPORT

IN BRIEFOn 1st January, 2015, Solios Carbone and Solios Environnement SA in France merged and changed their company name to Fives Solios SA. Similarly Solios Thermal in the UK and Solios Environnement Inc in Canada were respectively renamed Fives Solios Ltd and Fives Solios Inc. Our services subsidiaries in Bahrain and South Africa were respectively renamed Fives Services Gulf Spc and Fives Services Southern Africa Proprietary Ltd.Visit our website www.fivesgroup.com to know more about the Aluminium business line.

T E C H N O LO G Y

CO N T R ACTSFO C U S

work coordination and timing had to be taken into consideration from the early stage ofthe project. At the office in France, all the construction steps were carefully plannedby engineering teams according to a strict erection methodology from the design of each piece of equipment. This on-site preparation resulted in the erection of the new duct in less than four hours, thus generating a minor interference in plant operation. This time included the cutting ofa 4 m x 2.5 m hole into the main duct to

In January, 2014, Genios, the latest generation of electromagnetic metal moving system developed by Fives, was awarded the Engineered Sustainability® label. This is a label delivered by the Executive Innovation Board of the Fives Group following a thorough and succesful evaluation of best-in-class products in terms of environmental perfor-mance. It demonstrates Fives’ commitmentto reduce the environmental footprint for both the Group and its clients. Genios is an innovative and cost-effective technology which is the only solution that allows customers to stir and cast with the same system. From a single unit, it can stir metalto aid melt rates, alloy dissolution, submerge light weight additions, reduce cycle timesas well as energy consumption and transfer

In the beginning of January 2015, Emirates Global Aluminium (“EGA”), with the supportof SnC Lavalin International Inc. (“SLII”) as EPCM, awarded Fives with a turnkey contractfor the supply of one xelios and one anode cooling tunnel, as part of a project to revamp the Green Anode Plant Line 2 at EGA Jebel Ali, Dubai (the site of EGA operating subsidiary Dubai Aluminium, also known as “DUBAL”). This revamping project forms part of the «Larger Anode» project to meet the pot requirement in connection with amperage increase.

Fives has the ambition to fully assist and proactively help its clients to maximize the performance of their industrial installations during operation by developing life cycle partnerships. Our four service subsidiaries located in Southern Africa, in the GCC, in

connect a 6-ton additional ductwork to the existing one. replacing the existing fans impellers was also a critical step, the team having to deal with their size and the lack of space in the area. The scope also included an airlift designed by Fives.In accordance with Alba requirements, the production has never been impacted by the various interventions carried out on the GTCs. Alba’s team was really impressed by the work methods put in place by Fives who reached 118,000 hours without any Lost Time

Injuries at mid February 2015. In addition to the awarding of a Safety Award, the team was invited to present its Job Safety Analysis method to the Alba Board last January.This great achievement is the result of the combination of various factors includinga good HSE preparation, an excellent engineering job during equipment design,the complete mastery of fabrication anda perfect site organization that has led tothe success of this complex and challenging retrofit project.

metal to casting machines at a rate of up to 30 tons per hour.As demonstrated through the work achieved during the eco-design process, Genios is a solution combining industrial performance with sustainable development. This technology requires a minimal amount of energy to obtain a high level of alloy homogeneity: typically 20% savings on cycle time,10% on gas consumption compared to manual techniques, and 50% on electricity consumption compared to comparable electromagnetic solutions.It offers steady, controlled flow rates when transferring metal, it leads to a 15% decrease in metal wastage compared to mechanical transfer pumps and the typical dross production is reduced by 10% when compa-red to conventional furnace operations.In addition, this equipment is easy to install and use, with limited requirements for civil works or downtime for maintenance. Genios improves operator safety - as thereis no need for conventional tap out systems or mechanical pumps, thus allowing the operator to control the transferring function remotely via an operator screen. In the casting configuration, the patented casting sled system means that metal is transferred in a controlled way with low turbulence.In the event of a cast abort or power failure, metal transfer is immediately stopped, making the system extremely safe.The two contracts received in 2014 confirm the breakthrough position of the Genios

technology. The first application was on a 60-ton existing Holding Furnace in order to improve throughput with the objective of producing alloys in the future. This technology was selected for its safe and reliable stirring capabilities, its low energy consumption and its easy installation on existing furnace. At the end of 2014, a second producer selected this technology as part of an upgrade project. Two Genios will be mounted on two existing static furnaces, with a common control system and cooling unit; they will be used both for stirring and casting metal.These successes are a further indication of the market potential for GMAG, a new type of furnace developed by Fives. It consists ofa high efficiency low weight static furnace, incorporating Genios for stirring and casting. GMAG will be offered in lieu of tilting furnaces to reduce CAPEx and footprint.

The contract awarded to Fives entails replacing the existing vibrocompactor and cooling tunnel supplied by Fives in 1995, during the first project to revamp this line. This time, Fives will supply a xelios 2.0(the latest generation vibrocompacting machine), equipped with DynpacrT

(a real-time compaction controller). Tray conveyors of the cooling tunnel will be replaced by a chain conveyor.The production of the first anode is scheduled for December 2015, with a maximum 6-week shutdown of Line 2.

China and in India provide our geographical customers with direct support, includingafter-sales service and technical assistance.Thanks to this worldwide network, Fives has been collecting an important feedback of its installed base, promoting both the continuous improvement of the equipment and the increase of service quality. In order to extend the technical expertise easily accessibleby its clients, with an improved proximityand reactivity, Fives has deployed specific training programs to these local subsidiaries and has increased the amount of resources dedicated to services. A specific methodology has been applied to meet clients’ needs in

both their normal routine tasks, modifications and upgrading projects. The approach is based on the definition of Key Performance Indicators (KPI), including target values with tolerance range, corrective and/or preventive actions as well as service added value with measurable indicators. The proposed range of services includes process and maintenance audits, punctual or long-term assistance, training and any highly skilled intervention upon clients’ requirements.Fives is convinced that such a collaboration fosters proximity and mutual trust and will help clients to better operate, optimize and evolve their plants.

GEnIOS, A PIOnEErInG TECHnOLOGy FOr METAL STIrrInG, SUBMErGInGAnD CASTInG

EMIrATES GLOBAL ALUMInIUM

SErvICES EnSUrES PErFOrMAnCE DUrInG THE LIFETIME OF InSTALLATIOnS

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Genios

Xelios

ALBA - GTC 3 & 4, A SUCCESSFUL PROJECT (continuation)

P R O J E C T S U N D E R E X E C U T I O N

In 2014, both Indian producers, Hindalco and vedanta, finalized the start-up of their new smelters located in India.Fives successively commissioned the Firing and Control Systems on one furnace at the Mahan smelter and on two furnaces at the Aditya site. The Firing and Control Systems were also started up on the first furnace at Korba. A total of 8 fire groups were put into operation in India in 2014.

Following the production of the first anodein Mahan at the end of 2013, the Aditya Green Anode Plant was commissioned in March 2014. At the end of 2014, the firstGas Treatment Center at the vedanta/Balco smelter was operating at 50% of its capacity, while the second GTC was completed.These projects were implemented in collabo-ration with Fives India, the Engineering subsidiary of the Group in India.

InDIA

At the beginning of 2014, Fives and rusal, signed an acceptance certificate for filter steelwork casings installation at the Boguchany Aluminium smelter (BoAZ) in russia. The

installation of the GTC is completed and a planning for commissioning was agreed by both parties at the beginning of 2015. Fives was responsible for the design, supply, site assis-

tance for erection and commissioning of the two Gas Treatment Centers (GTCs). Fives vostok, a russian subsidiary of Fives, was in charge of the site assistance, including training.

rUSAL BOGUCHAny

Gas Treatment Center

Gmag