Download - Ensuring Results Aluminium
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Ensuring Results in
Aluminium Manufacturing
Engineering Supply
Results
Ensuring
Construction
Management
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How does ABB ensure results?
Weve learned to ensure the return on your
aluminium investment through constant
attention to yourtime, yourmoney
and compliance with your project needs.
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Whether youre building a greenfield plant,
extending an existing potline, or modernizing your
whole plant, decisions about everything from raw
materials and energy consumption to the final
product play a key role in ensuring the security, and
profitability, of your aluminium investmentand
energy, automation and information management
can make or break your investment.
More and more owners, producers,
suppliers, consultants and their engi-
neers are recognizing the value of
a single responsible source to oversee
these critical issues.
Regardless of how you decide to obtain
this single responsible source, your
investment can only be safeguarded
through an integrated approach to
engineering, supply, construction and
management (ESCM).
Few companies can deliver the
complete, quality product portfolio
for your electrical and control needs.Fewer still can combine this portfolio with qualified
project teams who are intimate with your processes
and can install the best equipment in a tailored
and optimal fashion. This not only safeguards, but
maximizes, the return on your investment.
ABB is qualified in aluminium. Along with our
broad product portfolio and ESCM approach, we
bring with us a financially secure, long-term global
commitment and the services that ensure your
start-up results are met, maintained and exceeded
for the life of your plant.
The pa yoff: profitable a luminium o perations.
ABB for on-time success
in aluminium manufacturing
With experience and responsibility.
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ABB met ISALs electrical engineering requirementsand the need to safeguard the voltage quality of
Icelands electric system. Moreover, ABB met a very
tight project completion schedule of just 18 months.
Operating around the clock, aluminium
smelters require extremely high reliability to
maintain a profitable operation. With ABB,
ISAL has achieved both.
Since 1969, Icelandic Aluminium Co.,
Ltd. (ISAL) has depended on ABB for
reliability and efficiency in delivering
high voltage smelting power.
In June 1997, ABB completed ISALs
third potline, a 135 kA, 770 V DC facility capableof producing 62,000 tons per year of aluminium.
To supply the 160 pots, ABB installed a 220 kV
switchyard; 33 kV and 21 kV switchgear; four
single-phase main transformers; 3-filter reactive
power compensating plant; and a thyristor
controlled rectifier station. Electrification by ABB
has provided ISAL with the most advanced DC
power system and control electronics available.
ABB helped ISAL address the challenges of its large
power usage. Combining the fast reaction time of
computer control with the dynamic characteristics
of thyristor-based rectifiers, the ABB control
system prevents the potential collapse of a small
grid caused by under-voltage or under-frequency
power. The energy consumption of the ISAL plant
totals 2600 GWh/a, nearly 50% of the annual
energy production of Icelands National Power
Company. ABB has not only been instrumental in
making the ISAL plant a reality, but has con-
tributed to the continuing electrification of Iceland.
ABBs reliable expertise
helped ISAL focus on
operati ng the day-to-day business dur ing constructi on,
whi le smoothly completing the expansion on schedule.
Leading producers look to integrated ESCM
Icelandic Aluminium Co. Ltd. (Alusuisse)
Mr. Rolf WrglerExpansion Project Manager
Alesa Alusuiss e Eng ineering LTD.
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Excellence in aluminium plant engineering depends on in-depth experience.
ABB uses a functionally integrated team approach to produce professional
engineering documentation, designing all required electrical interfaces with the
clients appointed consultants, engineers, and mechanical and civil partners.
Engineering design concepts are established early for guidance and
conformance during project execution. This integrated engineering delivers
maximum concept standardization with re-use design for multinational,
multilingual detail design teams.
Engineered standardization also generates benefits in terms of spare parts
inventories, simplified staff training and reduced maintenance expenditures.
ABBs engineering processes integrate your staff and other contractors
into the design and engineering teams.
The result is not only an efficient, low-cost start-up and commissioning,
but the foundation for optimum maintenance and support once production
is underway.
As a leading global manufacturer of industrial electrical equipment,
and the world's leading source for advanced rectifiers, we have an intimate,
working knowledge of the technologies that make up your plant. The
result is a level of end-to-end plant connectivity and efficiency that can only
come from designing the equipment we install. ABB is your single, responsible
source for your plant engineering and hardware needs.
The logistical challenges you face in coordinating local and international
procurement issues are immense, as equipment and services markets forthe aluminium industry globalize. ABB's wide range of products means that
you get your key equipment -- switchgear, rectifiers, transformers and
motors -- from one manufacturer, ensuring seamless connectivity from one
end of your plant to the other. And all your components will be designed
and manufactured to ABB's high standards of quality and reliability.
We then ensure safe and on-time delivery of the equipment to your plant
through our world-wide, integrated suite of supply services that includes
insurance, documentation and customs, forwarding and warehousing. And we
solve the challenges of bridging finance, bonds and investor guarantees,
which can be especially critical on complete plant projects that have executionperiods measured in years.
Engineering
Supply
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LVSw itchgear
MV- HVSw itchgear
Power Factor Compensation &Filtering
Power System Analysis
Emergency Power Plant
Large Fan Systems
High-current Rectifiers
Fixed &Variable Sp eed Drives
Control Systems (Open and Distributed)
Instrumentation
Process Optimization
Management Information Systems
Laboratory Systems
Cable Systems
Heating, Ventilation &Air Conditioning
Civil &Mechanical Interfacing
Fire Detection &Protection
Lighting &Small Power
Communications S ystems
Site Administration
Safety
Labor
Plant &Machinery /Tools
Supervision
Scheduling
Documentation Control
Functional Tests
Spec ial Tests
Performa nce Tests
Production Commissioning
Start-up &Acceptance
Proce ss Tuning &Optimization
Expediting
Inspection &Sho p Tests
Supply Management
Packing
Insurance
Certification
Customer Liaison
Quality
Quantity
Performance
Scheduling
Forecasting
Recovery
Resource Management
Budgeting
Cost Control
Power Distribution
Drives Applications
Automation Applications
Equipment Installation
Manufacturing & Supply
Quality Assurance
Buying
Shipping
Bridging Finance
Site Management
Erection
Supervision
Commissioning & Start-up
Time
Money
Compliance
Experienceand
Responsibility
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ABB focuses on helping our clients effectively manage their aluminium
projects in terms of contract compliance, time and money. From start to finish,
ABB applies modern, process-oriented methodologies. The smooth
transition from one project phase to the next is assured by your ABB project
managers attention to the communication and documentation
requirements of everyone involved.
The phase-to-phase interdependence that is a given in any project is
controlled by a project management team which ensures that engineeringdocuments flow methodically through the (procurement) phase into
construction, commissioning and operations.
At each stage, we manage risks, responsibility and warranty requirements
in strict accordance with our clients and partners safety and quality demands.
ABBs project oversight enables early recognition of potential issues and sub-
stantially mitigates the risks you face. It is the foundation for your targeted
return on investment.
Prior to delivery, ABB is establishing the site organization. Short, effective and
standardized procedures are planned for site supervision. Stores are organized for
incoming goods. Insurance, safety and transport matters are settled early.
Erection with skilled and unskilled labor places high demands on ABB site staff,
who are well-qualified to bring solutions in the most demanding situations.
With electrical equipment in place, ABB progressively energizes systems in
unison with mechanical and client site staff. As-built documentation is smoothly
integrated through to hand-over, optimization and routine maintenance.
Maintenance and operating staff are trained on ABBs latest technology,
empowering them to operate, service and optimize with confidence and total
competence. Support procedures are put into place, and hotlines to leading-edge
expertise are arranged.
Construction
Management
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Over the past 15 years Aluminium Bahrain (ALBA)
has grown to become the western worlds largest
producer of aluminium, powered by four power
stations producing over 1500 megawatts of
smelting power. ABB worked closely with ALBA
to modernize their existing Line 3 using a
pioneering hot revamp process. ABB also
electrified ALBAs 288-cell Line 4. Today ALBA is
producing over 500,000 tons of metal per year -
more than three per cent of the worlds supply - at
the lowest operating cost in the industry.
ALBA chose ABB for its long standing reputation
for technical excellence and wide range of
capabilities, including ABBs record of bringing
even the largest of projects in on time. ABBs hot
revamp process enabled engineers
to safely replace, commission and
test new rectiformers on Line 3
using live busbars. ABB also
played a major role on the 288-
cell Line 4, successfully bringing
in the project within budget andahead of schedule.
Modern aluminium facilities
like Aluminium Bahrain
require an increasingly complex
matrix of electrical control
technologies to efficiently and
effectively operate. ABB helped ALBA continue to
meet the worlds aluminium demand and the
Bahrain governments growing demand for energy.
The close partnership between ABB and ALBA
created a hand-in-glove working atmosphere
that allowed ALBA to meet all their production
goals safely and cost-effectively.
ABBs experience, cooperative
approach and abi li ty to
coordinate people and events helped Aluminium Bahrain
deliver potl ine 4 ahead of schedule and within budget. Thei r
equi pment and work on Lines 3 and 4 has made it possible for
ALBA to meet i ts power needs and provide a 270 megawatts
to the national power gri d.
ABB demonstr ated a hi gh degree of ski ll in managing thi s
very large project. ALBA and ABB created and maintained a
producti ve atmosphere, resul ting in the essent ial teamwork
that helped Alumi nium Bahrain become the most efficient ,
low-cost alumi nium smelter i n the worl d.
for results in aluminium manufacturing.
Aluminium Bahrain B.S.C.
Mr. A. Karim SalimiAct ing Chief Executive Officer
Aluminium B a hrain
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Aluminium leaders recognize
Engineering
Construction
Management
Supply
ABB specializesi n bringing process-based, large
project experti sewhen buildi ng integrated
electrical, automation and information manage-
ment solutions for the aluminium industry.
ABBscomprehensive ESCM approach ensures
start-up resultsby combining internationally sup-
ported resourceswit h single-sourceresponsibili ty.
Operating results grow year by year
when electrical installati onswith standardized
engineering conceptsare harmonized with
operating procedures.
ABBscommit ment to ongoing support with
regular investments in new, open technologies
builds security for thef uture.
ABB masters the crit ical elementsof ESCM
int egration with a team of experienced aluminium
industry engineers.
Responsible team leaders havetheproduct, process
and servicesknowledgedeveloped from hundredsof
successful installations.
ABBsproject teamst ailor the optimal
electri fication packagewit h int egrated engineering,
supply, construction and management activit ies.
Int erdisciplinary client-supplier teamslearn to
unleash the real power of ESCM i ntegration work-
ing hand-in-hand toward start-up results.
Maximize alumini um manufacturi ng
profits with in tegrated electr ical solutions.
Include ABB in your interdisciplinary
investment teams.
Let ABB take responsibil i ty and
deliver results.
ABB ensures results in alumi nium
manufactur ing through
constant attention to time,
money and compliance with
the world-leading ESCM approach.
the power of integrated ESCM.
Results
Ensuring
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