ensuring results aluminium

8/13/2019 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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ensuring results aluminium

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