XERVON - Professional services for the process industry
Transcrição
XERVON - Professional services for the process industry
A magazine for XERVON customers www.xervon.com 1/2012 up²date XERVON – PROFESSIONAL SERVICES FOR THE PROCESS wn Shutdo Full gement Mana Service INDUSTRY gy Technolo M aintenance Surface Scaffoldin g Insulation Latest news XERVON is part of the REMONDIS Group and, therefore, of a strong network Piping Services Surface protection work on four new frigates at three different shipyards – not a problem for XERVON reservation gP Buildin People Supporting future talent with cooperation work and grants up²date 1 | 2012 Contents Welcome to REMONDIS Priority given to nature conservation Experts in many fields XERVON has been part of the REMONDIS Swallows' nests posed a particular challenge Electrical & instrumentation engineers must be Group since the end of 2011 – adding to and during a project to renovate the “Donnerschleuse” able to do many things and one thing in complementing its range of professional road bridge. Page 12 particular: they must have a talent for maths industrial services. Page 6 for this demanding job. Page 20 Latest news 4 XERVON – professional services for the process industry 6 REMONDIS – a successful service provider steeped in tradition Services 10 Protecting the surface of new frigates 12 Bridge renovation work in a lifejacket and lifeboat 16 Expertly equipped 18 Ruwais: on the way to becoming a major petrochemical complex People 20 Electrical & instrumentation services: a talent for maths is a must 23 Creating the future – together with universities and institutes Imprint Published by: XERVON GmbH // Theodorstr. 180 // 40472 Düsseldorf // Germany Tel.: +49 211 54242-600 // Fax: +49 211 54242-950 // www.xervon.com // [email protected] Edited by: Corporate Development/Marketing XERVON GmbH Print-run: 17,000 Design by: www.atelier-14.de // Printed by: Lonnemann, Selm, Germany Editorial Dear Readers! Most of you are already aware of the fact that the sale of We are convinced that we will continue to steadily develop ThyssenKrupp Xervon GmbH was completed on 30 Novem- and grow within the REMONDIS Group and by doing so ber 2011 following the resolutions of the company boards further extend our services for your benefit. As a result, we and the official approval from the merger control authorities. will not only be safeguarding the future of the company but As a result, XERVON has been a part of the REMONDIS also the future prospects of our employees. Group since the end of 2011 and is being run under the name XERVON GmbH in Germany. We would also like to give you, our customers, the assurance that you will continue to have a strong partner at REMONDIS' division for industrial services, which has your side that can master projects – no matter how small a turnover of around 1 billion euros, now consists of the or large they may be. Your contact people shall remain the Buchen Group and XERVON. XERVON is an excellent same and they shall continue to offer you the usual compe- strategic addition to this division both from a national and tent and reliable support. international point of view. This edition provides a detailed introduction to XERVON's XERVON shall continue to be an independent brand name new owner. However, you will also, as always, be able to and this can clearly be seen by the company's new logo that read about the company's exciting and successful projects. has already been implemented throughout the company. We hope you enjoy reading this edition of up²date! Hans-Dieter Behrens Olaf Karrass Carsten Lange Andreas Oellerich Andreas Rittel up2date | 3 Latest news Industrial services Professional services for the process industry Industrial customers benefit from having all services provided by just one company Following the closing of the transaction on 30 November, XERVON became part of the REMONDIS Group with retrospective effect from 01 April 2011, making the group the first fully integrated service Individually or combined: our services for your success log y Insu latio n Su rfa ce Tec hn o Scaffolding provider for the industrial sector across the world. g in Pip ce ervi S Full nce ena nt Mai Shutdown Building P ent Managem reservation 4 | up2date XERVON has an excellent international set-up and, besides its European activities, also focuses on the Middle East and Asia. Sweden Norway Benelux Germany Austria Great Britain Poland China Saudi Arabia Qatar United Arab Emirates Malaysia Egypt “There is nothing comparable to this on the market,” explained REMONDIS board member, Bernhard Heiker. Industrial customers from the energy sector, the steel industry, chemicals and petrochemicals, shipbuilding, the construction industry and other industries will, for the first time ever, be able to receive all services directly from just one company. The services range from scaffolding, insulation, surface technology and piping, to carrying out all maintenance measures at process plants on rotating equipment, electrical & instrumentation equipment, fittings and processing equipment, to comprehensive plant management (including budgeting, planning and carrying out maintenance work), infrastructure services and shutdown management. Another company division is active in the area of building preservation work. This comprises of “We are really pleased to have found this perfect strategic addition for our area of industrial services.” Thomas Breitkopf, board member of REMONDIS AG & Co. KG comprehensive services covering large engineering projects as well as residential and commercial buildings: from roof- and optimise the range of technical industrial services for ing and insulation work, to façade paint and plaster work, our customers.” to concrete repair work, to the full refurbishment of housAs far as XERVON's customers are concerned, their day- Just like XERVON, REMONDIS to-day business will not be affected by the integration of can look back at around 80 “We are really pleased to have found this perfect strategic the company into the REMONDIS Group. They will continue years of company history and addition for our area of industrial services,” explained Thomas to have the same local contact people and the regional tradition. Breitkopf, a board member of REMONDIS AG & Co. KG. structure will also remain unchanged. XERVON has a Following the takeover by REMONDIS, XERVON will be nationwide network of business locations in Germany able to further expand its range of services and thus and has international subsidiaries in Scandinavia, the generate growth. The independence of the XERVON brand Benelux countries, the UK, Austria, Poland, Algeria, Egypt, shall remain unaffected by the purchase. The company the Middle East and Asia. Its new owner also has a large will be run under the name XERVON GmbH within the network and financial strength so that XERVON will REMONDIS Group. Olaf Karrass, a new managing director of continue to be a reliable partner in the future – in particular XERVON, said, “Both XERVON and its service portfolio fit in for large-scale projects. ing complexes to reduce energy costs. perfectly with REMONDIS. Together we shall further develop up2date | 5 Latest news A strong partner REMONDIS – a successful service provider steeped in tradition Sustainability – the principle of success REMONDIS is one of the world's largest privately run water and environmental service companies. What began as a small haulage business in the North Rhine-Westphalian city of Selm in 1934 has developed into a global service provider with over 500 locations in 29 countries across three continents. The business that the company founder, Josef Rethmann, The REMONDIS Group's head office is in the German city of began as a forwarding agency and waste disposal business Lünen (District of Unna) and provides professional services to is now a global partner for numerous companies and local ensure natural resources are used economically and efficiently. authorities. In 2011, this family-run company and its 22,600 REMONDIS is active within the area of water supply and employees generated a turnover of 6 billion euros (consolida- water treatment. Moreover, it recovers raw materials from ted). The company's board chairman, Ludger Rethmann, is waste, develops innovative recycled products and supplies the grandson of the legendary company founder. alternative forms of energy. Through this same commitment, the company uses eco-friendly methods to dispose of x6.0 billion residual waste and hazardous materials which are unable to be recycled either for ecological or economic reasons. The REMONDIS Lippe Plant in Lünen is, for example, the turnover* largest recycling centre in Europe. By closing material cy- 22,600 *preliminary figures 6 | up2date cles, REMONDIS makes an important contribution towards protecting the environment and natural supplies of water as well as towards preventing climate change. In 2010, REMONDIS processed over 25 million tonnes of recyclables employees* and raw materials in its network of more than 500 plants and facilities. REMO “By acting the way we do, we take on ecological as well as economic and social responsibilities – throughout the whole of our operations.” Bernhard Heiker, board member of REMONDIS AG & Co. KG Water resources management In the area of water resources management, REMONDIS supplies water, treats wastewater and builds and operates plants. REMONDIS taps into new sources of raw water and builds, renovates and operates wells, water processing facilities and facilities for extracting surface water. The com- 25 over The REMONDIS Lippe Plant is the largest recycling centre in Europe. million tonnes of recyclables & raw materials processed pany then processes this water into drinking water either at waterworks it has been commissioned to operate or at companies in Germany following its takeover of the REMONDIS' water and plants it has built itself. The focus of the company's work as EURAWASSER Group in December 2011. Moreover, in the recycling services are used far as its industrial customers are concerned is on closing same month, REMONDIS purchased a 50 percent share in by private individuals, local water cycles in their production processes as well as on KED GmbH & Co. KG from RWE Deutschland AG. authorities and companies. processing water so that it is of the right quality for their production needs. REMONDIS supplies whole towns and Recycling industrial sites with drinking water and runs pipe networks The company has summarised its commitment to recycling where it is responsible for both the business and technical with its motto “Valuable raw materials come from deep in side of the operations – a growth market for the company the ground. Or from REMONDIS”. The Group's core activities which is now one of the leading water management are professionally handling, collecting and transporting up2date | 7 Latest news ONDIS REMONDIS provides services across the whole world – for example, operating state-ofthe-art wastewater treatment facilities in Turkey. material streams. Its global network of pre-treatment supplies cement works and other plants operating industrial facilities with their cutting-edge sorting and processing furnaces with substitute fuels that have been produced from systems ensures that all recyclable materials are recovered high-calorific waste fractions. REMONDIS' sister companies and that non-recyclable substances are disposed of using produce biodiesel which is used by the majority of the com- eco-friendly processes. In its efforts to close material cycles, pany's fleet of vehicles (around 7,000 trucks and vans). REMONDIS was one of the first companies to develop new products from recycled materials and these are now being used in a wide variety of areas as brand-name products. 7,000 The company, for example, produces an exceptionally white Integral service provider trucks & vans in the company's fleet of vehicles mineral which is sold under the “CASUL” brand name. This Being a professional service provider, REMONDIS offers both REMONDIS carries out product has a high covering capacity and creates high gloss local authorities and companies integral solutions that take ongoing research work into results and is used by the paper and paint industry as well both social and environmental requirements into account as alternative types of energy as by the construction sector. The “RADDIBIN” system of well as their existing business processes. This is true for all and fuel so that they can binding agents is also a REMONDIS product and is used in aspects of our work whether it be city maintenance work, be made available to the the construction sector and in dental medicine as well as to redeveloping old sites or REMONDIS' range of services in market. produce drinks and fertilisers. the area of facility management. The Group's subsidiaries XERVON and BUCHEN are responsible for providing profes- Energy sional industrial services. Thanks to its takeover of XERVON, The REMONDIS Group's third line of business is the energy REMONDIS has succeeded in further extending its activities market. On the one hand, the company supplies high-calorific in the area of maintenance work. BUCHEN offers industrial fuels and, on the other hand, operates power plants to businesses and power plants a range of highly specialised generate electricity, steam and heat (for example waste-to- services covering the areas of industrial services, waste energy plants and biomass-fired power plants). REMONDIS management and remediation work. REMONDIS – a name understood across the world The word REMONDIS is a made-up name – and yet the eight letters represent exactly what the company stands for. RE, the Latin prefix for “back”, symbolises our main area of expertise: feeding materials back into production cycles and closing material life cycles. MONDIS refers to the word “mondial” which in many languages means worldwide and encompassing the whole world. Being part of the company name, it describes our global commitment and also our international presence which we shall continue to extend. By combining these two aspects, our name is more than just a word. For REMONDIS, it is “a symbol and a seal of quality for everything we do”. 8 | up2date S The RETHMANN Group – three internationally successful divisions REMONDIS is closing an ever increasing number of material cycles helping to conserve natural resources and prevent climate change. Rhenus offers its customers flexible and bespoke logistics solutions – across the whole of Europe. SARIA helps to ensure communities receive the supplies they need by using high-quality raw materials sustainably and producing renewable energy. The family-run RETHMANN Group is active in three business Rhenus areas: water management & recycling, logistics and the The Rhenus Group is one of the leading providers of logistics bio-industry. services in Europe, intelligently managing complex supply chains in the areas of contract logistics, freight logistics, REMONDIS port logistics and public transport. Furthermore, the company The REMONDIS Group is one of the world's largest offers a wide range of value-added services. The three divisions have the best possible set-up – to privately owned water and environmental service companies. The company's services range from water SARIA fulfil today's requirements as supply and wastewater treatment to industrial services The SARIA Group is active around the world and manufac- well as those of tomorrow. and recovering raw materials, to developing recycled tures high-quality products for use in human and animal products and supplying alternative sources of energy. foodstuffs, agriculture, aquaculture and industrial applications. Moreover, SARIA produces new forms of energy and offers a range of services for the food industry and the agricultural sector. The three divisions are united under the umbrella of the family-run company, RETHMANN, and all three stand out thanks to their innovative and future-oriented concepts. up2date | 9 XERVON | Services Surface technology Protecting the surface of new frigates XERVON to treat and coat steel for four new frigates The ARGE F125 working group, consisting of ThyssenKrupp Marine Systems and the Friedrich Lürssen shipyard, has called on the expertise of XERVON to provide corrosion protection for the new F125 frigates it has been commissioned to build on behalf of the German Navy. XERVON's Hamburg offices have received a contract to join the team with the brief to help plan and carry out surface preparation and coating work on the four new frigates. The project will be a logisti- For many years now, XERVON has been active on site at at Blohm + Voss Shipyards in Hamburg, at the Friedrich cal challenge with construc- the Blohm + Voss shipyard where it has its own halls and Lürssen shipyard in Lemwerder as well as at P+S in Wolgast. tion work being carried out extensive storage facilities assisting in projects to repair or XERVON will have to be present at all three locations with at three shipyards at the build ships. No matter whether it involves frigates, corvettes a sufficient number of employees and sufficient volumes of same time – a challenge the or luxury yachts – these corrosion and scaffolding specialists equipment and materials to carry out the work whenever XERVON experts will master have worked on many types of vessels currently sailing the they are needed. The production schedule is the same for with confidence. oceans. The project to build four new frigates for the German all four frigates: the individual sections of the ships will be Navy will mean that a total of around 80,000 square metres made during the first construction phase and then assem- of steel – per ship – need to be pre-treated and coated. bled in the building dock during the second phase. The final stage of the project will then involve adding the superstruc- The special challenge that the company will have to face tures and fixtures as well as installing the marine equipment. during this project is not the high quality standards that the navy is demanding from them. According to Peter Zubrod, Hand in hand: scaffolding & corrosion protection a manager for the north German region, “it goes without The XERVON specialists will be involved in all three construc- saying” that they will fulfil such standards as achieving such tion phases. During the first phase, which will last around quality is “what we do every day”. It will be, above all, the twelve months per frigate, corrosion protection work will logistics that will pose the most difficulties for the experts be carried out in XERVON's own blasting hall located on during this project. The reason for this is because the frigates the grounds of the Blohm + Voss shipyard in Hamburg. The are to be built at the same time at three different shipyards: individual frigate sections and modules will be delivered to The F125 frigate – areas of operation & technical details The F125 is the latest generation of frigates in the German The F125 frigates are 149 metres long and 18 metres wide. Navy. The ships will be used for a variety of missions ranging They can reach a maximum speed of 26 knots and displace from national and alliance defence, to peacekeeping and around 7,000 tonnes of water. The ship has a main crew humanitarian rescue missions, to fighting terrorism. As a re- consisting of approx. 120 people and this can be extended sult of having the F125 at its disposal, the German Navy will to a maximum 190 people. In order to enable the ships to be able to take part in long-term, multi-national assignments be used as intensively as possible, a two-crew concept is to all around the globe to carry out conflict prevention work. be used on the F125 by the German Navy for the first time in its history. By doing so, the ships can be deployed non- 10 | up2date the hall and then processed there – which will be a great wanted materials. It also ensures that the surfaces have the Each frigate section will spectacle considering the sizes of the actual pieces. The largest exact, predefined degree of roughness needed for the coats undergo special, precisely section that will be delivered to Hamburg will be, for example, to be applied. Once the sections have been protected against defined surface treatment. approx. 19 metres wide, 24 metres deep and 11 metres high. corrosion, they will be taken to the building dock, where the In order to ensure that the corrosion specialists can reach the ships will be assembled and the final construction work car- whole surface, the individual parts will first be surrounded by ried out. This is the point when the corrosion specialists must scaffolding. This work will be carried out by their colleagues pack their mobile equipment and relocate to the building from XERVON's scaffolding division which is also located at dock together with any machinery they will need. Working the shipyard. Once this has been completed, the modules closely together with the other teams involved in building and sections will undergo the scheduled treatment under the ships, they will then carry out their coating work on the strict quality control. Completely different types of corrosion frigates as they are gradually put together. protection systems with precisely defined properties will be applied depending on the requirements of the surface being [email protected] treated. Whilst epoxy resin material will primarily be used, polyurethane and special coats will also be applied as well as, The new F125 frigate for example, anti-fouling systems. In order to ensure that the anti-corrosion systems protect the surfaces for as long a time The contractor for the four F125 frigates is the ARGE F125, made up of TKMS (ThyssenKrupp as possible, the steel surfaces will first be carefully prepared Marine Systems) and Lürssen. TKMS has commissioned Blohm + Voss Naval to carry out before being coated, i.e. they will be blasted and cleaned. This the construction work as subcontractor. Blohm + Voss Shipyards has, in turn, concluded a preparation work is not only carried out to remove any un- subcontractor agreement to build the ships. stop for up to 24 months. By way of comparison: a 124 frigate must return to home base after nine months. This frigate programme for the German Navy further emphasises the excellent global standing of the German naval shipbuilding sector and its auxiliary industries. Such projects help to further strengthen the key national competences in the naval shipbuilding sector as well as to secure jobs in Germany. 149 18 26 120 metres metres long wide knots people at top speed in the main crew up2date | 11 XERVON | Services Anti-corrosion protection Bridge renovation work in a lifejacket and lifeboat XERVON ensures the 'Donnerschleuse' road bridge is protected against corrosion 12 | up2date The XERVON experts have received the best possible training – and so they can react flexibly to unexpected challenges. What have swallows' nests got to do with corrosion protection? Absolutely nothing really. These feathered creatures and their young, however, caused the work schedule drawn up to renovate a two-lane road bridge over the Donnerschleuse (a lock on the Elbe-Lübeck Canal) west of Ratzeburg to be completely reorganised. The XERVON team reacted very quickly adapting their project plan to the new situation. For all intents and purposes, the public tender awarded to the Kiel branch was a standard task: the coating on the steel sections of the 'Donnerschleuse' road bridge had to be removed and then a new anti-corrosion coat applied – including erecting and enclosing any necessary scaffolding as well as controlling traffic flow. The client, the Lauenburg waterways and shipping authorities, expected the work to be carried out correctly and professionally and for its high demands concerning environmental protection and work safety to be strictly adhered to. A number of German laws had to be taken into account and observed during this project – the laws governing road and inland waterway traffic, the laws concerning the protection of nature and the countryside, emission control laws and workers' health and safety – and the work carried out was monitored continuously to ensure this was the case. The manager responsible for the anti-corrosion project and his scaffolding colleagues had already incorporated these stringent Shipping travelled through the lock as usual whilst the work was being carried out. requirements into their concept when they drew up their offer. To achieve this, they had been assisted by XERVON's vibrations were set off each time a car travelled over the The high wind load and the surface technology division which is well versed in all bridge, which were then absorbed by the scaffolding. More- vibrations caused by the aspects of anti-corrosion work. over, as the scaffolding was enclosed, it also had to withstand road traffic had to be taken high wind load: a very demanding structural engineering into account when the scaf- Safety first – nature conservation, too task. The 15-metre-long scaffolding suspended under the folding was being designed. The team renovating the bridge had to work on a total of bridge, for example, was not allowed to hang down more approx. 2,000 square metres of steel surface. To achieve than two metres to prevent the shipping and lock operations this, both the underside and one side of the bridge (includ- from being disrupted. At the same time, however, this ing the steel arch) were surrounded with scaffolding and scaffolding acted as a supporting surface for the scaffolding then the whole structure was enclosed. This meant that fixed around the bridge arch. A special construction made one lane of the bridge could be kept open for traffic even of lattice girders and modular scaffolding elements was though the scaffolding would have to absorb higher loads – designed by XERVON to overcome all these issues. up2date | 13 XERVON | Services The first task that had to be done was for the experienced Considering the special circumstances, the client was very specialists from the shipyard in Kiel to erect the scaffolding. happy to accept the inevitable delay that was caused by All necessary safety precautions were taken with each this change in plan. employee having their own safety equipment on them at all times: a climbing harness and a lifejacket – and if someone Enclosed system had fallen from the bridge despite these precautions, a life- The corrosion protection work was then carried out from boat was on hand to rescue them from the water. the scaffolding. The specialists moved in with their com- At the end of the day, satisfied customers are the best proof that a project has been completed successfully. pressors, high-pressure cleaning equipment, hydroblasting devices, airless pumps and suction equipment working under pressure – in all senses of the word – to clean the enclosed bridge. The surface area was then blasted using a The scaffolding should not have taken longer than a week particularly gentle system involving a water/sand mixture. to erect but during that time the men noticed a number This so-called sweeping process works with special blasting of swallows' nests under the bridge. The XERVON team media that prepares the surface in a gentle but effective way. XERVON reacted immedi- decided to change the planned project schedule so that Both the blasting media and the dirty water generated by the ately to the new situation the birds could raise their young undisturbed until they cleaning work were collected in a basin at the base of the so that the young swallows could leave their nests. The nesting area, therefore, was scaffolding which had been created from the material used were not disturbed by the not touched to begin with, the work above the bridge was to enclose the whole structure. The media and water were work. brought forward and the size of the team reduced. then sent for professional recycling or eco-friendly disposal. The XERVON team had to observe a large number of regulations whilst carrying out their work to protect the “Donnerschleuse” bridge from corrosion. 14 | up2date Following the sweep blasting, the steel construction was once again cleaned with fresh water and then – once it was completely dry – a first coat of primer was applied. This was then followed by a second coat of primer and the final top coat completing the bridge's new corrosion protection system. The coats were applied using airless blast equipment. By carrying out all work inside the enclosed area, the team was able to prevent any water, blasting media or coating spray being released into the environment; the team themselves were well protected with their special The underside of the bridge with its new anti-corrosion coating. suits and face masks. As soon as the first side of the bridge had been completed, confirmed, “During the final inspection, the Lauenburg the scaffolding experts moved the construction to the other waterways and shipping authorities praised us again for side within just three days. Once again the second bridge the professional manner in which we had carried out the arch was enclosed and the same process was followed to project as well as for our flexibility. We fulfilled all of our protect it against corrosion. All work was completed within client's requirements without receiving a single negative a period of two months and the XERVON team received comment.” some well-earned praise from their client. Stephan Teegen, XERVON site manager for the north shipyard division [email protected] up2date | 15 XERVON | Services Scaffolding Expertly equipped Roof renovation project successfully completed at SCA Hygiene Products GmbH Projects involving roof renovation work at industrial plants must be prepared and planned in great detail – especially if business operations are to continue during the work. A basic prerequisite for such projects is to have a professional scaffolding structure to ensure the work can be carried out safely and quickly. XERVON has both the required safety standards and the necessary know-how to supply such complex scaffolding on schedule. These scaffolding specialists were able to underline this fact during a recent project to renovate the factory roof of SCA Hygiene Products GmbH in Mainz-Kostheim, a manufacturer of consumer tissue products. The project involved a total roof area of around 600 square metres which needed to be kitted out with various scaffolding systems. A time period of just 14 hours had been allocated for the As O-version decks were used, additional bracing was particularly critical area directly above the four paper not required on the top boom. As a result, a two-percent machines – an area covering 140 square metres. “This incline was created so that any rainwater could be diverted was the only time that the machines were turned off to at the front end into gutters installed for this purpose. allow the scaffolding and sealing work to be carried out,” explained Timo Toperi, site manager at XERVON GmbH's Mastering the challenges Frankfurt branch (part of XERVON's regional company for The suspension points posed a structural engineering the south west.) “This area, however, covered 600 square challenge during the planning process as they were up to metres with a third of the roof area having to be equipped seven and a half metres from each other. “When there is with system scaffolding and the remaining 400 square such a huge distance, the few suspension points have to metres with hanging stages.” Besides having to erect the bear very heavy scaffolding loads,” explained Toperi. Whether it involves industrial combination of static and hanging scaffolding (load cat- “A combination of Dywidag threaded rods and a steel tube plants or buildings: XERVON egory 3), a water-proof and dust-proof protective roof also coupling system meant that the load borne by the fixing is one of the world's leading needed to be set up to prevent particles and objects, no points could be reduced and distributed evenly.” Lattice scaffolding companies. matter how small, from falling onto the machines during the girders were suspended and two-metre Layher working renovation work. “Our client manufactures highly delicate decks laid out. The team of between 10 and 15 XERVON products that are subject to very strict purity standards – employees also had to face gruelling conditions when even the tiniest of particles falling down could jeopardise erecting the scaffolding with temperatures reaching 60°C the whole production process,” Toperi continued. Another and up to 80-percent humidity levels. “My colleagues always reason, therefore, why it was important to integrate a tem- master their work – thanks to our many years of experience porary professional drainage system into the structure. and our high safety standards, we always produce the best 16 | up2date Special customer requirements and a tight time frame: XERVON mastered this difficult task without a problem. possible results, no matter how difficult the working condi- XERVON's work,” summed up Jürgen Ruppert, technical tions may be,” commented the site manager. manager at SCA. Looking ahead, Toperi said, “Having successfully completed the project, the client has already Having been briefed about the construction, the scaffolding contacted us with further enquiries about cleaning work was then handed over to the company carrying out the and scaffolding.” renovation work exactly on time. “There was not a single problem with the scaffolding throughout the whole of [email protected] the roof reconstruction work. We are really pleased with An experienced scaffolding specialist XERVON offers a very wide range of scaffolding services – also for projects involving special constructions with particular structural engineering challenges and difficult erection conditions. With over 1,000 employees and several hundred vehicles in Germany alone, the company is able to guarantee a quick supply of both materials and personnel. We are your partner for the following types of scaffolding: industrial scaffolds mobile maintenance platforms lifting work and mast climbing work platforms façade scaffolds enclosed scaffolding/housing lifts special scaffolds platform construction work up2date | 17 XERVON | Services Major projects in the UAE Ruwais: on the way to becoming a major petrochemical complex Comprehensive range of services for building and extending industrial plants Ruwais, an industrial site in Abu Dhabi, is booming. For many years now, XERVON has been playing an active role here – acting as a specialist service provider for complex shutdown tasks as well as for projects involving new builds or extension work – as this site has developed from being a refinery to becoming a mega-sized chemical and petrochemical complex. Thanks to the many success- Signs have been pointing towards expansion ever since XERVON has been active in the region as a specialist for ful projects it has already the Abu Dhabi National Oil Company (ADNOC) created the shutdown services for many years now. It has been in- carried out, XERVON has an Ruwais industrial site when it built its first huge refinery volved in a large number of turnarounds at the Abu Dhabi excellent reputation as a plant (120,000 b/d) there in the late 70s. Today, this loca- site successfully carrying out a very wide range of tasks shutdown specialist in Abu tion – around 200 kilometres west of Abu Dhabi City – not and earning a good reputation at the same time. Only Dhabi as well as throughout only refines crude oil and processes and liquefies natural just recently, XERVON successfully completed a complex the region. gas but also produces large volumes of fertiliser and poly- maintenance project at the crude oil processing plant on propylene. The large Shuweihat power plant (1,500 MW) Zirku Island (also Abu Dhabi). During the shutdown period, and its desalination plant are also part of the site supplying for which only 27 days had been scheduled, a team of energy and water to the industrial complex and a small 225 employees carried out a whole variety of tasks in- town nearby. volving electrical & instrumentation services as well as 18 | up2date XERVON's complex services are in high demand in the United Arab Emirates, too. We are involved in many major projects that will run until 2020. insulation and painting work on various parts of the plant awarded a contract to carry out a whole work package – Around 800 XERVON and pipe racks. consisting of painting, insulation, scaffolding, fire protec- employees – from trainees tion and flooring work. During the various project phases, to site managers – are on “We have a very good set-up here in the region,” com- the scope of the contract will involve, among others, paint- the job site to ensure the mented Waleed Al Hazmi, managing director of the XERVON ing a total surface area of more than 500,000 square me- extension work to the companies in the Middle East and Malaysia. “This is true tres as well as insulating a 6-kilometre-long pipe (“jetty“) Takreer Refinery is com- for the high qualifications of the employees we supply which runs into the sea to a loading terminal for shipping pleted on time. in large numbers.” The best preconditions for the mega oil and other refinery products. projects due to take place in and around Ruwais, since the expansion plans of the plant operators there – Takreer XERVON's local site management team is responsible (refinery), Gasco (liquefying gas), Borouge (PE and PP for ensuring that employees, equipment and material are production) and Fertil (fertiliser production) – are far always supplied just-in-time. This concept involves short from over. distances as all XERVON employees live and work so to speak “under one roof” during both expansion phases. The aim is to turn Ruwais into a petrochemical complex by Whether it be apprentices, labourers, supervisors or 2020 with work planned or already started to extend the site managers: they all live in an area covering approx. existing facilities and build new plants. The first extension 12,000 square metres, where XERVON has created accom- phase, which is estimated to involve contracts worth a modation and an infrastructure to ensure that the approx. total 40 billion US dollars, should be completed by 2014. 800 employees have a comfortable place to live. This is A further estimated 20 billion US dollars will be invested in an important factor helping to contribute towards the the sites from 2013 onwards. The current Borouge II exten- company's success as a service provider in Ruwais. From scaffolding to paintwork: XERVON has been commissioned to carry out a six-phase work package in Ruwais. sion project, for example, involves the installation of the world's largest ethylene cracker with a capacity of 1.5m t/a. The Borouge III project, due to take place in 2014, then plans to increase the plant's polyolefin capacity to 4.5m t/a. Fertil, a producer of fertilisers, is intending to raise the capacity of its urea plant from 0.8m tonnes to 2m tonnes of urea per year by 2013. It is likely that a further 3 billion US dollars will be invested to extend the existing Shuweihat power plant. The cost of building four nuclear power plants at Braka, which are due to have been put into operation by 2020, is estimated to be around 40 billion US dollars. XERVON has already signed several contracts to provide services for some different current and future projects helping their clients to extend their various facilities in Ruwais. For the six-stage extension plan for the Takreer Refinery, (which aims to increase its processing capacity by 400,000 b/d by 2013), XERVON has, for example, been up2date | 19 Menschen People People Electrical & instrumentation services: a talent for maths is a must E&I experts have to master a whole variety of tasks Whether it be a coffee machine or a mobile phone, a nuclear plant or a chemicals park: all over the place, processes need to be measured, controlled and regulated – sometimes hydraulically, sometimes pneumatically and often electronically. The range of applications, therefore, for which E&I specialists involved in electronics are needed is just as wide. There are two things that such people really need: they must find technology fun and have a talent for maths. 20 | up2date E&I experts involved in the field of electronics analyse auto- engineer which lasts three and a half years. E&I mated systems to see how their different functions are linked services involving electronics (known as “EMSR” and how their different processes operate. They install mea- technology in Germany) is not actually listed surement and control equipment. They assemble, configure, as one of the main subjects of this apprentice- program and adjust sensor and operating systems as well as ship course. “You notice very quickly however if networks. They control and maintain these systems, service someone is good at “EMSR” technology,” commented them and ensure that professional documentation is drawn Martin Euringer, who has been training young people at up for all work carried out. XERVON's Münchsmünster branch for many years now. “The legislator introduced new and considerably more XERVON trains young people flexible training regulations in 2003 which merely set out a At XERVON in Germany, young people can take part in a rough structure for the training content. When we train dual apprenticeship course to become an industrial electronics people in our companies, we are allowed to focus on the up2date | 21 Menschen People areas for which the young people show the most machine and drive unit technology, converter control etc. talent and where we will need them most once A special six and/or eight-week training course on they have finished the course,” explained Martin E&I services is integrated into the third year of training. Euringer. “I train people, therefore, to become industrial electronics engineers and focus on E&I services as we need people skilled in this field to carry out maintenance work at our industrial park.” When asked about what skills people interested in such a career should have, Martin Euringer answered without a moment's hesitation, “They must be able to do maths and they must enjoy maths. Electronics engineers, industrial mechan- Later, as part of their job, they have to ensure that the control ics and mechatronics engineers cannot do their jobs without equipment functions smoothly. Such specialists know all having a basic knowledge of maths. They must all know the about pressure sensors, other types of sensors and valves and basics of algebra and trigonometry.” That is not all though: can reprogram, repair and replace programmable controllers. “Our electronics engineers must also be able to speak English. Some of the questions in the final theory exam are “It is very rare indeed that my day turns out to be the way I had planned it.” Wolfgang Harste, E&I engineer at XERVON asked in English and must be answered in English, too.” Despite this fact, people from all types of secondary school can complete the course. “What they must have is energy and staying power,” concluded Martin Euringer. Their list of tasks, however, also includes being able to lay cables – for example, when a facility is installed for the first Contact person: [email protected] time. Whilst the first year of the apprenticeship course focuses primarily on teaching a basic understanding of mechanical and electrical principles, the second and third years focus on electronics: power distribution, high voltage technology, What do E&I engineers do? Each year, XERVON offers E&I engineers install, maintain and monitor a very wide an electronics engineer for automation technology, a around 100 apprenticeship range of automation systems. They are informed of faults mechatronics engineer or a similar such course. Such places – and not only in the and narrow these down by using test software and diag- courses are divided up into teaching core qualifica- field of electronics! nostic systems. They analyse the reasons for the errors and tions, which are the same for all industrial electronics overhaul the equipment – taking all relevant regulations professions, and specialist qualifications specific to the and safety requirements into account. profession which are, above all, taught by the company training them. At XERVON, the apprentices take part in The majority of E&I engineers in Germany gain their pro- a special six and/or eight-week training course on E&I fessional qualifications by taking part in a dual apprentice- during their third year of training. ship course to become an industrial electronics engineer, 22 | up2date Cooperation work Creating the future – together with universities and institutes Practical research and development work XERVON has a long tradition of working with German universities. Over the years, it has developed close ties to science institutes resulting in the company regularly taking part in research projects relevant to its fields of business. As a result, XERVON's maintenance management depart- ures. Such measures are being outlined and evaluated with The body behind the ment, headed by Dr Marcus Schnell, is currently taking regard to additional or reduced use of resources. The target “EffizienzClusters LogistikRuhr” part in the RESIH project (resource-efficient maintenance is to improve performance whilst using fewer resources. is the DLR, the German Aero- logistics/FKZ: 01IC10L07C), which began in the middle of space Centre, which is acting 2010 and aims to find ways of using existing resources in Besides this and another research project, which is due to on behalf of the Federal spare parts logistics more efficiently. Three companies – begin soon, XERVON also supports the scholarship pro- Ministry of Education and the Fraunhofer Institute for Material Flow and Logistics, gramme for the dual bachelor “Industrial Service Manage- Research. Infraserv Knapsack and XERVON – are working on the pro- ment” course at the University of Applied Sciences and Arts ject together as part of the “EffizienzClusters LogistikRuhr” in Dortmund. The company is providing support for three group. The project is due to last just under five years. students who began studying their three-year course in 2010 and will graduate with a “Bachelor of Engineering”. Those involved are analysing their current consumption of The support given also includes a monthly grant in line resources and looking at ways to sustainably reduce their with the maximum loan received by students in Germany consumption by implementing suitable maintenance meas- (Bafög). Besides attending their lectures and seminars at the university, all three scholarship holders also receive a Dr Marcus Schnell high amount of practical training at XERVON's business locations in Marl, Cologne-Merkenich and Düsseldorf. Dr Marcus Schnell is head of the maintenance management department and acts as an interface The “Industrial Service Management” course for maintenance matters between the company and covers a variety of subjects. universities and associations. Since 2004, he has been a lecturer at the University of Applied Sciences and The maintenance of: Arts in Dortmund where he teaches industrial project production facilities management and knowledge-driven enterprise devel- mobile facilities & vehicle technology opment. He has published numerous articles and is infrastructural facilities a popular speaker at conferences and other events. energy plants & environmental protection facilities Contact person: [email protected] up2date | 23 2012 2021 2030 2039 2048 2057 2066 2075 2084 2093 2102 2111 2120 2129 2139? No Titanium – No Modern Aviation Planes are essential for many people. So titanium is, too, as it provides stability for the undercarriage, engines, fuselage and wings. The world would be a much smaller place without this metal. However, natural reserves of the material are finite and are expected to last another 137 years. REMONDIS is thinking ahead and developing processes to return titanium to production cycles. The highest levels of quality, worldwide. For a secure future. German Qualität. REMONDIS AG & Co. KG // Brunnenstr. 138 // 44536 Lünen // Germany // T +49 2306 106-0 // F +49 2306 106-100 [email protected] // remondis.de Source: United States Geological Survey (USGS 2010)