Clear values for a strong “we

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Solutions for Industrial Services
www.BIS.bilfinger.com
Information from Bilfinger Berger Industrial Services AG for clients, partners and the group
Issue 01 / 2008
CONTENTS
BIS AG sponsors a lectureship at the
Berufsakademie Sachsen
2
New market leader in Scandinavia
Takeovers in the USA and Spain
3
Winning orders with occupational safety
BIS Izomar on course for growth
4
Multi-purpose production plant
for CU Chemie Uetikon
5
BIS companies combine
expertise
Current contracts
6
Optimised plant engineering for
greater environmental protection
Safety has top priority
7
Life returns to the open-pit mine
BIS Salamis increases turnover
with power grid maintenance in the UK
8
Clear values for a strong “we-feeling”
With its exceptionally successful growth, Bilfinger Berger Industrial Services AG (BIS AG) is setting
the standard for comparison in the field of industrial services providers. The group clearly consolidated its position as the leading European service provider in the process industry in 2007 and once
more significantly increased its profitability. For BIS CEO Thomas Töpfer, this economic
success confirms that the company is on the right strategic track: “With the continuous expansion
of our service portfolio, we‘ve won our clients‘ confidence as a solution provider. We want to use
this as a basis to ensure and further increase our earning power.”
In the 2007 business year, the BIS Group successfully increased its total revenues by more
than 27 percent from €1.36 billion to over €1.73
billion. Adjusted for the revenues of the Ship Technologies area sold at the end of 2006, the revenues of the industrial services divisions (2006:
€1.27 billion) actually increased by around 36 percent. Alongside the strong organic growth in
all business units, this growth was also helped
by acquisitions accounting for around €100
million of revenues. The
renewed swift growth in
performance was accompanied by an disproportionately large increase in operating
profit. At the start of the new
business year, further acquisitions followed in the USA
and Norway with revenues of
more than €400 million per
annum. With these acquisitions, the number of
employees in the BIS Group
increased by over 5,000 to
around 21,000.
neur,” states Thomas Töpfer. He‘s not just talking
about the unusual fact of the management‘s participation in many of the affiliated companies, but
also the high significance attached to entrepreneurial thinking at all levels and in all units within the entire organisation.
Addressing the individual
This is very clearly and explicitly expressed in the
corporate principles, which have been evolved on
the basis of Bilfinger Berger
AG‘s revised corporate mission statement. For the Board
of Directors, it‘s about a
common understanding of
the values that shape the
corporate identity and lay
the foundation for a strong
“we-feeling” in this expanding company. “Befitting our
broad range of services as a
solution provider, we begin
with a clear standard: We are
BIS. We are Best in Solutions”, explains Töpfer. “We
throw down the gauntlet to
“With the continuous
As an international company,
all of our teams to adopt
expansion of our service portfolio,
the BIS Group combines
our principles as their own.
we‘ve won our clients‘
confidence as a solution provider.” By addressing our employees
some 85 consolidated affiliated companies which gear
Thomas Töpfer, directly, we place special
their operations in the respecCEO of BIS AG emphasis on them and by so
tive markets to the requiredoing let them know the
ments of their clients with
esteem they can expect to be
the greatest possible entrepreneurial independheld in within our Company. We know that it‘s
ence. For Thomas Töpfer, this “medium-sized comultimately our employees who translate our stanpany flexibility” combined with the financial
dards of quality, service orientation and integrity
power of the Group is an important competitive
into reality for our customers.” The evolved corpoadvantage. “We‘re the company of the entreprerate principles are described in this edition and
remain a key topic of discussion in the Company‘s
communication.
markets. “This year, more than 70 percent of our
revenues will be generated outside of Germany.
We‘re taking this into account by restructuring
our divisions. The restructured Northern & Eastern
Attractive thanks to complete solutions
Europe division is responsible for Norway, Sweden,
The positioning of the company as a leading indusPoland, Hungary, the Czech Republic, Romania and
trial services provider with a complex range of servSlovakia. The North America division established at
ices is, for Thomas Töpfer, likewise a programme for
the start of the year looks after our activities in the
further growth. “Many of our clients‘ industrial
USA and Canada.“A further
plants are currently running
consequence of the dynamat the limits of their capacity.
“Fair and responsible action by
ic growth and increasing
The backlogged need for mainall employees as well as strict
internationalisation is the
tenance and investment
adherence to all relevant statutory
continuous advancement of
has resulted in significantly
regulations is the basis for sustained
the internal risk manageincreased demand for the past
corporate success.”
ment and compliance systwo years. Attractive industrial
tems. “Fair and responsible
services providers from the
action by all employees as well as strict adherence
client‘s point of view are those that offer complete
to all relevant statutory regulations is the basis for
maintenance, servicing and outsourcing solutions.“
sustained corporate success,“ explains Töpfer.
Thomas Töpfer doesn‘t just see potential for growth
Corporate compliance is highly rated within the
in individual countries, but also among global operBIS Group and will be one of the key issues in
ators thanks to the company‘s international orienthe coming business year also. “With our strong
tation. The group‘s financial power provides a stable
growth, the administrative requirements have also
foundation in this respect for the fast growth rate.
become more complex. This makes it all the more
important for us to stay true to our virtues: team
Divisions restructured
spirit, open communication culture, the flexibility
Thomas Töpfer ultimately wants to remain on
of our decentralised organisation and, all above,
course for growth by systematically expanding marcustomer orientation,“ stresses Töpfer.
ket leadership in Europe and opening up further
We are BIS.
We are Best In Solutions.
BIS [Bilfinger Berger Industrial Services]
is Europe’s leading provider of
SMARTLY
ACT
ACT
ACT
ACT
CONFIDENTLY
industrial services. We render complex
industrial services for the process
industry and power production industry
over the course of the entire life cycle of
a plant and equipment wherein we are
essentially a one-stop shop for services.
TOGETHER
CREATIVELY
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2
HIGHLIGHTS
BIS AG takes a leading role
850 bicycles for Munich
First sponsor of a lectureship
Bilfinger Berger Industrial Services AG is partnering with the city of Munich as a premium
sponsor for the city‘s 850th birthday. “We expect
to significantly raise our profile as a modern,
technically-oriented industrial services company
in the economic region of Munich. We also want
to portray ourselves as an attractive employer,”
says Thomas Töpfer, CEO of BIS AG. One of
the high points of the city‘s birthday is the
Altstadtring festival on 19 and 20 July. BIS AG is
taking part with a large presentation stand
directly at Stachus square in the centre of
Munich. A very special initiative by BIS AG will
ensure environmentally-friendly mobility and
attention in the Bavarian capital: 850 silver BIS
bicycles decorated with the blue lambda will be
trundling through the city from this summer.
Jim Whitehorn (centre) with the award for BIS
Salamis, Lee Hunter (left) from the competition
host and Peter Casebow from the award sponsor.
Bilfinger Berger Industrial Services AG is
taking a leading role with its long-term
investment in the sponsorship of the Berufsakademie Sachsen, Staatliche Studienakademie Leipzig. This partnership of industry and academia is also a direct response
to the lack of qualified employees in the
German workforce.
“We didn‘t want to be
onlookers, just another
voice complaining about
the situation; we wanted
to take the initiative ourselves and actively search
out forward-looking solutions,” says Thomas Töpfer,
CEO of Bilfinger Berger
“Action, not talk”
Industrial Services AG (BIS
is Thomas Töpfer‘s
AG), of the cooperation
motto.
with the Berufsakademie
Sachsen, Staatliche Studienakademie in Leipzig. At the moment, qualified
employees are valuable assets in the personnelintensive maintenance industry. That is why an
international company like BIS AG has to take the
initiative early on to secure a good starting position
in the competition for the best brains. “We‘ve found
a first-class partner in the Staatlichen Studienakademie Leipzig. The Service Engineering course
produces precisely the experts that we‘re seeking
for our business,” says Töpfer.
Award for qualification
Branch of study to be developed further
BIS Salamis Ltd in Scotland has been awarded
for the first-rate qualification of its employees.
The “Human Resources National Award” was
accepted by Jim Whitehorn, Training & Competency Manager at BIS Salamis, who initiated and
implemented the skills-development programme.
“We‘re delighted with this prize, all the more
since it applies to the whole industrial sector
in Scotland and not just the gas and natural
gas sectors,” explains HR Director Paul
Matthews. It is a reward for the aboveaverage
effort of all the teams in helping to increase
qualification and occupational safety.
The sponsorship of this new academic position is
absolutely unparalleled to date at the Berufsakademie Sachsen. “For us, the opportunity now
presents itself to further develop the successful
BIS Maintenance Südwest GmbH‘s full service
contract with Almatis GmbH in Ludwigshafen
has been extended by a further four years,
until the end of 2011. The very high safety
requirements and the highly abrasive product
(aluminium oxide) place very high demands on
the maintenance of the production systems.
This contracts, with a value of more than €5 million per annum, demonstrates the customer‘s
satisfaction with the quality and professionalism
of the maintenance service provided by BIS
Maintenance Südwest GmbH.
Consolidation of the onshore business
BIS Salamis Ltd has been successful in acquiring
a considerable maintenance and servicing
contract for a large refinery in the Humberside
region in the north-east of Great Britain. The
activities will mainly be in the areas of scaffolding, insulation and corrosion protection. The
contract was awarded following an intensive
selection process and has a duration of three
years. With this contract, BIS Salamis Ltd has
made important progress in consolidating its
onshore business also.
Service Engineering course at many levels,” says Dr.
Ulrike Gröckel, Director of the Academy, of BIS AG‘s
sponsorship. This cooperation between industry
and academia represents new ground for the
expansion of capacities. It will allow more young
people to potentially improve their qualifications
and thus their prospects on the job market. “In our
courses, we put great emphasis on prac-tical
aspects. This partnership with a leading international company from the maintenance industry
is therefore a valuable help for us,” emphasises
Dr. Gröckel.
Practical information
Apart from BIS AG‘s financial sponsorship of
Berufsakademie Sachsen, the Service Engineering
course also receives functional support with teaching content from actual practice. Experts from
BIS AG are regularly on hand as lecturers. “Our
students can put this information to excellent
use in their education. This addition to classic
teaching content is typical of courses at the
Berufsakademie,” says Dr. Ulrich Rege, Head of the
Service Engineering course.
cooperation was born from the good experience
with this arrangement. Thomas Breuer has been a
student at Studienakademie Leipzig since 1 October 2007 and completed the practical section of
his course at BIS Industrieservice Ost GmbH.
Theory and practice combined
The academic content at Berufsakademie Sachsen
is characterised by the close dovetailing of scientific
theory and operational practice. Initiated and
financed by the state as well as supported by companies as a competent practical partner, this form
of study is now firmly established in Saxony. This
success is primarily rooted in the dual study system.
In addition to the theoretical aspect, the course
also includes a practical aspect. The Service Engineering course includes content such as maintenance planning, maintenance technology, technical
diagnostics, inspection, condition monitoring,
production and assembly processes, error and
weak point analysis in experimental work, cost
analyses, measurement, open-loop and closed-loop
control technology.
BIS to offer study places
BIS AG will also offer qualified study places in its
domestic subsidiaries for students from the
Staatliche Studienakademie Leipzig. “We consider
ourselves to have a social responsibility to ensure
a new generation of qualified professionals in Germany,” explains Thomas Töpfer. The maintenance
industry offers a multitude of job descriptions as
well as secure job prospects.
New framework contracts
Bilfinger Berger Industrial Services AG (BIS AG)
has expanded its good market position in
the area of main contracting with two new
framework contracts. As of 1st April 2008, BIS
Industrieservice Nord GmbH is the exclusive
sales partner for TOTAL Bitumen Deutschland
GmbH in Brunsbüttel as well as the Shell refinery in Harburg and Grasbrook. Both contracts
have a total value of nearly €10.5 million per
annum.
Practical orientation is the Berufsakademie‘s particular strength.
ANNIVERSARIES
40 years
Junginger, Horst
Leibrock, Bruno
Neuf, Ulrich
Statezni, Siegfried
27 May
2 Jan
2 Jan
29 Jan
25 years
Dr. Ulrike Gröckel and Dr. Ulrich Regel (right)
from Berufsakademie Sachsen and Thomas
Töpfer as well as Matthias Kopp (left) for BIS
seal their cooperation.
The partnership initiative goes back to Matthias
Kopp, Managing Director of BIS Industrieservice
Ost GmbH, which already employs a student from
the Berufsakademie. The idea for more intensive
JMT program relaunched
A springboard for many
The new Junior Management Team (JMT) launched in April with 21 participants from eight
countries. Since its inception in 2001, the JMT programme has established itself as one of
the most important elements in human resources development in the BIS Group. Its purpose
is to qualify young talent and as part of this process has also proven a springboard for career
progression for many.
The 18-month programme offers the participants
the opportunity to further develop their personal
and professional qualifications to master the
requirements of their careers in a total of six training units. “Our main priority,” says Michael
Schmitz, Head of Human Resources Development
at BIS AG, “is to enable the participants to master
their current tasks more effectively.” It also turns
out, however, that the training programme encourages many of the participants to set about the
next step on their career path.
An assessment of the human resources development revealed that of the participants
from the past three stages 19 have progressed in
their careers, in some cases greatly. A prime example of this is Tomasz Kalejta (37) and Witold
Wałachowski (39) from BIS Izomar Sp. z o.o.,
who have been with their company for more than
ten years and took part in the JMT as project managers – today they are managing directors
in their company.
This example illustrates that the BIS AG Group, with
its dynamic growth, offers interesting career
prospects for future managers. Thomas Töpfer, CEO
of BIS AG: “The Company invests in its employees
because their talents are an important prerequisite
in being able to realise further growth, including in
human resources, with good teams.”
Affeldt, Ralf
Balent, Josip
Beinert, Bernhard
Braun, Franz
Casar, Jozef
Christ, Leo
Eberle, Manfred
Einberger, Günter
Frühling, Dieter
Gräsel, Karl
Griessel, Juergen
Ismaili, Sefedin
Ivančić, Mile
Jansen, Bernd
Kieper, Hans-Peter
Kleinstueck, Andreas
Laier, Alfred
Matteo, Antonio
Noeske, Wolf-Dieter
Prock, Georg
Redenberger, Sabine
Regel, Lothar
Reichstein, Harry
Reiff, Harald
Savaş, Osman
Schmieder, Reiner
Schubert, Michael
Schubert, Stefan
Schüll, Ralf
Taflan, Aytaç
Tepper, Andreas
Uliczek, Manfred
Wagner, Helmut
Weise, Dietmar
Zimmermann, Jürgen
Zoels, Lutz
28 March
3 Jan
6 Apr
1 Apr
1 Feb
30 June
13 June
14 Feb
11 Apr
5 Apr
1 Apr
7 June
20 June
16 May
16 May
1 Apr
17 Jan
1 Feb
9 Jan
21 Feb
19 Apr
3 Jan
27 June
17 Jan
3 Feb
31 Jan
14 Feb
9 Feb
14 March
22 Feb
8 Feb
17 March
14 March
3 Jan
10 Jan
31 March
In addition to the company anniversaries here
in Germany, in the 02/2008 issue we‘ll also be
mentioning the people celebrating anniversaries
in the foreign associated companies.
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BIS AG acquires two service providers of Norsk Hydro ASA in Norway
New market leader in Scandinavia
Bilfinger Berger Industrial Services AG has assumed market leadership in Scandinavia with
the purchase of two subsidiaries of Norsk Hydro ASA in Norway. Hydro Production Partner
AS and PT Produksjonstjenester AS will complete BIS AG‘s industrial service portfolio in
Northern Europe.
“These major acquisitions represent the continuation of our expansion strategy in the lucrative and
growing market in Northern Europe. The portfolio
of the two companies is the ideal complement to
our previous service offering. This makes Bilfinger
Berger Industrial Services AG (BIS AG) the market
leader in industrial services in Scandinavia,“
explains Thomas Töpfer, CEO of BIS AG. This strategic acquisition more than doubles the total revenues in Northern Europe and in the future will
amount to almost half a billion euros. The number
of employees increases to around 3,600.
Growth in Scandinavia is continued
“We will continue our growth strategy and on this
basis plan an increase in activities for the entire
process industry,“ says Thomas Töpfer. For more
than 30 years already, BIS AG has been operating
in Scandinavia as a technically-oriented industrial
services company and has continuously expanded
its position in the market. Its most important clients
are from the areas of chemistry and petrochemistry,
power generation and the cellulose, paper and
steel industries.
Clients benefit from the extended portfolio
“The additional services gained, particularly in
the areas of mechanics, electrical, measuring and
control technology and full-service maintenance,
mean that, in future, our clients will be able to
access the full range of services,“ stresses Thomas
Töpfer. In this way, the lucrative business in the
area of main contracting will be consolidated and
further expanded.
Strong position in the process industry
Together into the future: Thomas Töpfer, CEO
of BIS AG, with Morten Mathisen, CEO of
Production Partners (right) and the Hydro M&A
Manager Tor-Ove Horstad (left).
The companies Hydro Production Partner AS (HPP)
and PT Produksjonstjenester AS (PT) were spun off
from Norsk Hydro ASA in 2005 and enjoy an
extremely strong position on the Scandinavian
market. They have service contracts running for
many years with a multitude of well-know clients
from the process industry at the locations in
Norway as well as a subsidiary in both Sweden
and Germany. The two companies together generated revenues of around €250 million in 2007 and
currently employee some 2,200 people.
PERSONNEL
Takeovers in the USA and Spain
The reorganisation and expansion of the divisions
bring personnel changes at management level,
with three managers assuming new roles in
BIS AG.
The new North America
division is being headed up
by Hans Petter Hansen (54).
Mr. Hansen joined R&M Industrier AS in 1999 and, as managing director, was responsible
for companies in Norway and
Denmark until 2004. Since the beginning of 2005,
he has attended to the core theme of business
development and mergers and acquisitions in BIS
AG at the top level as a manager. In this connection, he also worked on the acquisitions of the companies Salamis and OHARE as well as HPP and PT.
A management newcomer for
the Central Europe division
is Dr. Joachim Kreysing (43).
Dr. Kreysing, a doctor of chemistry, joined the group in 2005
as managing director of the
now BIS Prozesstechnik GmbH
and BIS Industrieservice Mitte GmbH. Before
switching to industrial services in 2003, he spent
six years in management consulting and two years
in research.
A new addition to the management of the Northern &
Eastern Europe division is
Harald Stöhr (42). Mr. Stöhr, a
chartered engineer, joined R&M
in 1997 to take up a position in
central project controlling. He
was appointed acting managing director of R&M
arnholdt Services GmbH & Co. KG in late 2003. At
the start of 2005 he became managing director of
R&M International GmbH and in 2006 also took on
the role of managing director of BIS OKI Insulation
GmbH.
Photo: flohagena.com
The industrial park at Porsgrunn on the Herøya peninsula is the headquarters of the new associated
companies.
Both companies are headquartered in Porsgrunn
on the southern coast of Norway, 160 kilometres
from Oslo. Porsgrunn, on the Herøya peninsula, was
chosen as the site of a large production location for
fertiliser back in 1929. In the decades that followed,
further plants were added, giving rise to the development of the largest industrial complex in Norway.
HPP looks after, among others, the well-known
companies Ineos, REG Scanwafer and Yara at this
location.
International growth continued
BIS AG is underlines its international expansion strategy with the takeover of two industrial
services companies in the USA and Spain at the end of 2007/beginning of 2008. This therefore represents a consistent continuation of the successful strategy of offering industrial
clients as extensive a service range as possible from a single source.
With the takeover of two business divisions of
the American Fru-Con-Construction Corp., a subsidiary of Bilfinger Berger AG, BIS AG has significantly strengthened its market position in the USA.
Fru-Con Special-Projects‘ industrial services focus
on maintenance, turnaround management and
pipeline construction, while Fru-Con Engineering
focuses on planning and engineering services.
“One of our key goals is to establish our own
structures to further expand our activities in
the USA,” says Thomas Töpfer, CEO of BIS AG, in
explaining the strategy for North America.
Sharing in the growth in the USA
75 percent of revenues is based on long-term
contractual relationships with clients who have
been receiving support in all questions concerning
industrial services for many years. The two companies will operate under the umbrella of
the new North America division in the future.
Strengthening the market position in Spain
BIS AG has expanded its position in the Spanish
industrial scaffolding market with the acquisition
of 90 percent of the shares of Desarrollo e Ingenieria del Andiamo S.A. (DIASA). DIASA generates
turnover of €15 million with around 200 employees. Combined with its previous activities in
BIS AG has already been operating in the USA
for around two years through a British subsidiary
and also has a direct equity holding in Canada.
“The market in the United States is constantly
growing and is becoming more and more lucrative.
By taking over Fru-Con‘s service companies, we
want to have a share of this growth and to break
into the oil and gas business in North America
in the medium term,” explains Thomas Töpfer.
With more than 2,000 employees, Fru-Con Special-Projects and Fru-Con Engineering will
contribute around €160 million to the BIS Group.
From their headquarters in Saint Louis, the two
companies look after clients in 13 states, primarily in the mid and eastern USA. One of the most
important clients for more than 60 years is the
Procter & Gamble Group. In addition, many other
well-known companies in the process industry
in the USA put their trust in the experience
and expertise of Fru-Con‘s specialists. Around
Spain, BIS Multiservicios Industriales S.A. is
thus the only company on the Iberian peninsula with the in-house knowledge and resources
to offer combined insulation and scaffolding
services for large and complex projects.
DIASA was established in 1998 and its core activities, industrial scaffolding, are in petrochemistry and
the energy industry as well as in the service business
for shipyards. In addition to the headquarters in
Ferrol (Galicia), it consists of three further subsidiaries in Madrid, Bilbao and Gijön (Asturias).
Managing director Isido Silveiva Rey, who built
DIASA into a well-known and successful company
over the years, will remain on as a shareholder. He
expects the affiliation with the BIS AG Group to
contribute significant growth momentum that will
lead to successful regional and customer-specific
expansion of the business.
ACT | smartly
and flexibly like a mid-sized enterprise with
the financial power of a large corporation.
ACT
SMARTLY
so we can benefit from the speed of a
decentralised organisational structure.
in order to keep a consistent appearance
despite all diversities.
in order to achieve more added value
through individual development of each and
every employee.
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Burgeoning service portfolio and high level of expertise impressed clients at home and abroad
BIS Izomar Sp. z o.o. continues its growth course
The continuous acquisition of knowledge and expertise is one of the uppermost maxims of
all BIS companies. BIS Izomar Sp. z o.o. in Poland and its subsidiary Izomar Pomorze Sp. z o.o.
are also constantly developing their range of services and successfully expanding their
client base both at home and abroad.
Izomar Pomorze Sp. z o.o. has its own workshop for the fabrication of bespoke steel structures. It also has a high level of expertise in the
manufacture and installation of exhaust gas and
air inlet ducts for numerous clients both within
and outside Poland.
250 tonnes of steel pipes produced
A major project was its cooperation with the mining company LKAB, a global leader in the supply of
purified iron ore. LKAB has been operating in Malmberget in the north of Sweden since 1870. To enable
it to increase annual production of purified iron ore
to up to 25 million tonnes, a new pelletising plant
was needed. Within this project, the team at Izomar
Pomorze Sp. z o.o. undertook the construction of the
pipelines and the associated supporting structures.
As part of this, it supplied over 250 tonnes of
vent lines and compensators with a diameter of
up to 3.8 meters and a wall thickness of up to 12
mm. Included in the job was designing and producing all the components as well as coating the
pipelines with corrosion protection. Once that had
been done, the company faced the challenge of
transporting the huge parts by road and sea from
Poland to Malmberget in Sweden.
Nine successful years in the marketplace
Since its establishment nine years ago, Izomar
Pomorze Sp. z o.o. has become an experienced and
well-regarded service company in the area of
plant maintenance. The technical industrial services
provided by Izomar Pomorze are particularly beneficial to operators of power plants. The company
focuses on the maintenance and servicing
of steam generators and boilers and their related
components such as electric filters, valves, pumps
and pipelines as well as coal and ash transportation
systems.
Izomar Pomorze Sp. z o.o. took on the role of general contractor in the replacement of the entire
electrical filter system in the WP 120 power plant boiler in the Toruń power plant in Poland.
The pipelines of the pelletising plant in Sweden
have a diameter of up to four metres.
One of its main clients is the Toruń combined heat
and power station that lies 180 kilometres to the
north west of Warsaw. Over the last eight years,
Izomar Pomorze‘s systematic approach to customer
acquisition has enabled it to repeatedly win largescale and technically challenging maintenance
contracts at this location. These contracts have
included the construction of an entire electric filter
system for the power plant boiler WP 120.
Expertise and reliability pay off
The parent company BIS Izomar Sp. z o.o. in
Warsaw has built up an excellent reputation over
the past years for refractory lining of industrial
plants in cement works. The foundation for this
good market position was laid in 1998 with the
.
first cooperation with the Oz arów cement works,
some 160 kilometres outside Warsaw. In the
course of time, BIS Izomar‘s high level of expertise,
.
flexibility and reliability made it one of the Oz arów
Group‘s permanent partners.
.
In the Ozarów cement works, BIS Izomar carries
out all modernisation and maintenance work on
the plants. The lining of complex plant components
requires sound expertise and considerable installation experience. A high level of engineering
expertise is also necessary, since lining solutions
are largely custom-built.
The lining specialists at BIS Izomar Sp. z o.o. have
for a long time now also been deployed at other
cement works such as Cementownia Małogoszcz
part of the Lafarge Cement Group, and Cementownia Chełm part of the RMC Polska Group. The
BIS subsidiary has also made a name for itself outside of Poland. For example, the Irish Cement
Group uses the lining services of the Polish company for its Podilsky Cement cement works in the
Ukraine among others.
BIS Industrial Services België N.V. supplies scaffolding and insulation for ExxonMobil
Gaining orders with occupational safety
discusses the weekly scorecards. BIS uses the services of Bruno Jans, the safety manager who came
up with the idea of the “buddy system”.
Quality, reliability and customer service are not the only success factors at Bilfinger Berger
Industrial Services AG. Its considerable efforts in the area of occupational safety and accident prevention also contribute to its strong market position. A current example of this is
the insulation and scaffolding work being carried out as part of the new construction of a
gas turbine power plant with cogeneration in Antwerp (Belgium) by BIS Industrial Services
België N.V.
One of the critical factors in the contract award
process was the high level of expertise when it
came to the occupational safety and qualification
of the employees. “It wasn‘t just about money,”
states Christof Bossuyt, Director of BIS Industrial
Services België N.V. “The fact that we could guarantee that our scaffolders wear double safety belts
when working really impressed our client,” continues Christof Bossuyt. The successfully introduced
new “Professional Workforce” (PWF) certification
and qualification system for scaffolders also played
an important role in award of the contract. Workplace safety is ultimately rated as extremely impor-
The good cooperation with the clients and the strict
adherence to all the occupational safety regulations
translated into follow-up orders. ExxonMobil only
cooperates with a few carefully selected companies.
“You have to earn your status, because ExxonMobil
classifies its contractors according to the categories
gold, silver and bronze,“ explains Ton Flintrop, a
project manager at BIS Industrial Services België N.V.
Each time a contractor provides a service, the
service is assessed and the category reviewed.
“We obtained the status ‘silver’ in certain areas,
which is a constant incentive for further improvement,” continues Ton Flintrop. In the last major turnaround, the BIS team received a very good assessment. Ton Flintrop is confident that the current project will actually exceed this performance level. In the
meantime, BIS Industrial Services België N.V. has
already once been declared contractor of the month.
tant at ExxonMobil. PWF is based on an intensive
assessment of the professional aptitude of all scaffolders working in the service of BIS companies in
the Netherlands and Belgium or of subcontractors.
This qualification offers the client an assurance that
BIS always works with qualified professionals.
Organisational challenge
The scaffolding and insulation work started in July
2007 once the order was placed by the responsible engineering office, Foster Wheeler Italiana
S.p.A. Even though the project has to be completed on time and precisely as stipulated in the order,
safety always has top priority. “The biggest challenge is perfecting the organisation of the logistics. All the work is carried out while production is
underway and in limited space. A thorough plan
and good communications are critical here. BIS
handles this brilliantly,” says Pieter Coenraads,
Safety Manager at ExxonMobil, in praising the BIS
team‘s approach.
“Safety capital” of Europe
Contractor of the month award: Fons Dam and
Johan Vyaene from BIS Industrial Services België
N.V. with Bruno Jans from ExxonMobil (r to l).
Constant incentive to improve
To take account of the important role of occupational safety, the people involved in the construction of the cogeneration plant in Antwerp came up
with something special: the project was christened
“Cogenville” and, as the most senior project
manager in ExxonMobil, Franco Rabolini is the
“mayor” of this virtual city. He is depicted on
Future-oriented technology
Constructing scaffolding for ExxonMobil means
very high requirements for occupational safety.
posters and in brochures with the slogan:
“Nobody gets hurt.” Cogenville is described as the
“safety capital of Europe”. Monthly safety meetings are held at which the safety goals and accomplishments achieved are lavishly rewarded. Each
company involved has a partner manager from
ExxonMobil who is responsible for occupational
safety and, together with the project manager,
The gas turbines of the cogeneration plant on the
refinery grounds of ExxonMobil Corporation will
produce 136 megawatts once they are completed.
The cogeneration plants have a major advantage
over conventional thermal power stations, which
are designed exclusively for electricity production.
By simultaneously releasing electricity and heat,
they achieve a much higher level of efficiency
(up to 90 percent higher). The heat generated
by the power plant in Antwerp is used for steam
production and for heating the crude oil in the
refinery.
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5
BIS Industrieservice Mitte GmbH installs one of the most modern multi-purpose plants
“This build has gone well from the very beginning”
The two new production lines had to be constructed in the company‘s existing building, erected in
2002. All the work was carried out in the immediate vicinity of the existing plants while production
was underway. This represented an especially
big challenge for the general planner and the BIS
fitters in cooperation with other trades: the task at
hand involved sealing the construction site spanning a total of four storeys so no dust could escape
to maintain the clean-room and explosion protection requirements during the manufacture of other
Typical of the production plant in Lahr is the large
number of components and apparatus made glass,
which were fitted by BIS Industrieservice Mitte and
Mainz-based specialist supplier QVF Engineering
GmbH. The extremely delicate material again
required particular care in all installation work and
fastening of the infrastructure connections. Even the
slightest impact or vibration can cause hairline
cracks or fissures in the material, rendering it unusable. Hubert Raimann, Technical Head at CU
Chemie Uetikon, explains the use of glass pipes and
glass apparatus as follows: “It‘s important for us
that we see what‘s happening in the plant – glass
helps here.” When it comes to cleaning to, with
glass it‘s easy to tell whether everything is really
clean: an absolute must in this highly flexible batch
production system.
BIS Industrieservice Mitte impressed the client with
its competency as a service provider with its experience, proximity, flexible human resource capacities
as well as in-house pipeline production and storage.
Short procurement channels meant the size of the
construction site on the limited premises could be
reduced to a minimum. In addition, the BIS team
was able to respond much more flexibly to lastminute planning changes, additional work and unexpected special demands. This meant the team could
cope with a third more work than planned, in the
same time, without problem. This good performance
opened the way for the BIS electrical fitters, around
ten of whom likewise wired the entire plant, from
the fourth storey to the first, without any accidents.
“This build has gone well from the very beginning,”
Active pharmaceutical agent production extending over four storeys in Lahr.
says BIS project manager Arnold Gutgesell. “The
most difficult task in such a complex project is
always coordinating the trades. It‘s critical that the
teams get on together, that everyone knows what
matters and that everyone‘s committed.”
“More often than not, adhering to the very tight
schedule becomes the greatest challenge,” says
Hubert Raimann. This hurdle was overcome very
well together with the client and the general plan-
ner. Before the production plant as a whole was
started up, finished stages of construction were
inspected in cooperation with the BIS team and
components gradually commissioned. Complete
documentation for each individual welding seam,
each component and each union was standard
here. The critical moment for all those involved,
however, was when the plant started properly for
the first time. There were no problems during commissioning, thanks to the good cooperation of all
involved and careful preparations.
flohagena.com
Confined an challenging conditions
products. The vertical, confined build using components made from high-quality and very sensitive
special materials meant the BIS heavy-equipment
erectors had to be extremely careful. Thus boilers
made from corrosion-resistant Hastelloy, crystallisers, centrifuges and dryers with a weight of up to
18 tonnes had to be raised horizontally over the
facade and into the 24-metre high building with
absolute precision.
flohagena.com
CU Chemie Uetikon is a leading European manufacturer of active pharmaceutical agents, intermediates and special chemicals. With its staff of around
120 qualified specialists, the company produces
and supplies its own products as well as a variety
of different active agents to customer order to wellknown companies around the world. The new
production lines will not only double capacities in
the new multi-purpose production plant MPA-P3,
they will also extend the company‘s technical capabilities,
in particular those of the production programme. This will
cement the company‘s position
as one of the leading producers
of active agents. With a new
6,300-litre reactor as well
Hubert Raimann,
as three additional 3,000-litre
Technical Head of
reactors, the company also has
the plant.
the technical prerequisites to
perform low-temperature reactions down to a temperature of –90°C. This extends the range of services offered to include attractive organometallic
reactions, CC coupling reactions and highly exothermic reactions. There are already more than enough
orders for the newly-constructed highly modern
production capacities at Chemie Uetikon. According
to a statement by the experts from the US Federal
Drug Administration (FDA), CU Chemie Uetikon
now has one of the most modern plants for the
manufacture of active pharmaceutical agents.
flohagena.com
Time is money – a maxim proven once more in the plant extension of the company CU
Chemie Uetikon GmbH in Lahr. This medium-sized supplier recognised early on the trend
among large pharmaceutical companies to outsource the production of active pharmaceutical agents. Since the first two production lines were commissioned in 2002, the business has
developed very well. In March 2008, after just nine months of construction time, two further
production lines went into operation. BIS Industrieservice Mitte GmbH, under the direction
of a general planner, undertook the erection of the heavy reactor, centrifuge and dryer equipment, the construction of the entire pipeline including infrastructure as well as the installation of the electrical, measurement and control equipment.
Compact plant fitting required the utmost care by the BIS fitters.
Hydrogen plant of the TOTAL refinery in Vlissingen
Extension on a tight schedule
During the extension of TOTAL refinery‘s
hydrogen plant in Vlissingen (Netherlands),
BIS ROB (Montagebedrijf N.V. and Zeeland
B.V.) made a significant contribution to
making sure that the tight schedule was
observed. Within nine months running up
to the end of last year, the plant‘s production capacity was extended to 23,000 m3 of
hydrogen per hour.
BIS ROB was entrusted with construction of
a pipeline and fitting of key plant components
as the main contractor by the German company
Linde. The coating, insulation and scaffolding
work as well as the filling of the furnace lines with
catalysers was carried out by subcontractors.
The 5-man team at the start of the extension
increased to up to 120 specialists working 12hour shifts in July, August and September.
Because of the holiday season more subcontractors had to be used, including colleagues from the
Hungarian BIS subsidiary BIS Hungary Kft. This
cooperation worked out perfectly.
to the tight schedule the various trades all had
to be carried out at the same time in a very confined space. The mechanical work had to be hand-
280 tonnes of steel processed
The bulk of the order was completed by October.
The construction of the reactor and installation of
pumps then became the responsibility of a team
of around 25 employees. All in all, BIS employees
worked 85,000 man hours and welded 7,300
seams. More than 280 tonnes of carbon steel,
heat-resistant steel and stainless steel were needed for the project. Prefabrication of the pipelines
with a diameter of up to four inches took place in
the ROB workshop near Vlissingen, while the bigger diameters were fabricated in the central workshop in Beveren in Belgium. “TOTAL Vlissingen is
pleased with the quality of our pipelines and
welding work,” says project manger Koen Van den
Berghe. One particular requirement was that due
ed over by mid-November so that the new hydrogen plant could be commissioned at the end of
November.
ACT | confidently
in always striving for solutions that will
truly aid clients.
ACT
CONFIDENTLY
and constructively in standing up for
improved solutions.
in the context of lean decision-making
processes and enhanced modes of
action.
in order to work dynamically and
flexibly with all clients.
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6
CURRENT ORDERS INDUSTRIAL SERVICES
Customer
BIS companies involved
Project name
Place/country
Service provided by BIS
Implementation schedule
CENTRAL EUROPE
RAG AG Österreich
BIS E.M.S. GmbH, Cloppenburg
RAG GTA
Puchkirchen and Haag,
Austria
Planning, delivery, installation and commissioning of two
gas drying plants with a gas throughput of 88,000 Nm3/h
and 135,000 Nm3/h respectively
10/2007 - 06/2009
RWE Systems AG
BIS E.M.S. GmbH, Cloppenburg
RWE GTA Epe 5
Epe, Germany
Planning, delivery, installation and commissioning of a gas drying
plant with a gas throughput of 350,000 Nm3/h
11/2007 - 09/2009
Boehringer Ingelheim
BIS Industrieservice Mitte GmbH,
Frankfurt
Dabigatran fluid bed coater
Ingelheim, Germany
Delivery and installation of pipelines incl. insulation with a
nominal diameter from DN 25 to DN 500
01/2008 - 06/2008
Infraserv Höchst
BIS Industrieservice Mitte GmbH,
Frankfurt
EBS power plant
Frankfurt, Germany
Delivery and installation of pipelines incl. insulation with
a nominal diameter from DN 80 to DN 300 for accessing the energy
of the EBS power plant in Industriepark Höchst
12/2007 - 08/2009
RAC Chemnitz GmbH
BIS Industrieservice Ost GmbH,
Leuna
Cold reservoir
Biberach, Germany
Delivery and installation of 2,500 m2 of cold
insulation/corrosion protection
05/2008 - 09/2008
FISIA Babcock
BIS OKI Insulation GmbH, Pforzheim Expansion plant insulation (SCR)
Heringen, Germany
25,000 m2 of heat insulation
02/2008 - 12/2008
SNC Lavallin
BIS OKI Insulation GmbH, Pforzheim LNG terminal
2
Saint John,
New Brunswick, Canada
3,000 m of cold insulation
01/2008 - 03/2008
NORTHERN & EASTERN EUROPE
Intecha
BIS Czech s.r.o., Most, Czech
Republic
New reactor
Litvínov,
Czech Republic
Fabrication of the reactor
(32 t, 41 m3, length 10 m, Ø 2.7 m)
11/2007 - 02/2008
Intecha
BIS Czech s.r.o., Most, Czech
Republic
New reactor
Litvínov,
Czech Republic
Fabrication of pipes for the heat radiator
(1) 8.5 t, 2,863 m3, length 7 m, Ø 0.84 m;
(2) 3.9 t, 3.2 m3, length 7.4 m, Ø 0.85 m, corrosion protection
12/2007 - 02/2008
Fintec
BIS Czech s.r.o., Most, Czech
Republic (Chemopetrol Chembuild,
Monpetrol, SI Unimontex)
Special procedure on visbreaking plant
Litvínov,
Czech Republic
Prefabrication and installation of pipelines, weight: 34 t,
prefabrication of an apparatus for a machine
01/2008 - 04/2008
Heat insulation on two new boilers
Tušimice,
Czech Republic
Prefabrication and installation of the insulation
for the boiler, 60,000 m2
04/2008 - 09/2008
Vitkovice Heavy Machinery BIS Czech s.r.o., Most, Czech
Republic (Chemopetrol Chembuild,
Monpetrol, SI Unimontex)
Turboteam Kft.
BIS Hungary Kft., Budapest, Hungary Compressor station
Beregdaróc, Hungary
Fabrication of large pipelines (Ø1200 x 28 mm, Ø1100 x 22 mm,
Ø800 x 20 mm), operating pressure: 64 bar
01/2008 - 08/2008
Skanska
BIS Isenta AB, Kungälv, Sweden
Pfizer medical plant
Strängnäs, Sweden
Insulation of 15,000 m of pipeline
01/2008 - 10/2008
SC AMV Group Bucharest
BIS Nimb S.A., Bucharest, Romania
Steel construction in a Bucharest apartment block Bucharest, Romania
Fabrication and installation of a 523 t steel construction
11/2007 - 07/2008
Karrena Sp. z o.o.
BIS plettac Sp. z o.o.,
Ostrzeszów, Poland
Saint Gobain
Dąbrowa Górnicza, Poland Assembly and removal of a support scaffold for
construction of a vault
01/2008 - 05/2008
WESTERN EUROPE
ExxonMobil
BIS Industrial Services België N.V.,
Belgium
Construction of a new cogeneration plant
Antwerp, Belgium
Scaffolding and insulation
10/2007 - 06/2008
Air Liquide Rotterdam
BIS Industrial Services Netherlands,
Zwartewaal, Netherlands
New maintenance contract for four plants
Rotterdam, Netherlands
Scaffolding and insulation
2008
TOTAL Raffinerie Antwerpen BIS ROB Montagebedrijf N.V.,
Beveren-Melsele, Belgium
Waste heat boiler replacement
Antwerp, Belgium
Replacement of a waste heater boiler
02/2008 - 03/2008
Conoco Phillips
(Humber Refinery)
BIS Salamis Ltd. Loughborough,
England
Fabric maintenance
Humberside, Great Britain
Scaffolding, corrosion protection and heat insulation
01/2008 - 12/2010
Fairfield Energy
BIS Salamis (M&I) Ltd.,
Aberdeen, Scotland
Off-shoreinspection
Dunlin, Great Britain
Inspection service and non-destructive testing
01/2008 - 12/2009
Misurata, Benghazi
Libya
Delivery of exhaust gas gates for 4 bypass systems
01/2008 - 07/2008
TECHNICAL NOISE CONTROL
NEM
BIS Gerber GmbH, Dortmund
Construction of a turnkey sour gas drying plant by BIS E.M.S. GmbH
BIS companies combine expertise
The exploration, transportation and processing of natural gas in Germany is part of the main
business of ExxonMobil Production Deutschland GmbH (EMPG). This Hannover-based company operates primarily in northern Germany, where the largest deposits of natural gas can be
found. It also transports the sour gas found in this region, which needs to have the hydrogen
sulphide removed in special treatment plants.
From January to July of last year, a further well,
the Deblinghausen Z6, was drilled in the Deblinghausen gas field in the Nienburg district of
Weser-Ems-West. Once a gas find was reported,
BIS E.M.S. GmbH was able to start the construction of the turnkey acid gas drying plant including the accompanying 1.5 kilometers of pipeline
in August.
EMPG started its search for natural gas in northern Germany 50 years ago with the Deblinghausen
Z1 well in the Nienburg district. Not all natural
gas is the same, however. “Sweet” gas consists
mainly of methane and can be fed directly into the
pipelines and transported for immediate use after
it has been crudely purified and dried. “Sour” gas,
on the other hand, which is found most often in
northern Germany, contains up to 30 percent
hydrogen sulphide and is purified in two modern
natural gas treatment plants (Großenkneten in
Oldenburg and NEAG in Nienburg) in a complex
technical washing process before it can go to the
consumer. The sulphur that is removed is sold on
to the chemical industry as a raw material.
Special material requirements
Deblinghausen Z6 is a sour gas drying plant in
which solids and liquids are removed from the
delivered natural gas at approx. 95 bar and the
gas is dried to a water content of max. 50 mg/m3
(Vn) in an unmanned, fully automated setup. The
plant, a turnkey construction by the BIS company
E.M.S., consists of numerous plant components
such as surplus water separator, heater, gas/air
heat exchanger, separator, absorber, regenerator,
flare, flash gas compressor, pumps and valves.
Sour gas is purified and dried in a fully automated setup.
“The drying of sour gas places particular demands
on the materials that come into contact with the
media involved,” says Günter Suing, the project
manager responsible at BIS E.M.S. GmbH. According to Günter Suing, media containing sulphurous
water can result in costly hydrogen damage to
components. In an unsuitable material, even relatively low stresses can produce cracks and fractures leading to sudden component failure and
posing a serious threat to people and the environment due to the explosive power of hydrogen
sulphide and the combustibility of the media. To
avoid such damage, the steels used must adhere
to precise limits for alloying elements.
That is why, according to Günter Suing, the materials appropriate for use with sour gas are not only
20 to 30 percent more expensive, they also have
longer delivery times. All welded seams with the
exception of the welded seams on high-alloy
steels and buried pipelines outside the stations
must undergo stress-relief annealing and 100 percent non-destructive testing.
This was the first time that BIS E.M.S. GmbH used
other BIS companies as subcontractors to complete
a project for EMPG. And with good success. BIS
Nordwest GmbH undertook the insulation work
and BIS Heinrich Scheven GmbH laid the pipeline.
After a total of 42,000 hours, the plant was handed over to EMPG on schedule in December 2007 –
and without any reportable accidents.
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7
RWE extends the brown coal power station in Neurath
Optimised plant engineering for a greener approach
RWE Power AG is currently constructing the largest and most modern brown coal
power plant in the world in the Neurath district of Grevenbroich as part of a far-reaching renovation. This project, scheduled to run until 2010, will see the construction of
two new power plant blocks featuring optimised plant engineering that will take into
account environmental protection with reduced carbon dioxide emissions. The two BIS
companies BIS Industrieservice West GmbH, Düsseldorf and BIS OKI Insulation GmbH,
Oberhausen both have a significant involvement in the construction.
The brown coal power plants in the Rhineland
guarantee around 50 percent of the power supply
for North Rhine-Westphalia and 15 percent of the
power supply for the entire country. Neurath is one
of four power plant locations in the Rheinland
area. The first block with an output of 300
megawatts was commissioned here in 1972.
Today the location has a total output of more than
2,200 MW.
Significantly higher efficiency
Two new power plant blocks F and G with the most
modern, environmentally compatible plant engineering have gone up in Neurath in the past year.
The redeveloped BoA double-block plant increases
the efficiency of power generation on the basis of
brown coal by more than 30 percent compared with
old plants. Carbon dioxide emissions are reduced
accordingly. Overall, this means a reduction in
annual emissions of carbon dioxide of up to 6 million tonnes.
The two new blocks in Neurath have an operations
area of around 90 acres. The gross output is 1,100
MW each. By improving the fuel utilisation, efficiency of more than 43 percent can be achieved.
The most striking elements are the two buildings
for the steam generators (boilers) and the two
cooling towers. The plants will be around 173
meters high. To compare: Cologne Cathedral,
the third-highest church in the world, is 157
meters high.
Extensive scaffolding work
Within the framework of an equal joint venture,
around half of all the scaffolding work on the site
was carried out by BIS Industrieservice West. The
experts from Düsseldorf already had a good track
record with RWE Power. For the past
three years or so, they have taken
responsibility for all scaffolds for the
boilers and process plants both during
operation and for inspections within
RWE‘s brown coal power plant in Frimmersdorf. The scaffolding work in Neurath places the highest demands on
logistics and the employment of material and vehicles. The amount of material
consumed is enormous at around 9,000
tonnes. The boiler dimensions are a
challenge for construction of the scaffold. It comes down to creating secure
and easy access points for the numerous
subsequent trades to guarantee a
smooth operation. Scaffolding is therefore a key trade within the overall power
plant project and a lot of what happens
subsequently depends on the quality of
the workmanship.
Extensive insulation work
There is a further BIS company involved in
Neurath: BIS OKI Insulation GmbH has
been commissioned to insulate the two
boilers. The scope of delivery and services
includes all secondary activities needed to
carry out sound and heat insulation work. The new power plant blocks F and G in Neurath have huge dimensions. Their operations area covers 90 acres.
Above all this includes engineering, doc- The plants have a height of 173 meters and their gross output reaches 1,100 MW.
umentation, scaffolding, studding and
welding work, corrosion protection repairs, conbe 250 fitters, who will install a total of 400,000 m2
“BIS OKI Insulation was already responsible for engistruction management, building site equipment,
neering, documentation, project and construction
of mineral wool mats and 300,000 m2 of sheet steel
coordination, quality assurance, inspections and cermanagement for a comparable boiler in Nieder(companies from the BIS Group will be involved in
tificates as well as the procurement of all materials
außem,” explains Klaus Harzheim, Managing Director
carrying out the insulation work). In addition, BIS
needed to carry out the work. The total area to be
of BIS OKI Insulation GmbH, “and as always, we will
OKI Insulation will undertake insulation of the elecinsulated is around 200,000 m2. All work must be
make sure this time too that the work is carried out
tric filters for blocks F and G with a volume of
professionally.”
40,000 m2.
completed within 20 months. At the peak there will
BIS arnholdt GmbH introduces a scaffolding manual to implement statutory regulations
Safety has top priority
Safety in the workplace plays an important role throughout the Bilfinger Berger Industrial Services AG Group. Regular training and further education are just as important here as clear rules
and regulations. BIS arnholdt GmbH has compiled its own scaffolding manual to implement
the ordinance on industrial health and safety.
A working group established in 2006 comprising
BIS arnholdt GmbH safety and structural engineers
as well as managers with practical experience compiled a print-ready manual in just six months. This
manual draws upon all existing statutory regulations and standards, the ordinance on industrial
health and safety, regulations of the builders‘ trade
association as well as the current documentation
from the scaffold manufacturers. One challenge the
authors of the manual faced is the use of scaffold
material from different manufacturers and their systems that has resulted historically at BIS arnholdt.
The goal was to combine all the previously known
rules and the new statutory regulations in one work
to provide to employees and clients as a handy universal assembly and usage manual. The purpose of
this manual is to regulate the assembly, modification and disassembly variants of the scaffold systems used (modular, frame and non-standardised
scaffolds). A further goal is to
reduce additional expenditures
for designs and structural analyses without neglecting safety in
any way. The manual additionally serves as a reference work for
employees since it also contains
load tables and empirical values
that permit rough calculations
on-site.
As a safety officer, Johannes Moor trains employees from the
Gelsenkirchen subsidiary.
The manual comprises 129 pages
with general safety-related rules,
measures to protect against collapse, comprehensive installation
instructions, components, assembly variants, risk
assessments and test reports.
Upon completion of the manual, every technical
employee (site managers and all trade employees)
in BIS arnholdt GmbH received a copy. All employees are trained about what happens in the respective subsidiaries. This is done by means of monthly
instruction. In addition, the information learned is
reviewed using questionnaires.
The response of employees and clients to the
manuals has been positive throughout. The plan
now at BIS arnholdt GmbH is to continue the
training measures so that implementation into
practice becomes a matter of course. With this
internal project, it has succeeded in pulling
another step ahead of the competition in terms
of safety and quality, thus consolidating its position as a leading provider of industrial scaffolding services.
ACT | together
so that all individuals can take their
fair share of our mutual success.
ACT
TOGETHER
in keeping up correct behavioural
conduct and maintaining high job
safety standards.
in consistently striving for
goal-oriented implementation.
in maintaining the entrepreneurial
spirit of all individuals.
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8
Corrosion protection and scaffolding work on the F60 conveyor bridge in Reichwalde
Life returns to the open-pit mine
The brown coal in the Reichwalde region lies at
depths of up to 85 metres and the beds are an
average of 9 to 12 metres deep. By the year 2050,
around 360 million tonnes of brown coal will
have been transported from the depths of the
earth to the coal storage yard directly at the
power plant via a 13.5 kilometre conveyor system. With an efficiency rating of over 43 percent,
the new block in the Boxberg power plant is
state-of-the-art. The modern plant is designed for
a service life of 40 years. Operating at full load,
the Boxberg power plant needs around 50,000
tons of raw brown coal every day. With the new
power plant block, the demand will increase by a
A 20,000 m3 enclosure was needed to provide
protection from the winter weather.
Archiv Vattenfall Europe Mining & Generation
For almost ten years there has been no brown coal mining in Saxony‘s Reichwalde.
Now life is returning to the huge mine, with extraction due to start again. The
reason for this is the decision by the energy company Vattenfall to invest almost
€900 million between now and 2011 in the construction of a new 675 megawatt
block in the nearby Boxberg power plant. BIS arnholdt GmbH is actively helping to
restore the open-pit mine in Lusatia to full operation within two years.
further 15,000 tonnes. Before extraction starts in Reichwalde in 2010,
some 30 companies are involved in
the recommissioning, including the
Großräschen-based East Branch subsidiary of BIS arnholdt GmbH. A key
component in the overall project is the
large F60-type conveyor bridge. This
huge steel construction will be used to
bag, transport via the shortest path
and tip out the open-cast layers locat- Approx. 360 million tonnes of brown coal will be extracted from the Reichwalde open-pit mine up to 2050 or so.
ed above the coal bed in one process. Production is set to begin in 2010.
It can transport up to 500,000 m3 of
supplied by Vattenfall Europe Mining AG. Over
excavated material each day. The dimensions are
The project started in June 2007 with construction
1,000 tonnes of steel grit as well as approx. 30
impressive: around 500 metres long and 60
of the scaffolding, followed by the corrosion protectonnes of coating material were used for the overmetres high. It weighs around 11,000 tonnes,
tion work just one month later. All in all, the corroall project. The project was originally scheduled to
which corresponds to a freight train with a length
sion protection work on the conveyor bridge
be completed by the end of October 2007. Severe
of approx. 7,000 metres.
involved an area of over 20,000 m2. This building
rainfall and unfavourable weather conditions during
project also involved the largest contiguous internal
the corrosion protection stage, however, meant it
scaffold to date in the subsidiary‘s history with a
The largest internal scaffold in history
was necessary to postpone the completion date in
size of 83,000 m2. As the project managers responA joint venture established specially for the projconsultation with the client. This brought a new
ect comprising the companies BIS arnholdt GmbH
sible, Claus Fritzsche for scaffolding and Jens
challenge, since the rest of the work had to be com(East Branch) and Massenberg GmbH was comMuschick for corrosion protection brought all of their
pleted as a winter project. To this end, the remainmissioned by Vattenfall Europe Mining AG, based
experience to bear in this very challenging project.
ing open area of the conveyor bridge was fully
in Cottbus, to realise lot 2. BIS arnholdt GmbH
enclosed. The enclosed space had a volume of
assumed overall technical responsibility within the
1,000 tonnes of steel grit used
approx. 20,000 m2, equal to the dimensions of two
joint venture. The value of the contract was
The corrosion protection work was carried out in the
around €1.7 million. Overall responsibility within
stages of surface preparation and compressed air
airships. Appropriate air conditioning was installed
the joint venture rested in the hands of Dieter
blasting, followed by coating. The relevant DIN
to allow work to continue at exterior temperatures
Hildebrand, Head of the Corrosion Protection
standards were carefully followed during compleof –5 °C. The building project was completed at the
Department.
tion of the work, as were the detailed specifications
end of January 2008.
The power grid maintenance division of BIS Salamis Ltd enjoys good growth
Market leader in just a few years
In Great Britain, power is distributed above ground, with the transmission lines protected by
overhead line masts. As part of their legal and supervisory obligations, the operators of the
national power distribution network must guarantee a secure and reliable power supply and
therefore continuously maintain and service the supply network.
The power grid maintenance division of BIS Salamis
Ltd adapted very well to the special requirements of
this market in Great Britain and in the past four
years has increased its annual revenues to more
than €5.3 million (2003: €1.3 million). In addition,
the company is also the market leader in Great
PRODUCTION CREDITS
Publisher:
Bilfinger Berger Industrial Services AG, Munich
Responsible for content: Thomas Töpfer
Project management: Ullrich Esser
Editorial team: Ullrich Esser (copy and editing),
Beate Kneuse (copy), Michaela Helm (assistant)
Editorial address:
Zentralbereich Konzernaufgaben/
Unternehmenskommunikation,
Gneisenaustraße 15, D-80992 Munich
Telephone +49 89 14998-135
Telefax +49 89 14998-277
e-mail: [email protected]finger.com
Internet: http://www.BIS.bilfinger.com
Reprinting with indication of source permitted/
please submit copy.
The
is available in English, Czech, German,
Hungarian, Polish, Spanish and Swedish.
Britain for tower coating work. BIS Salamis Ltd has
the most experienced specialists in United Kingdom
in works manager Stan Krupski and his team. “This
growth is down to the efforts of Stan Krupski and
his team to always deliver the best possible quality
in this market with its special requirements,” says
Andy Birkett, Commercial Director of BIS Salamis
Ltd, in explaining this success.
Key clients include large supply companies such as
National Grid plc and Scottish Power Ltd for overhead transmission lines in the range from 400 kV to
132 kV as well as the regional power providers that
operate transmission lines with voltages from 11 kV
to 132 kV. BIS Salamis Ltd‘s range of services for
maintenance of overhead line and steel grid masts
includes surface preparation, industrial cleaning and
corrosion protection as well as condition inspections
including steel machining and grounding. Its expertise includes cleaning and coating work in the substations as well as more minor repairs and mounting of the safety notices.
as well as our record of reliability, quality and safety enabled us to win the tender for National Grid. A
high standard of quality has been achieved through
investment in management, further training and
equipment as well as our focus on maximum occupational safety,” says Andy Birkett. The framework
contract for the coating work on the substations is
already being carried out, while the work on the
branch circuits and power cut-out switches in the
substations in Exeter, Devon has already been successfully completed.
There are already further orders due to be dealt with
across the country.These include steam cleaning and
coating of cooling systems as well as work on the
outbuildings and control buildings of the substations. The framework contract for the construction of
anti-climbing devices and safety notices is already
being carried out.
BIS Salamis Ltd. is the market leader in Great
Britain for tower coating work.
ACT | creatively
Winning against strong competition
In 2007, the team from the power grid maintenance
division of BIS Salamis Ltd were successful in winning further bids. Two national framework contracts
for coating work on substations as well as the construction of anti-climbing devices and safety notices
for overhead lines were concluded with National
Grid. “We won against strong competition for both
of the contracts, which have a minimum duration of
two years. Our considerable experience in this area
so that we can continue to set market trends
as a successful company.
ACT
CREATIVELY
so that quality and integrity continue to be
central to our dealings.
in order to further develop the market
position of the leading industry service
provider.
in order to achieve sustained growth, as well
as shouldering social responsibilities.