SOLUTIONS FOR INDUSTRIAL SERVICESPage 3Page 12Page 52Continuity in the face of changeThe BIS Group’snew management teamBIS plus MCEAdded skillsQuality assuranceSystematic approach to achievinguniformly high standardsglob eThe BIS Group magazine forcustomers, partners and the Groupn o 1 2010Benchmark An effective für compliancein system der Praxis generates bewährtes trustCompliance-Systemand provides security
EDITORIALglobe 1/2010page 2» Everyone pulling on the same end of the ropeGLOBE, THE BIS GROUP’S INFORMATION MEDIUM, HAS BEEN GIVEN A NEWLOOK. YET, IT STILL HAS THE SAME FUNCTION – TO FACTUALLY PRESENT TO OURBUSINESS PARTNERS THE BROAD RANGE OF SERVICES PROVIDED BY OUR GROUP.WITH ITS SIZE AND INTERNATIONAL COMPOSITION, IT STANDS FOR THEDYNAMIC GROWTH OF OUR STILL RELATIVELY YOUNG INDUSTRY. FOR THISREASON IT IS ALL THE MORE IMPORTANT FOR US TO DEMONSTRATE CONTINUITYIN THE FACE OF CHANGE.In our new functions aschairman of the newlyestablished AdvisoryBoard of the BIS Groupand new CEO, we areboth committed to this.As the long-standing CEOand the new CEO, we areboth pulling at the sameend of the rope, signallingto our customersa clear consensus in allfundamental matters.This particularly appliesto our understanding ofcorporate compliance,Thomas Töpfer (left) and his successor as CEO, Dr. Michael Herbermann, want to continue theBIS Group's success story.which is the title themeof this issue to stressthe importance whichwe attach to it. We areconvinced that integrity forms the basis forearning our customers’ trust, thus creatingthe foundations for sustained partnerships.This is not merely a credo but stems fromthe experience that we have gained andwhich is confirmed by what our operatingcompanies and our customers have repeatedlytold us.In addition, this issue explores in detail theintegration of the former MCE companies.We have provided examples demonstratingsome of the skills which they are contributingto the BIS Group. Despite their differentbackgrounds, the BIS Group and the formerMCE companies have expressed from theoutset their clear commitment to providingtheir customers in the process and powergeneration industries with sustained supportas service partners in their efforts toboost productivity and efficiency. In its coremarket of Austria and Central Europe, thishas allowed MCE to evolve into one of theleading providers of plant engineering andindustrial services, while the BIS Group hasadvanced to become the European marketleader in industrial services. With the additionof the new companies, the BIS Group isfurther reinforcing its profile as a providerof solutions and as a strategic partner to itscustomers.The way in which customers are able tobenefit from the synergistic effects arisingfrom the integration of MCE is illustratedin the report on the construction of a pilotplant at the Schwarze Pumpe industrial andcommercial estate in the German Lausitzregion. Further examplescan be found in the“Divisions” section, rangingfrom processingplants for crude biogasto the development andassembly of new fluegas absorbers as well aspower station projectsand major contracts inthe oil and gas industry.In a further firm sectionentitled “Networks”, thenew Globe addressessubjects to which the BISGroup attaches particularimportance and whichour customers tell us arealso crucial for them. Inthis issue, we explorequality assurance as well as training for specialistsand executives at the BIS Academy.We are proud to be able to present thisbroad range of subjects to you. It is not leastof all confirmation of what our customersthink we are capable of achieving. We areworking in concert to ensure that this doesnot change.Thomas TöpferMember of the Executive Board of Bilfinger Berger SEand Chairman of the Advisory Boardof the BIS GroupDr. Michael HerbermannCEO of the BIS Group
EDITORIALglobe 1/2010page 3CHANGES IN THE EXECUTIVE BOARDDr.-Ing. Michael Herbermann was appointednew Chief Executive Officer of BilfingerBerger Industrial Services GmbH effective1 September 2010. He took over from ThomasTöpfer, who assumed the position ofChairman of the Company’s newly createdAdvisory Board in accordance with his responsibilityas a member of the ExecutiveBoard of Bilfinger Berger SE on that date. TheAdvisory Board has replaced the previous SupervisoryBoard following the change in theBIS Group’s corporate status, as a result ofwhich it was converted from a German jointstock company (AG) to a limited-liability company(GmbH) at the beginning of the year.Dr. Michael Herbermann (50) comes to the BISGroup from technology company GEA Group,where he was most recently Division Presidentat Netherlands-based GEA RefrigerationTechnologies and, in this function, CEO of RoyalGEA Grasso Holding NV. Before assumingglobal responsibility for industrial refrigeration,he was head of the Power business unitwithin the GEA Energy Technology segmentand simultaneously Chairman of the ExecutiveBoard at GEA Energietechnik, Bochum.Born in Krefeld, Germany, Dr. Michael Herbermannstudied mechanical engineeringat the Aachen University of Applied Sciences,majoring in process technology and industrialengineering. He completed his doctoratein engineering at the Jülich Research Centre.After commencing his career at RWE Entsorgung,where he was involved in thermalwaste disposal equipment, he joined theGEA Group in 1997.“I look forward to being able to contributemy international industrial experienceto such a successful company as the BISGroup,” says Dr. Michael Herbermann. “Iam convinced that the BIS Group’s statusas a provider of solutions and the crucialimportance which it attaches to serviceand customer orientation have been instrumentalin its business success. This proventrack record is to be maintained in thefuture.”In his capacity as chairman of the newAdvisory Board, Thomas Töpfer will continueto accompany the BIS Group closely.During his tenure as CEO, the Company’srevenues widened from around EUR 850million in 2004 to a current figure of EUR3 billion.THE NEW MANAGEMENT TEAMThe BIS Group’s Executive Board comprises – from left – Dr. Michael Herbermann, CEO, Matti Jäkel, CFO, Dr. Rudolf K. Jürcke , COO,and Gerhard Schmidt, COO.As part of efforts to streamline structureswithin the BIS Group, the Company’s managementteam has also been reorganised.Alongside the new CEO Dr. MichaelHerbermann, Matti Jäkel was appointedCFO effective 1 October 2010. He comes tothe Company from Bilfinger Berger Ingenieurbauin Wiesbaden, where he held thesame function. The COOs are Dr. RudolfK. Jürcke and Gerhard Schmidt, who areeach responsible for two divisions. Dr.Rudolf K. Jürcke is in charge of the Northern& Eastern Europe Division and theWestern Europe & International Divisionwith its focus on Northern America, whilethe Central Europe Division and the crossborderPlant Technologies Division reportto Gerhard Schmidt.The Central Europe Division comprises thecompanies based in Germany, Austria andSwitzerland as well as Benelux.With its new structure, the BIS Group isremaining on its growth trajectory underpinnedby organic growth as well asacquisitions aimed at reinforcing activitiesin existing markets or entering new ones.Matti Jäkel (49) sees this in particular asthe main appeal of his position as CFOat the BIS Group. Born in Düsseldorf, hegraduated from the Technical Universityof Munich with a degree in engineering.He then went on to study business administrationat the Henley ManagementCollege and Brunel University in England,completing a part-time MBA course. Uponjoining Bilfinger Berger in 1989, he initiallyworked as an engineer but assumed commercialduties as of 1994. His career withinthe Group took him to Australia, wherehe held management duties from 1997 to2000, and to the United States, where heheld the position of CFO. In this function,he was assigned to the Construction segment,moving on to the Engineering segmentin 2007.
CONTENTSglobe 1/2010page 4» Contents7 PIONEERING ROLE IN COMPLIANCEIntegrity is a core aspect of the BIS business principles. Thisgoes beyond simply complying with the law, somethingwhich in any case goes without saying, but refers to the basicway in which the Company defines itself. On page 11,Thomas Töpfer, who was the BIS Group’s CEO for many years,discusses compliance in globe’s title story, succinctly statingthat “we want to assert ourselves in the market place on thestrength of our performance, quality, reliability and fairness.”732 PIONEERS IN BIOGASWorking with renowned partners, the specialists at BIS E.M.S.have developed and launched a new process for treatingbiogas.36 FOR CLEAN AIRInnovative flue gas absorbers supplied by BIS Industrieservice Mitteensure that the sludge incineration plant in Frankfurt am Main isable to operate within the maximum levels prescribed by the EU.1212 A HARMONIOUS FIT AND REINFORCEMENTWith the integration of the former MCE companies, the BIS Grouphas sharpened its profile as a strategic solutions partner for industrialservices and plant engineering. The reports on our focus themeoffer examples of this, illustrating these additional skills and explaininghow they come together to create a situation which is bestdescribed as “Even better together”. This is also demonstrated bythe intensive collaboration between former competitors during theconstruction of a pilot plant in Lausitz (page 30).36
CONTENTSglobe 1/2010page 5TITLE7 Integrity is the basis of successfulpartnershipsFOCUS46 STRONG VOTE OF CONFIDENCEMaster contracts worth around EUR 230 million awarded by theoil and gas industry testify to BIS Industrial Services’ growing reputationin the United Kingdom.4652 SETTING STANDARDSBIS companies impress their customers with their systematic commitment to site safety.The HSEQ awards received by the BIS Group provide further incentive.55 INVESTING IN THE FUTUREThe extensive training activities organised by the BIS Academy for the employees of theBIS Group constitute major investments by the Company in its continued future viability.After all, only qualified operatives and executives are able to provide the qualityexpected by customers. The broad range of training activities and the depth which itachieves set the BIS Academy apart from the rest of the industry.12 BIS plus MCE – exemplary referencesillustrating the broad range of services16 “Linthal 2015” extension project18 Overhauling a blast furnace in the winter20 Ideally positioned for pipeline engineering22 A successful turnaround24 Award for VibraCheck25 High operating times26 Prestigious project in Paris28 Specialist in checking centresDIVISIONS30 Combined skills for pilot project in theGerman Lausitz region32 Top-quality biogas34 New maintenance base for the Gasscogas terminals36 Innovative flue gas absorbers38 Extensions to Hungarian power station40 Follow-up contract for large power station42 Clean energy for Europe44 Merger strengthening position in UKmarket46 UK oil and gas industry placing its trustin BIS skills48 BIS Salamis recipient of a safety award49 Current contractsNETWORK52 Convincing HSEQ efforts54 High-level quality assurance58 BIS Academy-Quality comes fromqualifications60 Credits52
TITLEglobe 1/2010page 7» Integrity is the basis of successfulpartnershipsINTEGRITY IS ONE OF THE MAIN ASPECTS OF THE BIS BUSINESS PRINCIPLES.IN A BROADER SENSE, IT ALSO DEMONSTRATES THE COMPANY’S COMMITMENTTO A POSITIVE DEFINITION OF HOW IT SEES ITSELF, WHILE PROVIDING THEUNDERPINNINGS FOR SUSTAINED BUSINESS SUCCESS. WITH INTEGRITY, WEARE ABLE TO SECURE OUR CUSTOMERS’ TRUST AND QUALIFY FOR A LONG-LASTING MUTUALLY BENEFICIAL PARTNERSHIP GOING BEYOND TECHNICALSKILLS. WITHIN OUR COMPANY, INTEGRITY ACTS AS A CATALYST, ENCOURAG-ING A CULTURE OF CLARITY, TRANSPARENCY, RELIABILITY AND A PREFERENCEFOR COMING STRAIGHT TO THE POINT.Andreas Frey, the BIS Group’scompliance officer, wants tostrengthen trust and peace ofmind by means of an effectivecompliance system.With its vision of “Solutions for Industrial Services” and resolute effortsto imbue this vision with life, the BIS Group has made a crucialcontribution to establishing industrial services as a separate sector.The leading European provider of services for the process industry isalso setting standards in corporate compliance. In fact, it was one ofthe first operators in this industry to establish a broad-based compliancesystem. As Andreas Frey, the BIS Group’s compliance officerstresses, “one of the main tasks is to impress on all parties involved thenecessity of a compliance programme, to heighten their awarenessof the numerous risks to which the Company and its employees areexposed and to encourage transparency in all business processes.”SETTING STANDARDS WITH COMPLIANCEThe importance of corporate compliance is repeatedly thrown intorelief when large international companies attract critical mediacoverage on account of corruption. In such cases, the economic loss isexacerbated by a heavily tarnished image. Consequently, honesty isincreasingly emerging as the crucial basis for protecting a company’spublic image and retaining the respect of customers and suppliers.Ultimately, an effective compliance system and transparent businessprocesses safeguard a company’s solidity and ensure its continuedfuture viability.Against this backdrop, it is the most natural thing in the world for acompany like the BIS Group to develop and implement a compliancesystem. Yet, as is the case with the many other standards which awell-managed company must take into account these days, complianceshould not be seen as a necessary evil but, on the contrary, embracedwith particular enthusiasm and resoluteness. Managementat the BIS Group have given compliance top priority out of their ownpersonal conviction. A further factor is the Group’s decentralisedstructure characterised by the allocation of a high degree of businessresponsibility to the operating units. In this connection it is andalways has been a question of defining integrity as a crucial elementof the entire Group’s approach to the way it does business. For thisreason, the BIS Group has been flanking its compliance activitieswith a broad-based information and communication strategy fromthe outset.“It is important for us,” says compliance officer Andreas Frey, “forcompliance not be seen as something negative which everyone associateswith unsuspected conflicts and personal risks. For this reason,we have taken a highly hands-on approach to this issue from the verystart and see one of our main tasks as being to render the numerouslegislative rules applicable to an internationally active companyas transparent as possible for each individual employee by defininga small number of basic and general rules and guidelines.” What ismore, this matter is continuing to grow in importance for nationaland international companies. Like the BIS Group, many enterpriseshave adopted a code of conduct or a similar set of rules. This opensup the possibility of working more closely together in the area of corporatecompliance in our relations with our customers and suppliersand of receiving and offering mutual support. The BIS Group willcontinue to play a pioneering role in the future.CLEAR RULES AS A GUIDELINEThe BIS Group’s compliance programme is based on the seven principlesof conduct binding throughout the entire Bilfinger Berger Groupand the ancillary code of conduct. They primarily cover matters suchas corruption, embezzlement and anti-competitive behaviour as wellas unlawful employment, moonlighting and social conduct withinthe Group. These rules are worded in a readily understandable andsuccinct form, giving each employee a clear basis for his or her ownactivity and providing protection in the event of any conflicts.
TITLEglobe 1/2010page 8Specifically, the Company is expressly committed to combating allforms of corruption and corruptibility. All attempts to exert illegalinfluence on the decisions of customers and other contractual partnersare rejected, as are all forms of enrichment at the Company’sexpense. Employees are made to realise that the consequences ofcorruption can wipe out entire company facilities and destroy jobs.The Company is also expressly against illegal agreements whichdistort competition. Submission agreements, price-fixing and market-sharingarrangements are specifically cited as being illegal andsubject to criminal prosecution. Clear rules also apply to the allocationof the Company’s own employees as well as the deploymentof subcontractors. Illegal employment and moonlighting are nottolerated.Over and above this, the Group is committed to the principles ofmutual respect, fairness and loyalty and thus rejects all forms ofdiscrimination and workplace bullying. The Company expressly remindsexecutives of their function as role models and expects themto treat their staff cordially and with respect. In addition, a duty isimposed on all employees to refrain from using confidential informationfor their own purposes without authorisation and to makedonations only in accordance with the applicable rules.However, merely having rules is not sufficient if a compliance systemis to be effective in practice. In addition, ongoing informationand training as well as clear monitoring and sanctioning mechanismsare required. Regular reports on new statutory requirementsand court judgements at executive meetings or at staff assembliesin particular have proven their merits. In addition, the complianceofficer is available for personal discussions on all matters related tocorporate compliance. All training sessions – both face-to-face andin the form of IT-based e-learning – aim to provide participants withbasic knowledge concerning corporate compliance and to describepractical examples from day-to-day operations. “We are broadeningORIGINS IN THE UNITED STATESThe term “compliance” arose at the end of the eighties in theUS financial services industry. Companies started implementingsystems imposing on all employees the duty to observethe applicable legal rules and regulations, particularly thoseaimed at preventing money laundering, corruption and insidertrading. As international business relations grew in importance,compliance also gained additional significance notonly in the European financial services sector but in otherindustries as well – especially at companies which operateon a cross-border basis in heavily regimented markets suchas energy, pharmaceuticals and chemicals and which mustcome to terms with rapidly changing local rules and guidelines.In Germany, all major companies now have compliancedepartments and systems, which are being extended allthe time. This reflects the fact that corporate compliance notonly entails the observance of all legal and statutory obligationsbut increasingly also involves adherence to ethicalprinciples. At the same time, large enterprises have adoptedtheir own specific codes of conduct. The BIS Group is playinga pioneering role in compliance in the industrial servicessector.
TITLEglobe 1/2010page 9Kurt Harald AaseHead of humanresources and compliance managerBIS Industrier ASFranz BraunManaging directorBIS Maintenance Südwest GmbHFriedrich LampeHead of sales and project managementBIS E.M.S. GmbHCOMPLIANCE SYSTEMS EXPECTEDTHESE DAYSCORRECT BEHAVIOURALWAYS PAY OFFTHE KEY TO FAIR COMPETITION“The decisive focus which BIS Industrierplaces on compliance has strengthenedmany customers’ trust in our company.Since the adoption of our principles ofethics in 2004 and the implementationof the BIS code of conduct, we have notedrising interest in compliance on the partof both customers and employees. The ongoingfurther development of the compliancesystem and the sharing of experiencewithin the BIS Group are therefore veryimportant for us. None of our customersin Europe would place any orders with acompany which had been known for compliancebreaches or did not have a compliancesystem in place.”“No-one can afford to breach legal or statutoryrules or principles of ethics. Thatis why mid-size companies have recentlystarted paying a great deal of attention tothis issue as they have not yet fully implementedend-to-end compliance systems.Accordingly, we broach this subject fromthe outset in our initial presentations anddescribe our business principles and codeof conduct in detail. Our customers respondvery favourably to this, applaudingthe clear vision which we have for executingour business in full observance of alllegal and ethical rules. They repeatedlyconfirm that we operate a very professionalcompliance system. And indeed, thesystem in use at the BIS Group is so tightlyknit that breaches are almost impossible.All our employees are very aware of thefact that it is not worth succumbing toshort-term temptations and that – likethe quality of their work – fair and correctconduct ultimately always pay off. What ismore, everyone has the peace of mind ofknowing that nothing can happen to thempersonally as long as they remain withinthe defined boundaries.”“Compliance has been part of ourday-to-day business activities for a longtime as we work with leading internationalcompanies. These companies havefor many years been implementing numerousmeasures aimed at preventing anybreaches and irregularities of any kind.This includes, for example, the unbundlingof networks and sales and regularjob rotation for executives. The contractswhich we sign with our customers alsoinclude compliance requirements, whichwe undertake to observe by signing thecontracts. Accordingly, our managementtakes a very proactive approach both internallyand externally to such issues andsystematically ensures that no breachesoccur. New employees are immediatelyacquainted with our compliance rulesand required to take part in training heldat the BIS head office. It would be desirablefor all companies in Germany to adoptcomparable compliance systems as thisis the key to fair competition.”
TITLEglobe 1/2010page 10our e-learning offerings both in terms of content and scope but arealso attaching key importance to face-to-face training with the possibilitiesthat this provides for sharing information and expressingopinions in person,” explains Benedikt Gruhn, corporate complianceassistant. “Experience shows that this gives us valuable feedback,allowing us to identify problems out in the field and pointing to areasin which we can provide additional support and information.”Experience gained from the local training organised by the individualBIS subsidiaries is also incorporated in the training syllabi on anongoing basis. In this way, the content of the training programmesand e-learning modules can be enhanced and additionally translatedinto the individual local languages in use within the BIS Groupstep by step to ensure that linguistic barriers do not stand in theway of a common understanding of the rules and requirements.All information and training activities are documented. It is also importantfor matters liable to be of relevance for compliance purposes,e.g. invitations, to be documented in writing. The transparencyand audit-proofness of business activities not only makes it moredifficult for individuals to breach compliance policies but also servesto protect employees.In addition to preventive information and training measures, effectivesupervision is, of course, also necessary. Any suspicions areinvestigated systematically but free of any prejudice in close collaborationwith other relevant departments within the Group, localcolleagues and, if necessary, business associates. As a matter ofprinciple, it is also possible for any suspicions to be reported anonymouslyor via an external ombudsman. These monitoring activitiesalso provide the Company with valuable knowledge, allowing it toadditionally enhance its compliance rules and practical implementation.ZERO TOLERANCE TOWARDS DELIBERATE BREACHESWith its compliance system, the BIS Group not only observes legalrequirements but also fulfils its duty to protect its employees asmany breaches are caused by ignorance. The code of conduct andthe information and training programme ensure that employees areaware of potential risks and heighten their awareness of conflict situations.However, the principle of zero tolerance applies to all casesof deliberate breach. Anyone deliberately and consciously breachinglegal and statutory rules and regulations in the performance oftheir duties for the BIS Group cannot expect to receive any leniencefrom their employer. In the interests of safeguarding the internaland external credibility of the compliance system, no compromiseswhatsoever are possible.Yet, for all the decisiveness with which the compliance system isimplemented, the main focus at the BIS Group is always on convincingstaff of the merits and importance of the system. This –far more than the fear of personal consequences – has helped to
INTERVIEWglobe 1/2010page 11ensure that compliance is not associated with the loss of businessopportunities. Rather, there is a general understanding that complianceserves to highlight the risks occurring in day-to-day businessand helps to find shared alternative solutions involving less risk. Asa result, a successful compliance team protects not only the individualemployees but the enterprise as a whole. However, in the longterm this is possible only with the active support of all employees.Within the BIS Group, what has become evident is that the key tothis is communication at all levels, clear commitment on the partof management to compliance and also support on the part of allemployees.“COMPLIANCE BREACHES ARE NOT ATRIVIAL MATTER”globe: Mr. Töpfer, as an industrial servicesprovider the BIS Group is operatingsuccessfully in a still young sector and isamongst the pioneers when it comes tocompliance. What prompted you to takesuch a pro-active approach to this issue?Thomas Töpfer: As one of the leading providersof industrial services, we are a rolemodel in every respect. This imposes onus a great responsibility which we takevery seriously. With our solutions-orientedrange of maintenance services, we arecommitted to enhancing the availabilityof industrial assets and, hence, to heighteningour customers’ productivity andimproving their cost structures. At thesame time, it goes without saying that weguarantee the highest order of health andenvironmental protection, on-site safetyand quality. And this also includes lawfuland correct conduct. We want to succeedin the market place on the strength of ourservices, quality, reliability and fairness.globe: What is the main reason for thesuccess of your compliance system?Thomas Töpfer: A recent study conductedby PricewaterhouseCoopers discoveredthat the acceptance and success of complianceprogrammes materially hinge oncorporate culture. The more positive thiscorporate culture is, the greater the acceptancewill be throughout the entireGroup.At the core of our corporate culture standscredibility. We have defined clear valuesand entrenched them in our businessprinciples to provide all our employeeswith orientation. At the same time, theystress the high priority which we give toquality, service orientation, integrity andsafety as well as team spirit and personalcommitment. These are the valuesby which we are measured – somethingwhich particularly also applies to thestrict observance of all applicable statutoryrules, internal guidelines and generalprinciples of ethics.globe: The same study stated that Germancompanies as a whole still havequite a bit of catching-up to do as far ascompliance is concerned. What is the situationwith respect to the BIS Group’scustomers?Thomas Töpfer: Our customers are predominantlyactive in the process industry.They not only have very demanding HSEQrequirements but also extensive compliancerules. This means that it is importantfor us to set standards with our own compliancesystem. In addition, we operate internationally,including in countries whichhave a far longer history of compliance,such as the United States and Norway,for example. We can learn from the experiencegained in these countries and usethem as a source of inspiration for ongoingimprovements.Thomas Töpfer, a member ofBilfinger Berger's Executive Boardglobe: Looking forward, will compliancecontinue to grow in importance in thiscountry?Thomas Töpfer: Yes, it probably will. Complianceis already crucial for the long-termsuccess of any company. Breaches are nota trivial matter and must never be viewedas such. Accordingly, all companies mustencourage a strong sense in all employeesof what is right and what is wrongand keep this awareness well-honed atall times. This takes time and effort butis something which we do gladly. In thisway, we are able to make sure that dishonestbusiness practices contravening thelaw or unethical conduct don’t have anychance at our Company at any time in thefuture.
» BIS plus MCE –a harmonious fit and reinforcementANNOUNCED IN OCTOBER, APPROVED BY THE EU COMPETITION AUTHORITIESIN DECEMBER, EXECUTED IN THE FIRST QUARTER OF 2010 AND ALREADYCOMPLETED IN ORGANISATIONAL TERMS ON 1 APRIL: THE SPEED WITH WHICHTHE ACQUISITION TOOK PLACE IS ALL THE CONFIRMATION NEEDED TO SHOWTHAT THE INTEGRATION OF AUSTRIAN INDUSTRY AND POWER STATION SER-VICE PROVIDER MCE WAS A PERFECT FIT FOR THE BIS GROUP. MCE IS MATERI-ALLY SUPPLEMENTING AND STRENGTHENING THE BIS GROUP AS A STRATEGICFULL-SERVICE PARTNER FOR INDUSTRIAL SERVICES AND PLANT ENGINEERINGIN THE PROCESS AND ENERGY INDUSTRIES.Even betterBIS + MCEtogether!
FOCUSglobe 1/2010page 14The new Plant Technologies Division is home to the extended range of services targeted atindustrial assets, making them available on a cross-border basis.In 2009, the former MCE companies which have been integrated withinthe BIS Group generated revenues of around EUR 700 million. Asa result, the Group’s total revenues have surged to some EUR 3 billion,accompanied by an increase in employees to more than 27,000.Customers are benefiting from an extended range of services anda broader regional reach. This is not least of all reflected in theenhanced organisational structure. In addition to the existing regionallyoriented divisions, namely Industrial Services Central Europe,Northern & Eastern Europe, Western Europe & International, thePlant Technologies Division has been established as an additionalstrong pillar within the BIS Group. The new cross-regional divisionis home to all of the BIS Group’s extended range of plant technologyactivities. The geographical divisions will retain their strong regionalrelationships with customers.INTERNATIONAL OUTLOOKThe new Plant Technologies Division specialises in international projects,to which it contributes its core skills in industrial plant engineeringand assembly expertise. It primarily targets the chemicals/petrochemicals, metallurgy, paper and pulp sectors as well as theenergy production and distribution industry with a range of servicescomprising planning, fabrication, assembly and commissioningof entire plants or sub-plants as well as components at power stationsand industrial installations. The previous core MCE companiesBIS VAM Anlagentechnik,Wels, Bohr- und Rohrtechnik GmbH – BIS,Vienna, BIS Gerätetechnik, Wels and Bochum, and Slovakian companyBIS Slovensko reside within the Plant Technologies Division. Inconnection with the integration plans, MCE Industrietechnik Linz hasbeen amalgamated into BIS VAM.With their regional focus, the geographic divisions primarily concentrateon the full range of industrial services, such as static equipmentand rotating machinery, E/I&C, scaffolding, insulation andsurface protection. Of the previous MCE companies, BIS Chemservwith headquarters in Linz and offices in Schwechat, Krems, Ebenseeand Burghausen in Lower Bavaria, BIS Industrietechnik Ost (Leuna),BIS TSG Industrieservice in Gersthofen and BIS Personalservices havebeen integrated within the Central Europe Division. At the sametime, the BIS Group’s position in the pharmaceuticals and bioengineeringindustry has been additionally strengthened with the inclusionof BIS Industrietechnik Salzburg. MCE’s specialist skills in steeland mechanical engineering, which entail activities in steel structureand bridge construction, have been added to the Northern & EasternEurope Division.Whereas Germany has previously formed the focal point of the BISGroup’s activities in Central Europe, the integration of most of MCEwill yield an additional strong market presence in Austria. All in all,the Company now has around 100 operating subsidiaries at 130locations as well as numerous further branches across Europe andNorth America. With the addition of the former MCE companies,the BIS Group’s profile as a solutions provider has been sharpeneddecisively. This is demonstrated by the references described on thefollowing pages.
FOCUSEven betterBIS + MCEglobe 1/2010page 15together!BIS’s geographically oriented divisions specialise in comprehensive maintenance services ranging fromindividual tasks right through to full-service solutions as well as personnel and equipment services.
FOCUSglobe 1/2010page 16BIS VAM Anlagentechnik is responsible for a substantial part of the steel engineeringfor the new Limmern power station in the Swiss canton of Glarus.» Demanding extension project“LINTHAL 2015” IS THE NAME OF A DEMANDING PROJECT WHICH KRAFT WERKELINTH-LIMMERN AG HAS LAUNCHED IN THE SWISS CANTON OF GLARUS. ITENTAILS THE CONSTRUCTION OF A NEW SUBTERRANEAN PUMPED STORAGEELECTRICAL POWER STATION TO ADD A FURTHER 1,000 MW TO THE EXISTINGPOWER GENERATION CAPACITY AT THIS SITE. BIS VAM ANLAGENTECHNIKTOGETHER WITH MCE INDUSTRIETECHNIK LINZ, WHICH HAS BEEN INTEGRATEDINTO IT, IS ALSO INVOLVED IN THE PROJECT.With its three storage power stations Muttsee, Tierfehd and Linthal,Kraftwerke Linth-Limmern AG, a partner to the canton of Glarus andthe energy company Axpo, primarily supplies peak power, i.e. thepart of electricity consumption exceeding the base load required tocover daily basic requirements. For this purpose, the Muttsee powerstation uses the water of Lake Mutt to produce electricity. The centralfacility is located in a rock cavern from which the water flows intoLake Limmern. The Tierfehd power station comprises two levels, oneworking with water from Lake Limmern and the other with waterfrom the Hindersand service reservoir. After the electricity has beenproduced, the water flows into the Tierfehd service reservoir. In timesof low demand for electricity, the water can also be pumped fromthe Hintersand service reservoir to Lake Limmern. The Linthal powerstation, in turn, makes use of the height difference between Tierfehdand Linthal.SIGNIFICANT BOOST IN OUTPUTThe power station array currently achieves an output of 460 MW. Asthere is steadily growing demand for peak power, the Limmern powerstation is to be fitted with a strong additional pumped storage
FOCUSEven betterBIS + MCEglobe 1/2010page 17together!station as part of the “Linthal 2015” project to help ensure reliablesupplies of electricity to the north-eastern and central parts of Switzerland.Unlike straight storage power stations, pumped storagestations not only generate peak energy but can also convert excesselectricity arising during low load times into peak energy.The additional power station is to pump water from Lake Limmernback into Lake Mutt, which is almost 630 metres higher. This watercan then be re-used to generate electricity when it is required. A newcavern facility for four pump turbines and a pump station is beingbuilt at an altitude of around 1,700 metres, roughly 600 metres insidea mountain. It will be supplied by water from Lake Mutt, which islocated at an altitude of around 2,400 metres, via two parallel pressureshafts connected to a pressure tunnel. In turn, water will flow viatwo subterranean water tunnels from the cavern station to Lake Limmern,which has an altitude of around 1,850 metres. In accordancewith current plans, the new facility will go into operation at the endof 2015/beginning of 2016, resulting in an increase to around 1,460MW in the aggregate output of the power station array.TWO-YEAR ASSEMBLY PERIODAt the end of last year, a contract for part of the hydraulic engineeringwork was awarded to BIS VAM Anlagentechnik together withMCE Industrietechnik Linz, which has since been integrated into it.This marks the first venture with Kraftwerke Linth-Limmern AG. Thecontract provides for the delivery of two Y-pipes and four distributionpipelines. Y-pipes are the elements used to connect piping witha smaller diameter. In the case of the “Linthal 2015” project, the Y-pipes measure 4.2 by 2.9 by 2.9 metres and weigh a total of 238 tons.The distribution pipes have an interior diameter of 2.9 metres anda length of up to 80 metres. Their weight ranges between 192 and244 tons. All pipes are made from high-strength steel sheeting andmust be able to withstand high operating pressures. The walls havea thickness of between 50 and 120 mm.The services being provided by BIS VAM Anlagentechnik include fulldetail engineering of the Y-pipes and distribution pipes as well as theprocurement of the necessary material, prefabrication and assembly.Work on the project commenced in November 2009. After the completionof detail engineering, the necessary parts will be fabricatedat the company’s plant in Wels over a period of one year and transportedby truck to the site in Switzerland, where they will be broughtto their final destination by means of a cable car.POOLED SKILLSBIS VAM Anlagentechnik, as it is now known, has been a leadingcompany in Europe for industrial plant, piping, apparatusand tank engineering for decades. The company offers a fullrange of services encompassing planning, fabrication, assemblyand start-ups. Individual components and full-scale plantsare supplied by the company’s industrial and power stationpipe engineering, subterranean pipe engineering, apparatusand tank engineering and hydro power departments. Its servicesare supplemented with the provision of expert specialists,non-destructive materials testing, welding support and trainingand skills development for welders.The skills previously held by MCE Industrietechnik Linz havealso been integrated. As a result, the company has evolved intoa leading partner for assembly and engineering services andprimarily targets the metallurgy and power production/distributionindustries. However, the Linz-based company is also athome with mining and tunnel engineering and works in thepaper and pulp industry, the rock, earth and cement industryand waste incineration.Assembly work is to commence in 2013 and continue over a period oftwo years. The parts are to be put together and welded on site. TheY-pipes will be tested with a pressure of 114 bar. “The difficult conditionsfor assembly pose a particular challenge,” explains managingdirector August Oberndorfer, “but this project will mark a further keyforeign reference in pressure pipe engineering.”The pumped storage station is to cover electricity requirements inNorth-Eastern and Central Switzerland.
FOCUSglobe 1/2010page 18» Highly adverse conditions overcomePREMIERE AT VOESTALPINE’S STEEL WORKS IN LINZ. FOR THE FIRST TIME, ABLAST FURNACE WAS CLOSED DOWN AND OVERHAULED DURING THE WINTER.MCE INDUSTRIETECHNIK LINZ, WHICH HAS NOW BEEN INTEGRATED WITHINBIS VAM ANLAGENTECHNIK, PLAYED A CRUCIAL ROLE IN THIS PROJECT.DESPITE THE HIGHLY ADVERSE CONDITIONS, THE DEADLINE FOR COMPLETIONWAS ACHIEVED.At its steel works in Linz, voestalpine operates blast furnace A as itsmain aggregate for producing pig iron as well as the smaller blastfurnaces 4, 5 and 6 with an interior diameter of eight metres. Theblast furnace is the first stage in the production of steel. Iron ore,coke and additional substances such as limestone are placed in thestack of the blast furnace, where they undergo various physical andchemical reactions in steadily rising temperatures, as a result ofwhich the iron ore is converted into pure iron. The waste productis slag together with blast furnace gas, which is used for heating inthe power station. The pig iron and slag collect in liquid form at thebottom of the blast furnace, where they are regularly “tapped”. Thisentails drilling a “tap hole” in the refractory clay plug, through whichthe molten mass flows at a temperature of around 1,250 degreesCelsius. The slag is separated from the iron by means of troughs andtransported away in ladles. The liquid pig iron is then immediatelyconverted to steel at the steel works.The three blast furnaces at the Linz site have a height of 75 metresand each contain a hearth and a stack which is 35 metres tall. TheMCE Industrietechnik Linz played a key role inoverhauling Blast Furnace 5 and 6 operated byvoestalpine at its steel works in Linz (left).The assembly team with bunker as part of thenew hopper system (right).
FOCUSglobe 1/2010page 20» Well positioned in pipe constructionPIPELINES ARE ESSENTIAL FOR THE SAFE AND SECURE TRANSPORTATIONOF RAW MATERIALS SUCH AS OIL AND GAS. BUILDING PIPELINES IS ANEXACTING AND DEMANDING JOB REQUIRING SPECIAL EQUIPMENT. BISGERÄTETECHNIK HAS RECOGNISED THE DEMAND AND IS PROVIDING ITSCUSTOMERS WITH THE LATEST PIPELINE CONSTRUCTION EQUIPMENT.CELEBRATION WITH EMPLOYEES AND CUSTOMERSTogether with its employees and customers, BIS Gerätetechnikcelebrated its 15th anniversary and also the inauguration ofits new logistics centre at its headquarters in Wels, Austria, inSeptember 2010. This also coincided with the traditional GTrace. Further highlights included bungee jumping, a climbingwall, a competition and a broad range of culinary treats.BIS Gerätetechnik is offering the latest generation of this heavy-dutypipeline construction machinery. Thus, sidebooms have a weight of25.9 to 58 tons or even more, while bending machines weigh between5.5 and 32 tons or more and welding beads between six and15 tons. “All the equipment is able to lift up to one third of its ownweight and also lower the load in a single process,” explains GerhardHunger, managing director of BIS Gerätetechnik. “In this way, we areable to offer our customers the best possible equipment for pipelineconstruction.”MACHINERY RENTALS A SUCCESS FACTORBased in Wels in Upper Austria, BIS Gerätetechnik has been specialisingfor many years in rentals of a full range of construction siteequipment. With further offices in Bochum, Vienna and Salzburg, itoffers the latest tools, equipment and vehicles for use at industrialplants in the metallurgy, energy, pipeline, steel and bridge constructionsectors. It boasts a pool of over 11,000 products including containers,welding machinery, vehicles, pipeline construction machinery,hydraulic tools, lifting equipment and power supply aggregates.This is backed by full service including procurement, rental, provisionof equipment, maintenance, repairs and, if requested, transport andinsurance. Qualified technicians provide advice and ensure compli-BIS Gerätetechnik’s new logistics centre at its headquarters in Wels.Currently, there are pipelines with a total length of some three millionkilometres around the world, a figure which grows by around25,000 kilometres each year. “Pipeline construction comprises multiplephases,” explains specialist Peter Lorenz, “for which there isspecial equipment such as bending machines, welding beads andsidebooms.” Cold bending is one of the first steps in the process:the bending machine is used to bend the cold pipes in the pit inaccordance with the surveyor’s measurements. Then welding beadsare used. Explains Peter Lorenz: “These are mobile machines used forwelding ancillary elements and links with the assistance of crawlervehicles in difficult terrain. In this way, the pipes can be preweldedoutside the pit and then welded together after being put in place.”Finally, the sidebooms are used to lift, hold and lower the weldedpipes. They have retractable counterweights to hold the vehicle withthe necessary stability.The pipeline is welded in a fully equipped tent.
FOCUSEven betterBIS + MCEglobe 1/2010page 21together!Sidebooms are used to lower the welded pipes into the pit.ance with the applicable statutory provisions and the application ofapproved testing processes. The pool of equipment is checked regularlyin accordance with the applicable statutory provisions in orderto ensure safety.NEW LOGISTICS CENTREA new warehouse was constructed at the company’s headquartersin Wels last year. Fitted with a modern shuttle system which is linkedto SAP, it provides greater convenience, efficiency and reliability inthe commissioning process. The goods are assembled in such a wayas to ensure that they reach the customer with minimum delay. AsGerhard Hunger stresses, “With our ultra-modern logistics systemwe serve around 1,000 construction sites per year. There is currentlya pronounced trend in favour of equipment service as renting machineryoffers major economic benefits over buying it, reducing investmentsand releasing capital which the customer can channelinto its core business, while also helping to ensure efficient assemblyactivities.”FIRM PART OF CONSTRUCTION SITESBIS Gerätetechnik has been supplying numerous constructionsites for 15 years now. One prime example is the constructionof Austria’s largest gas storage tank near Strasswalchen fromJune 2006 until January 2007 for which it supplied machineryand tools. BIS Gerätetechnik also supplied all the equipment– i.e. containers, vehicles, assembly tools, electrical tools, conventionalwelding machinery and WIG hot-wire welding equipment– for the construction site for the Kops II undergroundpower station in Partenen, Vorarlberg. Located in the Cantonof Wallis in the Swiss Alps, the 1,200 MW Cleuson-Dixencepower station is being fitted with an impressive new pressurepipeline. All the construction site equipment – includingthe entire machinery required for WIG hot-wire weldingfor high-strength steels – has been supplied by BIS Gerätetechnik.
FOCUSglobe 1/2010page 22» Successful team workWITH THE SUPPORT OF THE OTHER BIS GROUP COMPANIES, BIS CHEMSERVSUCCESSFULLY HANDLED THE TURNAROUND OF THE MALEIC ANHYDRIDE (MAH)PLANT OPERATED BY DSM FINE CHEMICALS AUSTRIA AT THE LINZ CHEMICALSESTATE. THE TURNAROUND TOOK TWO WEEKS AND, THANKS TO CAREFUL PREPA-RATIONS, IT WAS POSSIBLE FOR PRODUCTION TO BE RESUMED ON SCHEDULE.Owned by Dutch chemicals company DSM, DSM Fine ChemicalsAustria produces intermediates for the pharmaceuticals, crop andcosmetics industry at the Linz chemical estate. One of these productsis maleic anhydride, which is primarily used for producing non-saturatedpolyester as well as in the synthesis of surfactants, insecticides,herbicides and fungicides. Last October, the MAH plant with its threeproduction lines was scheduled for a general overhaul, somethingwhich entailed a full two-week turnaround. DSM Fine ChemicalsAustria assigned the turnaround duties to Linz-based BIS companyChemserv. With further offices in Vienna, Krems, Kirchdorf, Ebensee,Neustadt an der Donau and Burghausen, this company specialises inindustrial maintenance and has successfully handled a number ofturnarounds for DSM in the past.BROAD RANGE OF SERVICESAs the general contractor, BIS Chemserv was responsible for providinga large range of services. Specifically, these included planningand project management, plant service for apparatus and piping,construction such as furnace construction work and refractory work,assembly, dismantling and servicing of fittings such as hand, regulatingand safety valves, E/I&C including process control, USV facilities,frequency converters, analysis and calibration, servicing of motors,pumps, turbines and compressor, non-destructive materials testing,transportation and related activities such as scaffolding, insulationand cleaning by the customer’s contractors. It was also necessary toreplace the fluid bed steam generator, which has a function similarto that of a heat exchanger, and to overhaul the start-up heater, i.e.a gas burner with a stack required to start up the plant. The workperformed entailed replacing the interior gas and cooling lines andrepairing the firebrick lining.Other BIS companies were also involved alongside Chemserv. Thus,for example, BIS Industrietechnik Ost serviced the apparatus and dismantledand re-assembled the valves. Support was also provided bySlovakian affiliate BIS Industrietechnik Slovensko. Linz-based companyBIS Standortservices, which specialises in providing infrastructureservices at industrial sites, was responsible for the site infrastructureincluding the provision of equipment and tools. BIS PersonalserviceÖsterreich, which also has its head office in Linz, covered additionalstaff requirements.CAREFUL PREPARATIONSGiven the short turnaround period of only two weeks, careful preparationof the job was given top priority. In fact, BIS Chemserv started todetermine the scope of the necessary activities and to plan the individualtasks a year ahead of the turnaround, working closely and veryefficiently with the customer. The turnaround entailed a total of 350work packages comprising a total of 21,000 hours of work. Some 3,500flange connections were opened, 1,200 meters of welding seams appliedto apparatus and piping executed and 500 release certificates issued.Despite the onset of severe winter conditions in the second weekof the turnaround, not a single accident or leak occurred during theentire project. Looking back on the project, Dieter Greuter, turnaroundproject manager at BIS Chemserv, is very satisfied, saying, “We achieveda high degree of efficiency. Accordingly, our turnaround methodfrom the planning phase through to execution and full documentationproved its merits once more.”COMPREHENSIVE FINAL ANALYSISThe individual phases of the turnaround were analysed together withthe customer in detail in a concluding workshop and the results summarisedin an evaluation report. In this way, the knowledge gainedfrom the execution of the project can be put to good use in futureactivities. Summing up the project, Dieter Greuter has this to say:“The turnaround at DSM was further proof of the strengths of ourGroup, particularly the availability of qualified resources and expertiseat both the planning and execution level.”COMPLEX PLANT RELOCATIONFrom December 2008 until February 2010, BIS Chemserv relocatedexisting facilities at the Linz chemical estate and atBorealis sites in Sweden and Norway to the new Borealis InnovationHeadquarters at the Linz chemical estate. Amongother things, this entailed injection mould machinery, blownfilm equipment, fibre machinery, pipelines and laboratoryand testing equipment. Throughout the entire project, between30 to 40 BIS Chemserv employees were on duty at alltimes. All agreed schedule, cost, safety and quality targetswere achieved thanks to the successful collaboration of allparties involved.
FOCUSglobe 1/2010page 24» And the winner is …IT IS PRESENTED ANNUALLY – AND BIS CHEMSERV HAS ALREADY RECEIVEDIT TWICE. WHAT IS IT? THE MAINTAINER AWARD, THE “OSCAR OFMAINTENANCE”. BIS CHEMSERV IS ALSO A FREQUENT RECIPIENT OFCUSTOMERS’ AWARDS.In collaboration with industrial companies,consulting company T.A. Cook hasbeen presenting the Maintainer Awardsince 2009 to recognise and further thecontribution which maintenance makesto companies’ efficiency. The award comesin three categories: “project of the year/industrial company”, “project of the year/service provider” and “special innovationaward”. The recipients are announcedand the awards presented at the “Main-Days” industrial maintenance conferencein Berlin. In addition, the award-winningprojects are described in detail in the“Instandhaltung” trade magazine.IMPORTANT INNOVATIONThis year, the “Maintainer 2010” award for “project of the year/service provider” went to BIS Chemserv for VibraCheck®, its autonomousroller bearing monitoring system. This system providescustomers with an inexpensive and reliable diagnostic tool tohelp schedule maintenance in such a way as to maximise economicefficiency. It has been undergoing extensive field testing by 18selected customers in Austria and Germany since the beginning of2009. Using VibraCheck®, one company, Planung und Errichtungvon Kleinkraftwerken AG, was able to monitor existing damage tothe roller bearing of a machine on a condition-oriented basis untilthe next planned turnaround, thus preventing premature failure.BIS Chemserv received the “Maintainer 2010” award for itsautonomous roller bearing monitoring system VibraCheck.AWARDS RECEIVED FOROUTSTANDING SERVICESCustomers also greatly appreciate BISChemserv’s services. Thus, the Companyreceived the 2009 Safety and QualityAward from Bayernoil RaffineriegesellschaftGmbH in recognition of the qualitywith which it performs its core activities.For this purpose, the procurement, productionand engineering departments atBayernoil review the quality of the workperformed, incidents, employee qualifications,reliability, the construction sitefacilities/equipment, flexibility, the safetystandards of the machinery used andgeneral safety standards on a quarterlybasis. BIS Chemserv ranked very highly inall these categories in 2009.In addition, Chemserv was the only contractor to figure amongst therecipients of the Borealis “Runners-up Award” for HSE in 2009. Borealis,a leading producer of innovative high-quality plastics announces itsannual HSE awards in recognition of improvements made in the areasof accident prevention, process safety and environmental protection.Chemserv received the award in recognition of the engineeringand production of wagons for transporting metal panels and pipes atthe Schwechat plant, one of the most modern and important plasticproduction facilities in Europe with an annual polyolefin capacity ofaround one million tons.GREAT INTERESTVibraCheck® was developed by the Centre of Maintenance Methodsand Technology under the management of Erich Meyer. This systemwas developed, tested and finalised over a period of three years, afterwhich the finished product was unveiled. VibraCheck® has beenon the market since autumn 2009 and is now a firm part of BISChemserv’s maintenance services. “The product has aroused greatinterest and has met with a favourable market response,” says ErichMeyer. He was the recipient of the Maintainer Award on an earlieroccasion as well – specifically in 2008 for the maintenance schoolmanaged under his supervision.SATISFYING CUSTOMER REQUIREMENTS EVENMORE EFFECTIVELYThe Centre of Maintenance Methods and Technology (CMMT)ploughs the latest findings in maintenance technology intoday-to-day maintenance activities. It provides support in allaspects of operating and managing technical equipment inproduction plants and infrastructure. The focus is on improvingand optimising technology and maintenance. Says ErichMeyer, the head of the CMMT: “Our primary goal is to developnew methods and possibilities in the area of industrial maintenancein order to satisfy customer requirements even moreeffectively.”
FOCUSEven betterBIS + MCEglobe 1/2010page 25together!» Consistently high operating timesFOR MANY YEARS NOW, BIS INDUSTRIETECHNIK OST HAS BEEN A RELIABLEPARTNER IN MAINTENANCE SERVICES FOR BOREALIS AGROMELAMINDEUTSCHLAND GMBH VIA ITS WITTENBERG CUSTOMER SERVICE CENTRE.NOW THE EXISTING MASTER CONTRACT HAS BEEN RENEWED FOR THEGENERAL OVERHAUL OF THE MELAMINE PRODUCTION PLANT IN PIESTERITZ/LUTHERSTADT-WITTENBERG.In industry, melamine is mostly refined to produce melamine resin,which is used in high-quality resin adhesive systems, amongother things. In addition, melamine resin foam is utilised as a noncombustibleupholstery for aircraft and cinema seats as well asan acoustic absorber in cinemas, recording studios or sound-deadrooms. Conventional detergents also contain melamine. BorealisAgromelamin Deutschland, the world’s largest producer of melamine,put its melamine production plant in Piesteritz, Germanyinto operation in 2004, achieving an annual production output ofaround 80,000 tons.From the outset, the Wittenberg customer service centre operatedby BIS Industrietechnik Ost was assigned responsibility for generalmaintenance of the plant. Signed for a period of five years, themaster contract provided for maintenance and repairs of all of theequipment in use at the melamine plant, including pumps, piping,field equipment and process control systems. Even during the commissioningphase, the Wittenberg customer service centre workedwith the customer, planning and executing optimum maintenancewith the support of all of BIS Industrietechnik Ost. For thispurpose, “Comos iAge”, a modern maintenance managementsystem, was implemented, permitting improved planning andcontrolling of the necessary activities, among other things. Withthe introduction of this system-based maintenance scheduling,we were able to find an optimum way of performing allthe contractual services,” reports project manager Sven Kluge. “Theefforts which we took during system implementation paid offas we have been able to boost the technical availability of themelamine plant step by step.”BIS Industrietechnik Ost will be handling the maintenance of the Borealismelamine plant in Piesteritz for a further three years.In December 2009, Borealis renewed the master contract by afurther three years, thus confirming its satisfaction. The new contractfor general maintenance services also makes high demands ofthe Wittenberg customer service centre and BIS Industrietechnik Ostas it stipulates that operating times must be kept at a consistentlyhigh level. As well as this, the maintenance process is to be additionallyoptimised to render operations even more efficient and costeffective.“This is of crucial importance in difficult economic timesin particular,” explains Wolfgang Amerer, managing director of BISIndustrietechnik Ost. “And with our highly motivated team, we willmaster this challenge.” A total of 24 employees have been deployedfor the performance of the new master contract.FULL-SERVICE PARTNERBased in Leuna, BIS Industrietechnik Ost is a lifecycle partneroffering a full range of services in the construction and maintenanceof industrial assets. The company combines the technicalexpertise of a plant engineering company with maintenanceskills for industrial assets. Its range includes full-service partnerships,industrial maintenance, plant assembly, turnaroundsand revamping, fabrication, materials management andengineering. It is chiefly engaged in north-eastern and centralGermany and has nine offices throughout Germany.
FOCUSglobe 1/2010page 26» Prestigious project in thepharmaceuticals industrySANOFI-AVENTIS, THE WORLD’S THIRD LARGEST PHARMACEUTICALS COMPANY,IS CONVERTING ITS VITRY-SUR-SEINE PRODUCTION SITE CLOSE TO PARIS INTOA FULL-SCALE BIOTECHNOLOGY PLATFORM. BIS INDUSTRIETECHNIK SALZBURGHAS BEEN AWARDED THE LARGEST SINGLE CONTRACT WITHIN THIS PROJECT.Hitherto known for its vineyards, figs and lilac, Vitry-sur-Seine to thesouth of Paris is set to become a key centre for biotechnology in thefuture. Under the name “Biolaunch”, Sanofi-Aventis is establishing abiotechnology platform at a cost of around EUR 200 million comprisingresearch, development and production activities for harvestingmonoclonal antibodies from cell cultures, among other things, from2012 onwards. These activities are then to pave the way for a newgeneration of more effective and efficient forms of treatment withonly minor side effects. Monoclonal antibodies are already beingused today to treat cancer and autoimmune conditions and to suppresstransplantation-related rejection effects.SITE EVOLUTIONThe project forms a key part of the development plan for the Vitrysur-Seinesite, which is to be converted into a comprehensive biotechnologyplatform with research, development and productionactivities. BIS Industrietechnik Salzburg, which forms part of theBIS Group’s Central Europe Division, was awarded the largest singlecontract within this prestigious project. The BIScompany had sought close contact with a delegationof the Austrian chamber of commerce inParis in order to prepare as efficiently as possiblefor specific conditions in the French market.This delegation provided valuable support withthe project. Dr. Joachim Kreysing, Executive VicePresident of the Central Europe Division, stressesthe strategic significance of the project: “Overthe past year, the BIS Central Europe Division hasreinforced its activities in the biotechnology/pharmaceuticals segment by means of acquisitionsin Switzerland and Austria. The contractawarded to BIS Industrietechnik Salzburg willadditionally strengthen our position in what weconsider to be an important market segment.”The contract entails the mechanical installationof the entire process and energy supply piping,assembly of the apparatus including tanks,pumps, heat exchangers and filters and startupsupport. BIS Industrietechnik Salzburg willbe prefabricating the piping at its own productionsite in Salzburg, where it has the necessarymachinery including an NC-controlled bendingmachine, and will be specifically leveraging itstechnological lead in plant engineering for thepharmaceuticals industry. Around 40 employees will be assigned toprefabrication activities.MANY DECADES OF EXPERIENCEBIS Industrietechnik Salzburg specialises in planning, fabricatingand assembling piping, systems and facilities in thebiotechnology, pharmaceuticals, fine chemicals and energytechnology industries. Specifically, its range entails process,apparatus and piping technology as well as E/I&C. With aheadcount of 250, the company handles complex projectsthroughout Central Europe. Backed by 50 years of experiencein project execution and five offices in Austria, Germanyand Switzerland, it boasts both sector skills and customerproximity.
FOCUSEven betterBIS + MCEglobe 1/2010page 27together!ADDITIONAL PROJECTS IN SITEAt the site in Vitry-sur-Seine, the equipment will be installed andassembled, the piping and insulation laid, the necessary testing performed,the documentation drawn up and support provided duringthe start-up phase. Up to 120 employees have been deployed at thesite. “We are proud to have been awarded this contract for the largestsection of the project,” says Ludwig Gold, managing director ofBIS Industrietechnik Salzburg. “At the same time, promising negotiationsare currently ongoing for additional contracts in connectionwith which we stand to benefit from our experience as a supplier ofsystems and components.” These include the delivery of skids for theproduction of supply media for production operations and the delivery,fabrication and assembly of six super-skid production facilities. BISIndustrietechnik Salzburg started work on the project last December,with completion scheduled for the end of 2011. The managementspokesman, Ludwig Paradeiser, is highly optimistic about the future:“The pharmaceuticals market will continue to grow in importance forour Group. Sector representatives are paying close attention to thepooled skills and capacity which we are able to offer together withour affiliates.”The picture to the right shows assembly work on the Clone Explorer satellitefermenter system.
FOCUSglobe 1/2010page 28» All climatic zones under a single roofWITHIN A SHORT SPACE OF TIME, MCE STAHL- UND MASCHINENBAU HAS BEENAWARDED THREE CONTRACTS FOR THE CONSTRUCTION OF CLIMATE WINDCHANNELS FOR THE MOTOR VEHICLE INDUSTRY, INCLUDING ONE FOR THEWORLD’S LARGEST WIND TUNNEL. THE PROJECTS HAVE A COMBINED TOTAL OFAROUND EUR 175 MILLION, OF WHICH A SUM OF AROUND EUR 80 MILLION HASBEEN ASSIGNED TO THE LINZ-BASED BIS COMPANY.The BMW Group’s Energy and Environmental Testing Centre in Munich,for which a syndicate lead-managed by MCE Stahl- und Maschinenbauconstructed the turn-key test route with five climate wind channels,recently went into operation. The BIS company was responsiblefor the entire steel engineering, the delivery and installation of partof the testing facilities to simulate snow and rain, the boundary layerand exhaust extraction system, the main fan and the transportationsystem for the test vehicles. One particular technical challenge wasposed by the assembly in a single unit of the pressure chamber, whichweighs 190 tons, for the altitude testing facility.Vehicles undergo extensive testing at the BMW testing centre prior tobeing launched on the market. Mountain trips of an altitude of up to4,200 meters and speeds of up to 280 km/h as well as all climate zonesfrom the Arctic to the Sahara can be realistically simulated in the twoclimate channels and the three wind channels.Bilfinger Berger is currently constructing a comparable facility withtwo climate wind channels for a further major German carmaker.Other European automotive groups have also expressed interest insuch facilities. The first project of this type was completed by the companyin Vienna. This entailed the world’s largest climate wind channelfor Rail Tec Arsenal, an internationally active independent researchand testing institute for rail and road vehicles.MCE Stahl- und Maschinenbau is sought afterinternationally as a specialist in the construction oftesting systems for the automotive industry, suchas the BMW Group’s new Energy and EnvironmentalTesting Centre in Munich.
FOCUSEven betterBIS + MCEglobe 1/2010page 29together!» After 100 years time for a new bridgeTHE SUCCESSFUL COLLABORATION BETWEEN MCE SLANÝ AND EUROVIA CZ,WHICH SPECIALISES IN TRAFFIC ROUTE CONSTRUCTION, IS CONTINUING.IN THE CZECH TOWN OF KOLÍN, AROUND 35 KILOMETRES FROM PRAGUE, AGIRDER BRIDGE WILL BE LINKING THE TWO SIDES OF THE RIVER ELBE IN THEFUTURE. THE CZECH BIS COMPANY IS HANDLING THE FABRICATION ANDASSEMBLY OF THE STEEL STRUCTURES.MCE Slaný is responsible for fabricatingand assembling the steel structuresof the new dual-carriagewaygirder bridge in Kolín .The project involves the replacement of the existing railway bridge,which is a good 100 years old, with a new dual-carriageway girderbridge across the River Elbe and the neighbouring flood areas. At thesame time, the maximum clearance of the waterway is to be increasedfrom 4.35 to 5.25 metres. In addition, the lifting field above theshipping route is to be modified to permit a maximum clearance ofup to seven metres.CONSTRUCTION SITE ACCESSED BY TRUCKThe new bridge comprises two load-bearing steel structures, whichMCE Slaný is fabricating and assembling. They have a total length of133.8 metres and, together with the road flooring, weigh 1,384 tons.With the exception of the final coating and sealing of the bridge deck,the steel structures including anti-corrosion surface protection werecompleted at the BIS company’s facilities in Slaný, around 25 kilometresnorth-west of Prague, from August 2009 until February 2010. Witha width of 5.2 metres, a length of 29 metres and a weight of some43 tons, the assembled right-hand structure, which comprises sevenroad and girder elements, was transported directly to the constructionsite in Kolín in mid-March. There, heavy-duty mobile cranes placed theindividual elements in their final position on top of provisional stilts,after which they were joined and welded together.ASSEMBLY IN TWO STEPSA different approach is being taken to the second field. “This is thelongest part of the bridge and has been split into three elementsfor assembly in two stages,” reports project manager Karel Kovář.After the first two elements are assembled by crane and then joinedand welded together, a first longitudinal shunt is performed. Thisis a special construction process which allows long elements to beshifted without any interruption. Then the third element is mounted.“During a second shunt,” explains Karel Kovář, “the entire fieldis then pushed into its final position.” The longitudinal shunt has atotal length of 46 metres.After the completion of all the assembly work, the final coating isapplied. The railway link was closed for a total of 70 days while theassembly and all the construction work was completed on the firststructure. The same amount of time will be required again for thecompletion of the second structure, which was transported to Kolínonce more by truck in July.SPECIALIST SKILLS IN STEEL AND MECHANICALENGINEERINGMCE’s specialist skills in steel and mechanical engineering havebeen added to the BIS Group’s Northern & Eastern EuropeDivision. MCE Stahl- und Maschinenbau GmbH & Co. KG hasmany years of experience in planning, engineering and assemblingcomplex steel structures such as steel bridges, steel constructionelements and hydraulic steel structures as well asspecial industrial and infrastructure elements. With its ownengineering and assembly facilities, it is able to provide highprecisionelements and execute construction and assemblywork within a short space of time. MCE Slaný is a subsidiary ofMCE Stahl- und Maschinenbau in Linz.
DIVISIONSglobe 1/2010page 30180 tons of piping material and 15,000 welding seams are required for the plant being built by Schmid Silicon Technology at theSchwarze Pumpe industrial estate.» Combined skills for pilot projectin the German Lausitz regionTHE INTEGRATION OF MOST OF MCE AG WITHIN THE BIS GROUP HASALLOWED MANY DIFFERENT TYPES OF SYNERGISTIC BENEFITS TO BEHARNESSED. THIS IS ALREADY BECOMING EVIDENT FROM INITIAL PROJECTSSUCH AS THE CONSTRUCTION OF A PILOT PLANT FOR THE PRODUCTION OFMONOSILANE AND SILICON AT THE SCHWARZE PUMPE INDUSTRIAL SITE INLAUSITZ. BIS INDUSTRIETECHNIK OST (FORMERLY MCE INDUSTRIETECHNIKOST) AND BIS INDUSTRIESERVICE OST ARE PLAYING A KEY ROLE IN THISPROJECT. BOTH COMPANIES ARE HEADQUARTERED IN LEUNA.
DIVISIONSglobe 1/2010page 31“As affiliates within the BIS Group, our partnershiphas gained a new intensity, offeringa multitude of benefits for our customer,”says Matthias Kopp, managing director of BISIndustrieservice Ost. “It is now receiving allservices under the same roof and has a singlecontact.” Adds Wolfgang Amerer, managingdirector of BIS Industrietechnik Ost: “As wellas this, the customer benefits from greatertransparency and can depend on enhancedreliability in the execution of the project. Thisis because we are far more flexible as a group– not least of all with respect to personnelcapacity. In this way, we are able to plan andcoordinate the project even more efficiently.”The first joint project being executed by thetwo BIS companies is already well under way.BIS Industrietechnik Ost is the general contractor,offering a wide range of services forthe construction of a pilot plant for the productionof monosilane and silicon for SchmidSilicon Technology at the Schwarze Pumpeindustrial estate in Lausitz. At the same time,BIS Industrieservice Ost is responsible for allthe insulation work. Both BIS companies areworking for Schmid Solar Technology for thefirst time, a leading supplier of technologyfor the production of high-purity silicon andmonosilane based in Baden-Württemberg.dustrial production. Silicon is an importantmaterial in the production of solar panels,computer chips and transistors. “For BISIndustrietechnik Ost and BIS Industrie serviceOst, the construction of the pilot plantis both a challenge and an opportunity,”explains Frank Heyme, the department managerat BIS Industrietechnik Ost responsiblefor the project. “A pilot plant is like a livingorganism, developing as construction progresses.For this reason, changes may ariseat any time, making it important for us to beas flexible as possible.” When it comes to refrigerationinsulation, this is no mean feat asthe foam glass used is a special, non-flexibleinsulation material. “If any subsequent changesare necessary, the insulation is adjustedaccordingly, something which is a very complextask,” explains Matthias Kopp.Even during the pre-project phase, BIS Industrietechnik Ost was able to contribute itsextensive experience as a plant engineeringand maintenance specialist. “At the sametime,” Frank Heyme says, “maintenance,which is an important aspect of our range ofservices, was a crucial issue. If certain thingssuch as the pipeline configuration are takeninto account during the construction phase,this simplifies the ensuing maintenance andrenders repair work easier.”The two BIS companies’ acknowledged expertiseand great commitment during theplanning and construction of the pilot plantare to form the basis for further contracts.“With our detailed knowledge of the plant,we are in the running for post-constructionmaintenance contracts,” says WolfgangAmerer. “Our aim is to build up an establishedposition in Lausitz as the SchwarzePumpe industrial estate is clearly a very importantsite in strategic terms.” On top ofthis, the two affiliates are hopeful of beingable to participate in the construction ofthe plants required for large-scale industrialproduction and thus of forging a long-termpartnership with Schmid Silicon Technology.An additional benefit could also be thefurther intensification of business relationswith Linde Gas, which will be marketing themonosilane and is one of BIS IndustrietechnikOst’s key customers. At the Leuna chemicalestate, it is currently constructing apilot plant for Linde Gas for the productionof “green” hydrogen, i.e. hydrogen producedfrom regenerative raw materials.Specifically, the services provided by BISIndustrietechnik Ost include pipe assembly,picking, temporary storage and the assemblyof all machinery and apparatus as well as thedelivery of two conversion tanks and a reactorweighing 40 tons. The piping activitiesentail the delivery of pipes with a diameterof between eight and 400 mm including bracketsand ancillary structures, prefabricationand assembly. The necessary isometrics areproduced on the basis of the PIDS providedby the CAE System PDMS.All told, around 180 tons of piping materialare required, necessitating close to 15,000welding seams and 60,000 hours of work.BIS Industrieservice Ost is supplying around6,000 m² of insulation for tanks and pipelines.Both thermal and refrigeration insulationis required. The two BIS companies haveassigned a total of some 100 employees tothe project.With the pilot plant, Schmid Silicon Technologywants to find the optimum technologyand plant configuration for the new processwhich it has developed for the productionof monosilane as a basis for large-scale in-AN INDUSTRIAL SITE WITH A LONG HISTORYBIS Industrietechnik Ost and BIS IndustrieserviceOst are both based at the Leunachemical estate in the German stateof Saxony-Anhalt, where they have beenworking on joint projects since Germanreunification. Now, the two BIS companiesare strengthening their operationsin Lausitz with their participation in thepilot plant project at the Schwarze Pumpeindustrial and commercial estate. Withan area of 680 hectares, Schwarze Pumpeis currently home to some 80 companieswith 3,600 employees. The estate canlook back on more than 50 years of industrialhistory. Up until the eighties, a largepart of Eastern German electricity andgas production was based there. Numerousinnovative coal processing and chemicalprocesses were implemented on alarge scale at the industrial estate for thefirst time.Over the last few years, Schwarze Pumpehas evolved from an energy productionand coal processing site into a multifunctionalindustrial estate. For one thing, itaccommodates one of the world’s mostmodern lignite-fuelled power stationsand, for another, more and more companieswhich are primarily involved in newtechnologies, such as Schmid Silicon Technology,are settling at the industrial estate.At the same time, new uses are beingfound for deactivated industrial plants.Thus, for example, a methanol productionplant is to be started up again to producebio-ethanol.
DIVISIONSglobe 1/2010page 32» Top-quality biogasBIOGAS IS PLAYING AN INCREASINGLY IMPORTANT ROLE IN GERMAN NATI-ONAL ENERGY SUPPLIES. WHEREAS IT IS CURRENTLY STILL CHIEFLY USED FORGENERATING ELECTRICITY, IT WILL BE INCREASINGLY FED INTO GAS DISTRIBU-TION NETWORKS IN THE FORM OF BIOMETHANE IN THE FUTURE. HOWEVER, ITMUST FIRST BE CLEANED. WORKING IN COLLABORATION WITH BASF, WINGASAND WINTERSHALL, CLOPPENBURG-BASED BIS E.M.S. GMBH HAS THEREFORECOME UP WITH A NEW PROCESS FOR PREPARING THE CRUDE GAS EFFICIENTLYAND INEXPENSIVELY.The German federal government has definedambitious targets, stipulating that sixbillion m 3 of biogas a year are to be fed intothe German gas network by 2020, equivalentto around six percent of the country’s energyrequirements. However, biogas productionplants currently only produce 162 million m 3– barely 2.7 percent of the target set by theGerman federal government.For these ambitious goals to be achieved, itwill be necessary for around 900 biogas processingplants to be constructed in Germanyby 2020, up from the current figure of some35. “We want to help accelerate the progressbeing made in this area and, in doing so,open up a new area of activity for ourselves,”explains Andreas Möller, department headin charge of process technology at BIS E.M.S.To this end, the Cloppenburg-based companyhas joined forces with BASF and WIN-GAS, a BASF/Gazprom subsidiary, as well asWintershall, a solely owned BASF subsidiary,to develop a new method of processingbiogas. The chemicals giant developed thePuraTreat TM R+ detergent while BIS E.M.S.planned and engineered the technical facility.Working together, the participating companiesreadied the new detergent for themarket in a pilot plant, where it underwentover 1,000 hours of testing.The new detergent is now being used intwo of the largest European scrap fermentationplants in Schwedt and Zörbig nearBittersfeld, where BIS E.M.S. built two biogasprocessing plants incorporating the newprocedure. Upon completion, the two plantswill each be supplying 26 million m 3 of highqualitybiomethane per year.
DIVISIONSglobe 1/2010page 33EVERYTHING COMPLETED INA SINGLE GOEfficient and inexpensive, the newly developedprocess simplifies the process substantially.Thus, with the conventional method itis frequently necessary to desulphurise thebiomass during the fermentation process,something which requires ferric chloride andair. “However, the introduction of air has anadverse effect on the quality of the gas. Ontop of that, the use of ferric chloride costsmoney,” explains Friedrich Lampe, the projectmanager in charge of biogas purificationtechnologies at BIS E.M.S. In the case of thenew process developed by the four partnersthis step is not always required. “Our detergentremoves hydrogen sulphide and carbondioxide in a single sequence,” explains FriedrichLampe.The results achieved with the new processare highly impressive: gas with a methanecontent of over 99 percent, similar to highcalorienatural gas, is achieved. Thanks tothis high methane content, it is no longernecessary to blend the biogas with liquidgas.SWIFT INCREASE IN DEMANDWhile the two gas processing plants werestill under construction, the Cloppenburgbasedspecialists placed further bids in themarket. Demand is enormous as the Germanfederal government has stipulatedthat ten billion m³ of biogas per year are tobe fed into the gas network by 2030. Thismeans that a total of some 1,500 biogas processingplants still remain to be constructedin Germany.In contrast to previous products, the detergentused retains its effect even after extendeduse. “In addition, it can be regeneratedfor further use at lower temperatures thanis the case with comparable products,” headds. With its affinity to hydrogen sulphide,the BASF detergent can absorb a large proportionof this substance, thus removing italmost completely from the gas. A furtheradvantage is that only 0.01 percent of themethane is lost, compared with betweenthree and six percent in the case of otherprocesses. As Friedrich Lampe explains:“Water washing extracts the methane viathe water. With pressure swing adsorption,methane can be lost as a result of the extraction.”Almost identical in design, the two waste materialfermentation plants operated by Verbio AG inZörbig near Bitterfeld (to the left) and Schwedtfigure amongst the largest European referencefacilities. They were built and put into operationby BIS E.M.S. The picture in the top-right cornerof this page shows the stripping column underconstruction.GAS FROM LIQUID MANUREExperts assume that many fossil fuels willbecome scarce in 50 years’ time at the latest.This means that new processes forgenerating energy must be developed.One of these entails the use of biogas, acombustible gas which is produced fromthe fermentation of biomass in biogasplants. The input material for technicalproduction of biomass mostly comprisesliquid manure, dairy, biological and foodwastes or regenerative materials such asmaize.50 to 70 percent of biogas comprisescombustible methane as well as carbondioxide and a small proportion of hydrogensulphide, nitrogen, hydrogen andammonia. The biomass is placed in fermentersto produce biogas. The substrateis stored in the fermenters for a period ofup to 30 days and constantly stirred. Theactivity of microorganisms results in biogas.The next step is for the gaseous mixtureto be purified. Before it can be usedfor producing electricity and heat in combinedpower/heat stations, the gas mustbe dried and desulphurised. The massremaining after fermentation is suitablefor use as biological fertiliser.Whereas electricity can be fed into thegrid without any problems, there arefrequently no suitable uses for the heatproduced. This situation can be remediedby processing the biogas and feeding itinto the gas distribution network. In thisway, biogas can be used at any location asbioheat or bioelectricity or as biofuel formotor vehicles.However, this in turn necessitates priorprocessing of the biogas in special processingplants to remove the carbon dioxideand hydrogen sulphide. Consequently,the ideal gross caloric value is achievedand the risk of corrosion, e.g. as a resultof carbon dioxide, averted. The standardprocesses currently in use today are pressureswing absorption, water washing aswell as physical and chemical absorption.One of the chemical absorption methodsincludes the process described here calledPuraTreatR+.
DIVISIONSglobe 1/2010page 34» New maintenance baseNORWEGIAN COMPANY GASSCO AS HAS AWARDED BIS E.M.S. GMBH“MAINTENANCE AND MODIFICATION CONTRACTOR” STATUS. ACCORDINGLY,THE CLOPPENBURG-BASED BIS SUBSIDIARY IS NOW RESPONSIBLE FOR HAND-LING MAINTENANCE AND PLANT MODIFICATIONS AT THE THREE GASSCOGAS TERMINALS IN EAST FRISIA.stresses Egil Herløe, managing director ofGassco Germany. Adds BIS E.M.S. managingdirector Theodor Osteresch, “we see thiscontract as a great opportunity and will bedoing everything we possibly can to justifythe trust placed in us and to live up to ourcustomer’s expectations.”Looking forward to working together: Gassco German CEO Egil Herløe (right) and BIS E.M.S. managingdirector Theodor Osteresch.SUPPORT GUARANTEEDThe partnership commenced with a twomonthmobilisation phase during whichBIS E.M.S. acquainted itself with the processesand structures at Gassco. At the sametime, coordination and organisational taskswere defined to prepare the mechanical andE/I&C services. A five-strong managementteam will be overseeing the new base andhandling the necessary activities with ateam of 25 operatives. “Our headquarters inCloppenburg will be providing support andadvice during the preliminary phase in particular,”says Roland Päplow, general managerat BIS E.M.S., who played a material role inthe pre-contractual phase.East Frisia is an important region for Germangas imports. In fact, the gas delivered viaEmden currently accounts for around 27percent of total German gas consumption.Gassco operates three landing stations inEmden and Dornum, acting as the terminalsfor a total of three pipelines via whichNorwegian gas from the North Sea is pumpedto Germany. The gas is processed atthe terminals. This includes measuring the volumereceived, decompressing and par tiallydesulphurising the gas and finally feedingit into the downstream gas distributionnetwork.EXTENSIVE PARTNERSHIPIn the past, Gassco has handled maintenanceand repair work at the terminals itself.Now, however, it is relying on the skills andexpertise of BIS E.M.S. As the maintenanceand modification contractor, the BIS companyis responsible for the entire maintenanceactivities and modifications at all threestations. “We are very pleased to now haveon board a maintenance and modificationcontractor with whom we can organise ourprocesses even more effectively and who iscommitted to the same high standards ofaccident protection and safety as we are,”The contract between Gassco and BIS E.M.S.has a term of three years with an option torenew it by a further three years. Gassco intendsto extend the master contract in thecourse of the partnership to include otheractivities.
DIVISIONSglobe 1/2010page 35High expectations are being pinned to BIS E.M.S. as the maintenance and modifications contractor for the Gassco gas terminals in East Frisia.
DIVISIONSglobe 1/2010page 36» Innovative flue gas absorbersfor clean airCLEAN AIR IS FLOWING FROM THE STACK OF THE MUNICIPAL SLUDGE DEHYD-RATION AND INCINERATION PLANT INTO THE AIR ABOVE THE GERMAN CITYOF FRANKFURT THANKS TO THE NEW FLUE GAS ABSORBERS SUPPLIED BYBIS INDUSTRIESERVICE MITTE. THE IMPROVED ABSORPTION CAPABILITIES OFTHE ACTIVE CARBON ENSURE THAT THEY FILTER POISONOUS MERCURY FROMTHE FLUE GAS EMITTED BY THE PLANT.During the assembly of the flue gas absorbers, the ring elements were lifted one by one using a crane.
DIVISIONSglobe 1/2010page 37The sludge dehydration and incinerationplant in Frankfurt-Sindlingen on the outskirtsof the city burns the solid sludge recoveredfrom the Sindlingen and Niederradwaste water treatment plants. However, itis necessary for the resultant gases to befiltered out. “The flue gas, which has a temperatureof around 80 degrees in this partof the sludge incineration plant, flows fromthe top into the steel structure through thecharcoal beds and comes out at the bottomagain,” explains Stefan Korthals, projectmanager at Frankfurt-based BIS IndustrieserviceMitte.SUBSTANTIALLY IMPROVEDSECONDARY GAS LEVELSIn summer 2009, it was necessary for theold packed scrubbers to be replaced in twolines by new activated carbon absorbers. Atthe same time, it was not possible to retainthe old structure of the activated carbonabsorbers in two other lines. Accordingly,they had to be completely redesigned andre-engineered as progressive corrosion ofthe existing flue gas absorbers was creatingproblems for the plant operators. In additionto the mercury filter, further constituentsof the flue gas are removed with the assistanceof the active carbon, thus ensuringthat the thresholds stipulated by the EU areobserved. The City of Frankfurt called on BISIndustrieservice Mitte to build the new fluegas absorbers. Two of the systems went intooperation at the end of 2009, achieving topresults, while a further two are to follow thisyear.The new smoke gas absorbers offer multiplebenefits. Thus, the glass-fibre-reinforcedplastic with which the entire interior of theabsorber is lined helps to prevent corrosion.“It was necessary to channel the stream ofair through the charcoal beds in such a waythat we were able to achieve an optimumdegree of efficiency and make the greatestuse of the active carbon,” explains StefanKorthals. Whereas the charcoal beds in theold absorbers were located behind perforatedstainless-steel panels, BIS IndustrieserviceMitte is now using corrosion-resistant,louver-like brackets which are aerodynamicallyenhanced. These ensure that the charcoalbeds have an optimum fit while producingminimum air resistance and maximumflow rates through the active carbon.HIGH-PRECISION EXECUTIONThe assembly of the new flue gas absorbersposed a particular challenge. Given theirheight of ten metres and a weight of 17 tonseach, it was not possible for the units to belifted over the roof for final positioning. Asa result, the individual components wereconfigured to fit through the doors andgates at the incineration facility. In this way,the BIS specialists were able to dismantlethe absorber into five ring elements, whichthey moved piece by piece to the operatinghall for final assembly. “The top elementwas first positioned on the concrete foundations.Then we lifted it and placed the nextone beneath it. In a final step, everythingwas welded together,” the BIS project managersays, explaining the complicated process.Welding templates were used duringprefabrication of the individual segments toensure the correct fit. Reports Stefan Korthals:“We used a double-layer structure forthe interior walls. Needless to say, precisionfitting for this as well as the round parts wascrucial.” The BIS insulation specialists alsolived up to expectations, supplying a securelid stable enough to be walked upon and involvinga special construction made of firminsulation cassettes. Thanks to the inclusionof portholes, it is also possible for the operatorto perform visual examinations of theabsorber.The challenges were overcome with flyingcolours as all activities were synchronisedand coordinated carefully. The necessaryengineering, apparatus technology, coating,insulation, heavy duty assembly and scaffoldingactivities were all completed effortlessly,swiftly and safely in the course of theproject. Werner Fischer, project manager atthe municipal sewerage authority, is satisfied:“What was particularly praiseworthywas the adherence to the schedule despitethe occurrence of a number of unexpectedproblems as well as the efficient collaborationon all activities.”The GRP interior lining of the absorbers preventscorrosion and was mounted during prefabrication.DANGEROUS HEAVY METALMercury was identified back in thesixties as a neurotoxin. Consequently,the use of this substance in industrywas initially reduced and finally eliminatedaltogether in the mid-eighties.This is why it is no longer possible tobuy thermometers or batteries containingmercury.Yet, this poisonous heavy metal hasnot been banned in its entirety andis still released by incineration plantsthrough the combustion of fossilmaterials. Flue gas filtering systemsfitted, for example, with an activecarbon absorber remove a large partof the mercury from the flue gas.The emissions are measured and documentedbefore the gas leaves theplant via the stack.
DIVISIONSglobe 1/2010page 38» Extensions to Hungarian power stationONE OF HUNGARY’S LARGEST POWER STATIONS IS LOCATED IN SZÁZHALOM-BATTA, CLOSE TO THE NATION’S CAPITAL OF BUDAPEST. OVER THE PAST FEWYEARS, THE POWER STATION HAS BEEN UNDERGOING EXTENSIONS AND MODI-FICATIONS WITH THE AIM OF ENHANCING ITS EFFICIENCY AND OF IMPROVINGITS ENVIRONMENTAL STATUS. BIS HUNGARY KFT. IS ALSO INVOLVED IN THEMODERNISATION WORK AND IS CURRENTLY ASSEMBLING A HEAT RECOVERYSTEAM GENERATOR TO OPTIMISE THE EFFICIENCY OF THE POWER STATION.BIS Hungary was awarded a contract for full assembly of the heat recovery steam generator for the Dunamenti power station.
DIVISIONSglobe 1/2010page 39Built in the 1960s, the Dunamenti powerstation is located on the banks of the RiverDanube around 30 kilometres south ofBuda pest. With an output of some 2,000MW, it was once the largest power stationin Hungary. However, its efficiency starteddeclining in early nineties and it was convertedover the years into a combined gas andsteam power station with a current outputof around 1,740 MW.Work is currently being performed at fullspeed on extending and modernisingDuna menti. As part of these activities, anew gas turbine system is being installedin the power station. Belgian mechanicaland plant engineering company CockerillMaintenance & Ingénierie awarded BISHungary Kft. the contract for the constructionof the heat recovery steam generator.Specialists from the Hungarian BIS companywill be working on assembling the entireheat recovery steam generator up untilNovember of this year.These activities chiefly comprise the assemblyof the steel structure, which weighs over650 tons, the construction of twelve boilermodules, the stacks with a height of up to80 metres and the assembly of the steamboilers and the blow-down tank. This is supplementedby coating, piping and insulationboth inside and outside the facility coveringa total area of around 3,220 m 2 .IMPROVED QUALITY THANKS TOPREFABRICATIONThe severely confined spaces at the constructionsite posed a particular chal lengeduring the project. For this reason, theHungarian specialists decided to pre-welda large part of the necessary piping at theirown workshop in Tiszaújváros in EasternHungary. In fact, they prefabricated around80 percent of the piping with a total weightof 250 tons. Prefabrication has a furtheradvantage. “The quality is better,” explainsImre Somogyi, project manager at BIS Hungary.“At the workshop, the material is protectedfrom wind and rain. As well as this,the pipes can be turned and thus weldedmore accurately.”FURTHER CONTRACTS ON THEHORIZONParticular attention must be paid to HSEQrules at the construction site. “Our customerattaches particular importance to this,” saysImre Somogyi. For this reason, three employeesare permanently assigned to overseeingsafety at the construction site. Thesame thing applies to guidelines applicableto pressurised equipment such as steamboilers and pipes. “Normally, we work in accordancewith European rules. However, forthis contract, we were required to apply USASME rules,” explains Imre Somogyi. Theseare particularly strict regulations, which primarilyrelate to welding and non-destructivematerials testing.All told, up to 120 BIS employees will be stationedat the site until its completion in theautumn. Work with the customer is proceedingwell. Imre Somogyi is satisfied: “Wehave even been asked whether we are willingto handle work in other countries.”A steel structure weighing over 650 tons wasinvolved.DOUBLE BENEFITSA combined gas/steam power stationunites the principles of a gas-turbinepower station with those of a steampower station. The process uses thethermal energy of the hot waste gasesin two ways. For one thing, thesegases are used to directly drive thegas turbine as a means of generatingelectricity and, for another, thethermal energy contained in the gasis channelled into the heat recoverysteam generator. This process generateshigh-energy steam containingheat from which rotation energy isharnessed in the steam turbine andwhich thus generates additionalelectricity. With a utilisation coefficientof up to 60 percent, gas/steampower stations are amongst the mostefficient conventional power stations.
DIVISIONSglobe 1/2010page 40» Experienced team awarded followupcontract for large power stationEXTENSIVE MODERNISATION ACTIVITIES HAVE BEEN ONGOING ATBEŁCHATÓW IN POLAND, THE WORLD’S LARGEST LIGNITE-FUELLED POWERSTATION, FOR A NUMBER OF YEARS NOW. THREE POLISH BIS COMPANIES AREWORKING ON THE PROJECT: WHEREAS BIS PLETTAC SP. Z O.O. IS RESPONSIBLEFOR THE ENTIRE SCAFFOLDING, A WORK GROUP COMPRISING BIS MULTISERWISAND BIS IZOMAR SP. Z O.O., IS HANDLING THE INSULATION WORK.Located in Rogowiec, around 150 km southwest of Warsaw, and in operation since 1981,the Bełchatów power station has twelveblocks fuelled by lignite generating a combinedtotal output of 4,400 MW. This makes itEurope’s largest conventional thermal powerstation and also the world’s biggest lignitefuelledpower station. Work on modernisingthe power station commenced around fiveyears ago to bring it into line with the latestEuropean environmental standards.Following the completion of activities onBlock 4 last year, work is now being continuedon Block 5. As with Block 4, the boiler andpiping are being modernised, insulation replacedand the damaged parts of the boilershell repaired. BIS plettac is responsible forassembling, dismantling and maintainingthe scaffolding. The total volume requiredstands at around 55,000 m 3 plus platformsmeasuring roughly 1,500 m 2 in size. At thesame time, the two other Polish BIS companies,BIS Multiserwis and BIS Izomar, are responsiblefor ensuring that all the insulationwork is executed without a hitch. The customeris Steinmüller-Instandsetzung KraftwerkeGesellschaft für Energie und UmwelttechnikmbH, a subsidiary of Bilfinger BergerPower Services GmbH.WORKING AROUND THE CLOCKThis is the second contract which the PolishBIS company has received from Stein müller-Instandsetzung. Last year, it was also involvedin the scaffolding work required formodernising Block 4. Between January andNovember 2009, the experts from BIS wereresponsible for ensuring problem-free assemblyof the scaffolding. The services entailedscaffolding for the insulation of theinternal and external walls of the boiler,funnels, piping, flue-gas channels and thehot air system. All told, 50,000 m 3 of scaffoldingwas required. The job was completedwithout a hitch, as Piotr Kraszkiewicz,a member of BIS plettac’s management,stresses. “It was only thanks to careful organisationand planning that we were ableto assemble such a large volume of scaffolding.”An additional complication was thefact that the power station was still in operationwhen work commenced.Over at Block 5, the Polish experts are workingaround the clock once more to executeand oversee the assembly of all scaffoldingwhenever it is required by the participatingcompanies. On top of this,BIS plettac is responsible fora type of facility management.i.e. the orderliness andcleanliness of the site as wellas the logistic managementof the storage areas and lifts.This specifically entails loadingand unloading as wellas the storage of the technicalgases.20 percent of all the electricityproduced in Poland comes fromthe Bełchatów power station.As well as this, it operates the winches andlifts required to transport the materialsduring the execution of the modernisationactivities and is collecting and disposingof the industrial waste. All told, up to 80scaffolding assemblers are stationed at thesite. “The fact that we are coordinating allthe subcontractors for scaffolding and organisingthe site is of great advantage forour customer,” stresses Piotr Kraszkiewicz.“Even so, we were very pleased to be awardedthis follow-up contract as it shows howsatisfied the customer is with our work.”
DIVISIONSglobe 1/2010page 41» Combined expertise and skills in SpainIN SPAIN, THE TWO COMPANIES BIS MULTISERVICIOS INDUSTRIALES SA ANDBIS DIASA HAVE MERGED TO FORM BILFINGER BERGER INDUSTRIAL SERVICESSPAIN SA. AS A RESULT, THE NEW COMPANY WILL BE OFFERING INSULATIONAND SCAFFOLDING UNDER A SINGLE ROOF. IN ADDITION, THE MERGER OFTHE TWO SPANISH COMPANIES WILL ENABLE BIS SPECIALISTS TO BE DEPLOYEDACROSS THE ENTIRE COUNTRY.The new management team at Bilfinger Berger Industrial Services Spain SA:Ana Alzugaray, corporate director, and Ramón Oliver Ruiz, managing director, and (standing, from left)Antonio Martin Zapata, technical director, Jan van Asperen, production director, Jose Antonio Martinez,regional director, Iker Garrido, regional director, Federico Medina, regional director, and Sergio Corbacho,regional director.the company is in a better position to generatenew business and enter new markets.“DuPont is one of DIASA’s key customers.Today, we can offer this customer more thanjust scaffolding,” says Ramón Oliver Ruiz,citing an example. “As well as this, BISDIASA is active in the shipbuilding sector, anadditional market for demanding industrialservices.”The integration process was structured andoverseen by a committee especially establishedfor this purpose. This committeewas responsible for handling matters whichwere particularly affected by the merger,such as the overall structure of the company,the business model, specific trade-relatedmatters, corporate and financial factorsand changes to the management structure.In addition, processes were standardised.BOOMING SOLAR MARKETWith a total of some 600 employees, thenew BIS company has nine facilities, includingin Madrid, Barcelona and Ferrol. “Manycustomers seek contractors who can provideindustrial services not merely at a singlesite but at different places across the entirecountry,” explains Ramón Oliver Ruiz, the managingdirector of Bilfinger Berger IndustrialServices Spain SA. “As a result of the merger,we are now able to offer this service.”Back in 2003, BIS Multiservicios IndustrialesS.A., had already started broadening itsfootprint in the Spanish market for industrialservices. For this purpose, it initially restructuredits insulation business, followedin 2007 by the acquisition of DIASA. The twocompanies supplement each other well interms of their services, geographic locationand management. Whereas BIS MultiserviciosIndustriales SA is an insulation specialistprimarily active in the south east partof Spain, BIS DIASA is a scaffolding expertbased for the most part in the north of thecountry.ENTERING NEW MARKETS“The merger has simplified the company’sstructure,” explains Ramón Oliver Ruiz. “Atthe same time, we are able to coordinate ourresources more efficiently from a single headoffice and deploy our staff with greater efficacyat the construction sites.” In addition,The booming Spanish solar marketoffers great opportunities for BilfingerBerger Industrial Services SpainSA. This is because the piping and apparatusused in the solar power stationslocated in southern Span mustbe carefully insulated. Mineral wooland aluminium cladding are used toensure that as little energy as possibleis lost in the transportation of oiland steam. Bilfinger Berger IndustrialServices Spain SA has already beeninvolved in numerous projects, moredetails of which can be gained fromBilfinger Berger SE’s annual report(www.bilfinger.com).
» Clean energy for EuropeCOAL-FUELLED POWER STATIONS ARE INCREASINGLY BEING REPLACED BYENVIRONMENTALLY MORE FRIENDLY COMBINED POWER STATIONS – SUCH ASIN PORTUGAL AND THE NETHERLANDS, WHERE NEW POWER STATIONS AREBEING BUILT. BIS PREFAL HAS BEEN INVOLVED IN NO LESS THAN THREE SUCHPROJECTS. THE PORTUGUESE SPECIALISTS HAVE BEEN PERFORMING EXTENSIVEINSULATION WORK.The stipulations of the European Council areclear: All EU countries are required to cutemissions of greenhouse gases by at least 20percent relative to 1990 levels by 2020. Thisgoal is particularly to be achieved by utilisingrenewable and environment-friendly sourcesof energy. As a result, older coal-fuelledpower stations are being modernised andfitted with waste gas desulphurisation systems.New facilities are generally configuredas combined power stations.Also known as gas/steam power stations,they are generally fuelled with gas. The majoradvantage of this type of system is thecombined gas and steam turbine, which increasesthe overall efficiency of the powerstation to almost 60 percent. By comparison,conventional heating power stationsachieve an efficiency level of only around 35percent.One such gas/steam power station wentinto operation in Lares, Figueira de Foz inCentral Portugal at the end of last year.Owned by Energias de Portugal, SA (EDP),one of the largest European utilities, thisgas-fuelled combined power station comprisestwo blocks achieving a total output of862 MW. This is sufficient to produce around4,000 gigawatt/hours of electricity a year.Work was commenced on building the powerstation in June 2007 at a cost of EUR 400million. A total of around 250 companies –including BIS Prefal, which supplied the thermalinsulation – worked on the site.EXPERIENCE PAYING OFFThe BIS company commenced its workin August 2009, completing it on scheduleand free of any incidents in December.During this period, it was necessary to insulatea total area of 35,185 m 2 , including31,338 m 2 for the piping system alone.75,400 person/hours were required. Theinsulation was made of stone wool andan aluminium encasement. The insulationmaterial required for the gas/steam turbinewas provided by General Electric.A second gas-fired power station is currentlybeing constructed in Pego, Abrantes,also in Central Portugal. With an output of800 MW, this gas/steam power station isto go into operation in 2011. Here as well,
The new Flevocentrale combined power station in the Netherlands is locateddirectly on the banks of Markermeer, a lake with an area of some 700 m 2 (left).The piping, boilers and turbines at the Lares power station in central Portugalwere insulated with stone wool and encased with aluminium.The gas/steam power station in Pego, Portugal, was constructed directlyadjacent to a coal-fuelled power station.the BIS Prefal is responsible for providingthermal insulation for the piping, boilers,turbines and other equipment. In addition,the two boilers are to be fitted with soundproofing.Stone wool of varying thicknesseswith a specific weight of 70 kg/m 3 willalso be used here together with an aluminiumencasement. The total surface to beinsulated measures around 30,000 m 2 inarea plus 5,000 m 2 of sound-proofing. Onaverage, 50 insulation experts are workingat the construction site.PROGRESS IMPEDED BY RAIN ANDLOW TEMPERATURESThe work is to be completed by the middle ofthe year. “Despite the tight schedule, we willbe able to complete the job on time,” reportsHugo Pires of BIS Prefal, “even though workingconditions were far from easy at the beginningof the year in particular. We had a verycold and wet winter which continued untilinto April.”A third project on which BIS Prefal was workinghas recently been completed in Lelystadnear Amsterdam. Here, the Portuguese alsosupplied insulation for a new combined powerstation with an output of 870 MW. A surfacewith an area of 16,000 m 2 was insulatedin around 50,000 incident-free person/hoursprovided by some 45 employees.With these three projects, the Portuguesespecialists were again able to impressivelydemonstrate their core insulating skills andhave become sought-after experts. “We wereinvolved in all of the four combined power stationsbuilt in Portugal and a further three inthe Netherlands and Spain,” says Hugo Pires.This makes us one of the most experiencedinsulation specialists in Europe.”
DIVISIONSglobe 1/2010page 44» Amalgamation strengthening positionin UK marketA STRONG NEW COMPANY HAS ARISEN IN THE UNITED KINGDOM UNDER THEROOF OF BILFINGER BERGER INDUSTRIAL SERVICES (UK) LTD. IN JANUARY 2010,BIS OHARE LTD. AND BIS SALAMIS LTD. JOINED FORCES TO FORM BIS INDUSTRIALSERVICES LTD. THE MERGER POSITIONS THE NEW COMPANY WITH UNIQUE SKILLSDESIGNED TO REDUCE COSTS AND RISK FOR CUSTOMERS IN THE ONSHOREPROCESS INDUSTRY.Gas from the North Sea arrives at the Theddlethorpe onshore gas terminal in the east of the UK.By restructuring its UK companies, BIS hasconcentrated of its onshore and offshoreservice into separated entities in the interestsof heightened transparency for customers.Therefore the newly formed BISIndustrial Services offers onshore customersthe full range of professional engineering,mechanical, E&I and SIP (scaffolding, insulation,painting) capabilities. Aberdeen-basedBIS Salamis (M&I) is not affected by thesechanges. Managed by Mike Main, this companyspecialises in fabric maintenance andinspection services for the offshore market.Located in Cheshire in the north west ofEngland, the new company is managed byDuncan Hall. Some 1,500 employees arebased at six locations across the UK fromthe northern base at Sullom Voe in the ShetlandIslands to the south coast of England.With annual revenues of EUR 210 millionand 2,700 employees, BIS Industrial Servicesand BIS Salamis have been providingBIS service capability for the UK marketsince in 2007.COMBINED SERVICE OFFERINGSThe breadth and depth of service integrationprovided by BIS IS constitutes a substantialadvantage for customers. As SteveWaugh CEO of BIS UK explains: “This serviceaddresses the onshore markets in refining,chemicals, power and distribution. Inour view it provides ‘third generation’ outsourcesolutions for the onshore processindustry supply chain, offering customersa sustainable solution to a step change incost reduction execution models of up to 20percent.”The business commissioned work with aconsulting company early in 2009 to reviewthe options, opportunities and customerresponse to the proposition to combine engineering,MEI and SIP services into a singlemanaged service for the execution of project,overhaul and maintenance/inspectionservices in the process industry. It was clearthat significant opportunities existed forreducing delays/lost time in work executionand for making better use of the employees’skills to achieve overall customer objectivesas a single team.One of the recommendations made by theconsultants was that to achieve the maximumbenefits from combined service applicationthe skills, competencies, culture andcommercial interests had to be aligned inone organisation. The maximum benefitssimply cannot be delivered through normalsub-contract engagement or temporarybusiness “partnerships”. That is one of thereasons why the management merged BISOHARE and BIS Salamis into a single seamlessorganisation in January of this year andmade Simon Hicks the director responsiblefor combined services to meet its full potential.The first fully integrated combinedservices contract has already been secured
DIVISIONSglobe 1/2010page 45“WE OFFER UNRIVALLED CORE AND SPECIALISED SERVICES”Steve Waugh, CEO of BilfingerBerger Industrial Services (UK) Ltd.globe: In addition to your combined services,you intend to restructure the planningand execution of traditional services. Whatdoes this mean?Steve Waugh: To achieve the demandingtargets set by our customers, it is not sufficientfor us at BIS to merely have a broad rangeof high-quality services. In addition, thechanges which we offer our markets alsoinvolve comprehensive planning and organisationof work packages. A straight forwardexample of this is the use of rope accessfacilities instead of scaffolding for work atheight provided that this is appropriate.The services will still be carried out safelyand in full accordance with the applicablestandards. However, by including this optionin the planning and organisation phase,additional resources will be avoided whichcan lower the job cost significantly.At BIS we expect our management teams toadjust their working methods with the supportof our staff so that all our skills and capabilitiesare channelled into lowering timeand cost requirements.globe: Does this mean that the productrange has been extended?Steve Waugh: In addition to our core andcombined services, which of course entaildifferent delivery models, we have establishedalongside the BIS offshore divisiona range of specialist services providingour customers with alternative solutions.Examples of these include the fabricationand repair of GRP equipment, surfacetension welding, laser surveying and ropeaccess.globe: The UK industrial services market iscurrently dominated by three or four leadingcompanies. What competitive advantagedoes BIS Industrial Services have?Steve Waugh: BIS Industrial Services hasan unrivalled range of core and specialistservices and the engineering capabilitiesto incorporate those solutions safely andefficiently in the design and planning ofsolutions for customers in the UK processindustry. The business has proven expertisein the technical solutions available andthe skills within the management team toengineer change and improvement programmesthat benefit our customers.The company is backed by an experiencedand focused shareholder who providesknowledge, relationships and investmentbacking from across Europe to meetthe changing needs of the UK processindustry.BIS Industrial Services recognises the potentialwe have to provide our customerswith cost and risk reduction benefits inthe outsource market, but we know thatthe clear market lead we have needs to bemaintained through delivery, reputationand ongoing innovation in the way weserve customers.with BP, which is seeking 20 percent costreductions on a sustainable basis over thenext 12 - 24 months without compromisingsafety and essential engineering standards.THE BEST OF BOTH WORLDS“In basic terms we help customers to reducecosts and risks in the execution ofessential engineering and industrial servicedelivery in the process industries. Thedepth and breadth of our combined capabilitiesfollowing the merger allows BIS ISto eliminate waste at the interfaces of bothmanagement processes and work executionskill sets. That leads to fewer people andreduced complexity when work is planned,managed and executed. As a result, costsare reduced and risks are more adequatelydefined and mitigated. BIS IndustrialServices’ capabilities and track record ofreliable delivery provide a powerful sellingproposition in the market for ‘singlesourcing’”, Steve Waugh stresses.However customers retain the option to buyindividual services or cluster combinationsof services that meet their requirements orpurchasing policies. The company thereforeretain the core expertise necessary to providethose customers with flexibility andconfidence in our ability to deliver on ourpromises. The merger of the two companieshas also allowed the business to optimiseits cost base in the provision of the essentialsupport services and business facilities/assets that are necessary to operate a leadingoutsource service. Steve Waugh: “Werecognise that customers want attractivepricing as well as efficient service delivery,so we have made sure that the cost base ofthe business has been optimized withoutcompromising the skills necessary to supportour customers and the business operatingteams.”
DIVISIONSglobe 1/2010page 46» UK oil and gas industry placingits trust in BIS skillsMAINTENANCE REQUIREMENTS IN THE OIL AND GAS INDUSTRY ARE GROWINGALL THE TIME. BP, ONE THE WORLD’S LARGEST OIL AND ENERGY COMPANIES,IS RELYING ON THE EXPERTISE OF BIS INDUSTRIAL SERVICES LTD. FOR THIS PURPOSE.OVER AN INITIAL PERIOD OF FIVE YEARS, THE UK BIS COMPANY WILL BE RESPONSIBLEFOR EXECUTING INDUSTRIAL SERVICES AT THREE BP SITES. IN ADDITION TO THIS,BIS HAS ENTERED INTO A CONTRACT WITH A FURTHER UK OIL AND GAS COMPANY.THE TWO LONG-TERM CONTRACTS HAVE A TOTAL VOLUME OF SOME EUR 230 MILLION.Recently signed, the contract marks a milestonein the history of BIS Industrial ServicesLtd., which is headquartered in Runcorn. Forone thing, it is the largest contract whichBIS has ever been awarded by BP in the UKand, for another, it is the first major contractwhich the company has gained sincebeing restructured. Duncan Hall, managingdirector of BIS Industrial Services, additionallysees the contract as testifying tothe great confidence which customers areplacing in his company’s skills: “To securea contract of this scale with BP is a significantachievement for the growing reputationof BIS in the UK both onshore and in theNorth Sea”.He goes on to say that BP was particularlyimpressed by the broad range of servicesoffered and the ongoing technologicaland process improvements. Adds BernhardLooney, managing director of BP North Sea:“I am delighted that BIS Industrial Serviceshas been awarded this important onshorecontract and I look forward to a productivepartnership. The North Sea plays a crucialrole in our global business and we aim tocontinue our investments there over thenext decade and beyond.”SEVERAL HUNDRED SPECIALISTS ON SITEOver a period of five years, BIS IndustrialServices Ltd. will be supporting its customerBP with the full range of its industrialservices in maintenance, various projectsand turnarounds. The activities entail engineering,mechanical services, E&IC and SIPwork (industrial scaffolding, insulation, surfaceprotection). The BIS specialists will bestationed at the two BP terminals in Falkirk,Scotland (Forties Pipeline System Terminal)and the CATS (Central Area TransmissionSystem) terminal in Teesside on the NorthEastern coast.In addition, BIS Industrial Services Ltd. willbe providing services at a BP site on theShetland Islands. At the Sullom Voe Terminal,BIS is responsible for industrial scaffolding,insulation and surface protection.Depending on the project and the task athand, between 250 and 500 BIS employeeswill be deployed at the three BP terminals.NO COMPROMISES IN WORKSAFETY AND QUALITYBP and BIS plan to work particularly closelyat all three terminals to heighten safetyand also to boost productivity. The aim isto improve productivity by ten percenta year without sacrificing on-site safety,health, environmental protection or qualitystandards. This is to be done by analysingexisting processes so as to identify possibleshortcomings and inefficiencies. BIS will beapplying two different parameters in thisanalysis: firstly, “hard” factors such as theavailability of materials and the locationof warehouses and, secondly “soft” factorssuch as work and travel times, employees’ability to work in a team and motivation.“Using this process, we have been able toboost productivity for another customer ofours by 25 percent over a three-year period,”says Duncan Hall.
BIS Industrial Services Ltd. supports its customer BP in maintenance, project work and turnarounds by offering it the full range of its services such asengineering, mechanical services, E/I&C and SIP.In addition to this, BIS Industrial Serviceshas also signed a contract with another oiland gas company for a period of five yearswhich will substantially extend the existingrelationship. Under this new contract, theBIS specialists will be providing mechanicalservices in particular for one of the largestrefineries in the country. BIS has been workingwith this refinery since 2006, rackingup some 100,000 person/hours in the last17 months alone without a single reportableincident.LEADING POSITIONREINFORCEDDr. Rudolf Jürcke, the member of the BISGroup’s Executive Board responsible forWestern Europe, is very satisfied, saying:“The BIS Group’s UK companies have grownat an extraordinary pace in just a few years.BIS is seen as a strong name in industrialservices characterised by problem-solvingskills and reliability. These recent successesconfirm that we are able to achieve considerablegrowth in the United Kingdom.”The UK industrial services market is currentlydominated by three or four companies.“So as to maintain our leading position, wemust continue our HSEQ efforts and enterOIL AND GAS FROM THE NORTH SEAnew markets,” explains managing directorDuncan Hall. “As well as this, it is necessaryto develop new special services and to additionallybroaden our combined services.”The three terminals operated by BP in Scotland and Northern England play a crucialrole in the oil and gas market. The Forties Pipeline System, which terminates in theScottish port city and refinery centre of Grangemouth, is the largest oil and gas pipelinesystem in the United Kingdom, linking over 50 oil and gas fields in the North Sea.It has a capacity of more than one million barrels a day.Opened in 1993, the Central Area Transmission System (CATS) on the North Easterncoast transports gas from the North Sea to Teesside over a distance of 404 kilometres.With a capacity of some 48 million m 3 a day, it contributes around 20 percent to theUK gas market.The Sullom Voe Terminal is located on the Northern tip of the largest of the ShetlandIslands and is one of the most important oil and liquid gas terminals in Europe. It firstwent into operation in 1975, when oil fields such as Brent and Ninian initially startedsupplying “black gold” for Europe.
DIVISIONSglobe 1/2010page 48» BIS Salamis trainee recipient of a safety awardVICTORIA LEE, A TRAINEE HSEQ ADVISOR AT BIS SALAMIS (M&I) IN ABERDEEN,HAS WON THE “SAFETY AWARD FOR THE MOST PROMISING INDIVIDUAL”. THEAWARD WAS CONFERRED FOR THE FIRST TIME BY OIL & GAS UK IN RECOGNITIONOF OUTSTANDING EFFORTS TO PROMOTE ON-SITE SAFETY. THIS NON-PROFITORGANISATION, WHICH REPRESENTS THE INTERESTS OF THE UK OFFSHORE OILAND GAS INDUSTRY, ALSO ANNOUNCED A FURTHER FIVE AWARDS IN OTHERHSEQ CATEGORIES.Victoria Lee (right) is the recipient of the Safety Award for the Most Promising Individual.The 23-year-old trainee has been with offshoremaintenance service and inspectionspecialist BIS Salamis since July 2009. Duringthis short space of time, Victoria Leehas been closely involved in HSEQ matters.In order to gain a better appreciation of therisks arising in both onshore and offshoreactivities, she took part in training courseson rope access and high-altitude work. Inaddition, she visited the gas terminal in St.Fergus, which is operated by several largeoil companies, as well as four North Sea oilrigs.At the same time, Victoria Lee is workingactively on improving communicationswith her colleagues. One of her duties is tocoordinate the “Meet Joe” safety campaign.Each month, she selects a specific aspectof HSEQ such as safety to and from work oravoidance of injuries to the eye. Using thisas a basis, Victoria Lee develops a short story.This story is then illustrated and turnedinto a poster, which is put on prominent displayat all sites at which BIS Salamis employeesare deployed. In addition, the postersand stories are published on the Internet atwww.meetjoe.co.uk.“I would like to thank BIS Salamis for givingme the opportunity of taking part in thecompetition,” says Victoria Lee. “The awardis incentive for me to continue learning andthus to help make our jobs even safer.”
CURRENT ORDERSglobe 1/2010page 49» Current OrdersCUSTOMERBIS COMPANIESINVOLVEDNAME OF PROJECTPLACE/COUNTRYSHORT DESCRIPTIONEXECUTIONPERIODINDUSTRIAL SERVICES CENTRAL EUROPEAbendgoa BioenergyNetherlands B.V.BIS Industrial ServicesNederland B.V., Zwartewaal,Netherlands; BISICT N.V., Schoten, BelgiumNew bioethanol plantRotterdam,NetherlandsInsulation for piping with a total lengthof 33 km2010Alstom MannheimBIS arnholdt GmbH,Gelsenkirchen,GermanyRDK8 machine buildingKarlsruhe,GermanyScaffolding 03/2010 - 12/2012Alstom Power SystemsBIS OKI GmbH,PforzheimMannheim power stationMannheim,GermanyInsulation 04/2010 - 12/2012BioenergieHeizkraftwerkHirscheggBIS IndustrietechnikSalzburg GmbH,Salzburg, AustriaHirschegg district heatingnetworkHirschegg,AustriaPiping 04/2010 - 11/2011Borealis –Agro MelaminBIS Chemserv GmbH,Linz, AustriaAMI TA2010 Phase 1 Austria Turnaround: project management, timemanagement and documentation aswell as the termination of work for plantengineering, rotating equipment, electricalengineering and materials testing, 800items of equipment in the pressure gasificationplant, 20,000 hours03/2010 - 04/2010CorusBIS Industrial ServicesNederland B.V.,Zwartewaal, NetherlandsScaffoldingIjmuiden,NetherlandsNew framework agreement for scaffolding 2010 - 2013DeloBIS TSG IndustrieserviceGmbH, Gersthofen,GermanyConstruction of a pilotplant for the manufactureof adhesivesGermanyPlanning, procurement and construction ofa procedural pilot plant for testing and producingadhesive input and output products05/2010 - 06/2011EssentBIS Industrial ServicesNederland B.V., Zwartewaal,NetherlandsScaffolding for new ClausC power stationMaasbracht,NetherlandsScaffolding 2010ExxonMobilBIS Industrial ServicesBelgie N.V., Zwartewaal,NetherlandsScaffolding for newhydrotreaterAntwerp, Belgium Scaffolding 2010Nestrada S.A.BIS IndustrietechnikSalzburg GmbH,Salzburg, AustriaPhoenixKonolfingen,SwitzerlandPipeline construction, assemblycoordination, start-up01/2010 - 12/2010Ruhr Oel GelsenkirchenBIS Industrietechnik OstGmbH, Leuna, GermanyRhine Hub Olefin IV TAR2010Gelsenkirchen,GermanyMechanical inspection work on columns,reactors, tanks, heat exchangers, fittingsand valves09/2010 - 10/2010Schmid SiliconTechnology GmbHBIS Industrietechnik OstGmbH, Leuna; BIS IndustrieserviceOst GmbH,Leuna, GermanySilicon plantSchwarze Pumpe,GermanyPipeline work 09/2009 - 07/2010Sea InvestvoestalpineBIS ROB MontagebedrijfN.V., Beveren-Melsele,BelgiumBIS Chemserv GmbH,Linz, AustriaToo See Belgium Construction of 30,500 m of pipeline 09/2009 - 06/2010Continuous Casting No. 5 Austria Automation of continuous casting CC5 12/2007 - 07/2010TECHNICAL NOISE CONTROLDerif (French RoadConstruction Authority)BIS Gerber GmbH, Dortmund,Germany; BIS IndustrieserviceNordwest,Lünen, GermanyLandy tunnel on the A1motorway in ParisFranceDelivery and assembly of over 42,000 m² offire panels to improve safety in motorwaytunnel02/2010 - 11/2011
CURRENT ORDERSglobe 1/2010page 50CUSTOMERBIS COMPANIESINVOLVEDNAME OF PROJECTPLACE/COUNTRYSHORT DESCRIPTIONEXECUTIONPERIODGeneral ElectricBIS Gerber GmbH, Dortmund;BIS Hertz GmbH,Billerbeck, GermanySalalah Oman Delivery of various acoustic enclosures forfive gas turbines with associated generators,steel share about 250 tons, about3000 m² vibration control01/2010 - 09/2010SiemensBIS Gas TurbineSystems GmbH, Bremen,GermanyBasra/Kirkuk PP5 Iraq Delivery of eight air intake systems 2010/2011INDUSTRIAL SERVICES NORTHERN & EASTERN EUROPEČeská rafinérská a.s.EUROMONT GROUP a.s.,Most,Czech RepublicInspection of machineryand technical equipmentLitvínov und Karlupy,Czech RepublicMachinery, technical equipment,scaffolding, insulation05/2010 - 04/2013ElkemBIS ProductionPartner AS, Porsgrunn,NorwayMaintenance partnerconceptSvelgen, NorwayMaintenance, mechanical and electricalwork, instruments04/2010 - 03/2013Hydro AluminiumMetalBIS ProductionPartner AS, Porsgrunn,NorwayMaintenance partnerconceptVarious sites inNorwayMaintenance, mechanical and electricalwork, instruments03/2009 - 02/2014LinjebyggBIS Industrier AS,Sandnes, NorwayMaster contractOrmen Lange,Norway210,000 m² surface treatment andinsulation, 112,000 person/hours07/2007 - 12/2011StatoilBIS Industrier AS,Sandnes, NorwayISP - Offshore - Snorre,Sleipner, Oseberg,Heimdal, Huldra, Brageand VeslefrikkVarious sites inNorway780 tons of scaffolding,845,000 person/hours01/2011 - 12/2014StatoilBIS Industrier AS,Sandnes, NorwayISP onshore - Sture,Kollsnes and KalundborgVarious sites inNorway andDenmar375 tons of scaffolding,160,000 person/hours01/2011 - 12/2014StatoilHydroBIS Industrier AS,Sandnes, NorwayHammerfest LNGHammerfest,Norway560 tons of scaffolding, surface treatment,230,000 person/hours09/2006 - 12/2010Unipetrol RPABIS Czech s.r.o., Most,Czech RepublicInspection of chemicalplantsLitvínov,Czech RepublicMachinery, technical equipment,scaffolding, insulation01/2010 - 12/2010VattenfallBIS MainServ, Warsaw,PolandUR4 full-service contractfor five thermal powerstationsWarsaw, PolandMaintenance including repairs and inspection,mechanical and electrical works,instrumentation, control and regulationsystems07/2010 - 06/2014STAHL- UND MASCHINENBAUAirbus GermanyMCE Stahl- und MaschinenbauGmbH & Co KG,Linz, AustriaAirbus A350 XWB Section16 and 19Hamburg,GermanyPlanning, delivery and assembly ofassembly lines08/2009 - 06/2012DB Netz AGMCE Stahl- und MaschinenbauGmbH & Co KG,Linz, AustriaRailway bridge DietfurthDietfurth,GermanyPlanning, delivery and assembly of a steelstructure weighing 300 tons01/2010 - 04/2011North Rhine-Westphaliastate roadconstruction authorityMCE Stahl- und MaschinenbauGmbH & Co KG,Linz, AustriaBad OeynhausenNorthern bypassBad Oeynhausen,GermanyPlanning, delivery and assembly of a steelstructure weighing approx. 6,000 tons11/2009 - 09/2012ODS DopravnÍ StavbyOstravaMCE Slaný s.r.o., Slaný,Czech RepublicMokré Lazce bridgeMokré Lazce,Czech RepublicPlanning, delivery and corrosion protectionfor steel structures of around 2,300 tons01/2010 - 03/2011Premium AerotecMCE Stahl- und MaschinenbauGmbH & Co KG,Linz, AustriaAirbus A350 XWB Section13 and 14Nordenham,GermanyPlanning, delivery and assembly ofassembly lines08/2009 - 06/2012Thuringian RoadConstruction AuthorityMCE Stahl- und MaschinenbauGmbH & Co KG,Linz, AustriaSchmalkaldetal bridgeWernshausen,GermanyPlanning, delivery and assembly approximately1,400 tons of steel construction01/2010 - 06/2012
CURRENT ORDERSglobe 1/2010page 51CUSTOMERBIS COMPANIESINVOLVEDNAME OF PROJECTPLACE/COUNTRYSHORT DESCRIPTIONEXECUTIONPERIODINDUSTRIAL SERVICES WESTERN EUROPE & INTERNATIONALAustin EnergyBIS Tepsco Inc., DeerPark, Texas,United StatesCold water supply systemAustin, Texas,United StatesPipeline construction for a utility company 01/2010 - 01/2013BASFBIS Frucon IndustrialServices Inc., Ballwin,Missouri, United StatesAuto loadingAttapulgus, Georgia,United StatesMechanical work 01/2010 - 04/2010Exxon MobilBIS Industrial ServicesLtd., Runcorn, UnitedKingdomCPD term contract United Kingdom Master contract for five years, annualpiping construction of approx. 100,000 m2010 - 2015Ineos Chlor VinylsBIS Industrial ServicesLtd., Runcorn, UnitedKingdomISIS United Kingdom Engineering, mechanics, instrumentation,scaffolding, insulation and corrosionprotection, pipeline constructionQ1/2009 - Q3/2010Marathon Oil CompanyBIS Salamis Inc.,Broussard, Louisiana,United StatesOffshore maintenanceserviceOffshore, Gulf ofMexico, UnitedStatesMaintenance services 01/2010 - 12/2010NavantiaBilfinger Berger IndustrialServices Spain S.A.,Madrid, SpainAustralian helicoptercarrierFerrol, SpainScaffolding, construction of two specialvessels in Navantia05/2010 - 07/2012PetronorBilfinger Berger IndustrialServices Spain S.A.,Madrid, SpainADI 100 project Bilbao, Spain 25,000 m² of insulation,57,000 person/hours05/2010 - 06/2011ShellBIS Tepsco Inc., DeerPark, Texas, UnitedStatesInstallation of acompressor stationTexas City, Texas,United StatesInstallation of a compressor unit 11/2009 - 06/2010Tennessee Air NationalGuardBIS Frucon IndustrialServices Inc., Ballwin,Missouri, United StatesReplacement of andrepairs to roofsKnoxville, Tennessee,United StatesMechanical and engineering work 01/2010 - 04/2010PLANT TECHNOLOGIESE.ON AnlagenserviceGmbHBIS VAM AnlagentechnikGmbH, Wels, AustriaConstruction ofMaasvlakte hydropowerplant, reheat/cold reheat,ancillary steamMaasvlakte,NetherlandsPlanning, production, supply and installationof a high-pressure pipeline system02/2010 - 08/2012E.ON Gas StorageGmbHBIS E.M.S. GmbH,Cloppenburg,GermanyEON Etzel III Etzel, Germany Planning, delivery, assembly and initialstart-up of three gas dehydration plants03/2010 - 03/2012KremsmüllerIndustrieanlagenbauBIS VAM AnlagentechnikGmbH, Wels, AustriaRDK8 coal power stationKarlsruheKarlsruhe,GermanyPlanning and installation of linking systemsand pipes for a coal-fired power stationblock01/2010 - 12/2012LG BuR-IntegralBohr- und RohrtechnikGmbH – BIS, Vienna,AustriaGDL Mellach Mellach, Austria Engineering, supply and installation of thewater-steam cycle02/2010 - 12/2011Nafta a.s.BIS Hungary Kft.,Budapest, HungaryUnderground gas cavern Garay, Slovakia Pipe engineering with a wall thickness ofup to 36 mm03/2010 - 10/2010Rohölaufsuchungs AGBIS VAM AnlagentechnikGmbH, Wels, AustriaPipeline and heavyassembly for 7 fieldsHaidach, AustriaInstallation of gas tanks at 3 differentlocations with compressor units08/2009 - 12/2010SIEMENS AG AustriaTechnip GermanyBIS Bohr- und RohrtechnikGmbH, Vienna,AustriaBIS RohrleitungsbauGmbH, Bitterfeld,GermanyGDK Mellach Graz, Austria Piping System for Balance of Plant (BoP) 01/2010 - 12/2011Lot 410 storage tank Germany Piping 01/2010 - 07/2010TurboteamBIS Hungary Kft.,Budapest, HungaryCompressor station fornatural gas pipelineBáta, Hungary Pipe construction, NW 50 – NW 800,total of 420 t01/2010 - 08/2010
NETWORKglobe 1/2010page 52» Convincing HSEQ effortsHEALTH, SAFETY, ENVIRONMENT AND QUALITY (HSEQ) AWARENESS IS FIRMLYENTRENCHED AT THE BIS GROUP, A FACT WHICH IS NOT LEAST OF ALL RE-FLECTED IN THE REDUCTION IN ACCIDENT NUMBERS. BETWEEN 2003 AND 2008,THE NUMBER OF ACCIDENTS WAS CUT BY 70 PERCENT, WITH FURTHERIMPROVEMENTS IN SAFETY AWARENESS AND CONDUCT RESULTING IN ANADDITIONAL DROP OF FOUR PERCENT IN 2009.The BIS Group’s HSEQ awards are designed to act as an incentive for the subsidiaries to heighten awareness ofworkplace risks and to take specific measures to successfully reduce accidents.
NETWORKglobe 1/2010page 53All BIS companies participate with greatcommitment and verve in the Group-wideHSEQ initiative. In fact, they repeatedly receiveawards from customers in recognitionof their consistent efforts to achieve the bestpossible HSEQ results. One particular successwas reported by BIS E.M.S. GmbH, Cloppenburg.In 2008 – just as it had previouslydone in 2007 – it attained the highest rankingin ExxonMobil Production Germany’s“EMPG Safety Award” ratings, thus defendingits leading position in accident protectionin maintenance and project managementin a field comprising 250 contractors.As a pioneer in HSEQ, EMPG has extremelydemanding expectations with respect tohealth and environment management.HSEQ requirements at Dow DeutschlandAnlagengesellschaft mbH are also of anexceedingly high standard. BIS E.M.S. receivedthe safety award at Dow’s Stade plantin 2009 in recognition of an exemplary sitesafety record and 13 years of incident-freeservice.NEW STANDARDS SETBIS Prozesstechnik and BIS Industrieservicewere awarded BG Chemie’s “Sicher mit System”seal of quality, the first companies atthe Höchst Industrial Estate in Frankfurt amMain to achieve this distinction. This awardfor outstanding site safety management recognisescommitment to systematic and effectiveplant safety beyond the scope requiredby law. With their extensive site safetyprogramme, the two BIS affiliates were ableto reduce by half the lost time incident frequencywithin two years, cutting the numberof lost days by 80 percent.BIS Industrial Services in the Netherlandsis also achieving considerable success withits far-reaching site safety programme. On9 July 2010, it recorded three million hours ofwork without a single accident-induced loss,thus breaking its own record which it hadset three months earlier on 20 April 2010,when it racked up two million hours of zeroaccidentwork. Customers appreciate thiscommitment. DuPont, one of the world’slargest chemicals companies, bestowed onthe Dutch BIS company an award in acknowledgementof five million hours of zeroaccidentwork. It was also the recipient ofExxonMobil Chemical’s “All Green Award”for its site safety excellence. Last year,Fina Antwerp Olefins, a Total/ExxonMobilChemical joint venture, bestowed on BISIndustrial Services the “2008 ContractorAward”. On top of this, BIS was the recipientof the “2009 Contractor Safety Award”given by the leading Netherlands utility Essent.Belgian affiliate BIS ICT NV was also anaward-winner, receiving as it did the “2009Global Contractor Award” from the TotalAntwerp refinery in June 2010.DETAILED CHECKSTo date, around 50 companies in the CzechRepublic have received the “Safe Enter prise”Award. In October 2009, BIS Czech was giventhe “Safe Enterprise Award” for the third timeby labour and social minister Petr Šimerka.The award is preceded by a detailed audit,during which seven inspectors scrutiniseall aspects of the company’s site safety andenvironmental management efforts over aperiod of 14 days. Since the establishmentof the “Safe Enterprise” award, safety standardsat large Czech companies have risensubstantially.Currently, the airport in Dublin is beingextended. BIS Willich Industrial Services wasalso materially involved in the constructionof the new Terminal 2. As the general contractorfor scaffolding, the Irish BIS companyworked for various customers on the site,ensuring the problem-free assembly of andextensions to all necessary scaffolding. BISWillich’s dedication to these activities wasacknowledged in April 2010 when it was named“Contractor of the Month Safety”.ADDITIONAL INCENTIVE FROMINTERNAL AWARDSIn 2009, the BIS Group introduced the “HSEQAward” and the “Best Improver Award” asadditional incentive for the subsidiaries toconsistently work towards achieving theGroup-wide “zero is possible” target. To beeligible for the “HSEQ Award”, companiesmust achieve a zero-accident record overthree consecutive years or during 700,000work hours performed in a period of up tothree years and prove that specific measureswere implemented to achieve this target.This is determined on the basis of theuniform Group-wide LTIF (lost time incidentfrequency) indicator.The first recipients of the reward in 2008were the North German company BIS E.M.S.,Czech company EUROMONT Group a.s. andNorwegian company BIS Industrier AS. Thisyear, South Germany-based BIS MaintenanceSüdwest and – for the second timerunning – Norwegian subsidiary BIS Industrieras well as BIS MainServ from Poland andUS company BIS Salamis Inc. were namedwinners of the 2009 Award. The Best ImproverAward goes to the company which hasmade the greatest progress in improvingLTIF. The award is accompanied by a sum ofEUR 10,000 for use by the winning companyfor social investments. BIS Willich IndustrialServices Ltd. of Ireland was named Best Improverin 2008 and BIS Isenta AB of Swedenin 2009.
» High-level quality assuranceCAREFUL EXECUTION OF PROJECTS CALLS FOR SYSTEMATIC OBSERVANCE OF ALLASPECTS OF QUALITY ASSURANCE, STARTING THE MOMENT THE CONTRACT ISAWARDED AND EXTENDING ACROSS THE INDIVIDUAL PHASES OF THE PROJECTRIGHT THROUGH TO FINAL ACCEPTANCE BY THE CUSTOMER. BIS ARNHOLDTAND BIS ROHRLEITUNGSBAU PROVIDE PERFECT EXAMPLES OF HOW THIS DEFINI-TION OF QUALITY ASSURANCE IS PUT INTO PRACTICE.For the quality management system at BIS Rohrleitungsbau to unleash its full effect, it must besupported effectively and constructively at the project realisation level by means of project documents,plans and instructions.
NETWORKglobe 1/2010page 55“Quality does not happen by chance but isthe result of a systematic approach,” stressesDr. Rudolf K. Jürcke, the member of theBIS Group’s Executive Board responsiblefor Technical Services/HSEQ. “The basis forthis is formed by enterprise-wide standardswhich are subject to ongoing further development.This is achieved by means of theintegrated management system which theBIS Group established last year as part ofits sustained quality initiative. It combinesthe constituent quality and environmentalmanagement systems with site safety andaccident prevention, the risk managementsystem and compliance, ensuring the endto-endoptimisation of processes within theBIS Group.Quality assurance awareness is just as firmlyentrenched at the BIS Group’s operatingcompanies as the realisation of the importanceof safety, health and environmentalprotection is. This is documented by the extensivequality objectives in project planningand execution as well as staff training, thefar-reaching audits and quality checks accompanyingeach step of the process as wellas regular certification in accordance withthe applicable quality standards.All aspects of quality assurance are intermeshedwith each other seamlessly, thusforming an uninterrupted chain. “Taken asa whole, the quality assurance measuresimplemented by all of our companies bothinside and outside Germany adhere to veryhigh standards. At the same time, expectationsare rising all the time,” explains AnkeSudeck, the BIS Group’s HSEQ manager.“This ensures that the customer receivesthe level of quality expected, thus resultingin a high degree of satisfaction and makinga crucial contribution to the entire Group’ssuccess.”SPECIAL CHALLENGESWhen it comes to scaffolding, for instance,the customer gauges quality directly in termsof the actual scaffolding supplied. Yet, thefocus is not solely on the way in which employeesassemble, modify or dismantle thescaffolding but also on the way in which thematerial is delivered. “For this reason, qualityassurance starts for us the moment wereceive the contract,” says Rainer Zielke, qualitymanager/safety engineer at BIS arnholdt.“This is because the entire organisation ofthe project hinges on what is to be scaffoldedand where it is located. Frequently, our scaffoldingreaches extreme heights or extendsthroughout the entire plant, for example, asit is required for pipelines. This always posesparticular challenges for us in terms of qualityassurance.”This is reflected in the requirements whichthe Gelsenkirchen-based scaffolding specialistshave formulated for site safety, employeequalifications and training. Thus, it goes withoutsaying that staff are provided with personalprotective clothing and that qualifiedassembly experts from within the companyare deployed. Subcontractors must also satisfystringent requirements. Key importanceis attached not only to the company’s owntraining activities for apprentices but also toensuring that staff undergo systematic andregular skills development. This takes theform of monthly instruction in accordancewith training plans as well as special trainingon such items as the “Gotcha” rescue kit.BIS arnholdt has implemented this rescue kitthroughout the entire enterprise – the firstscaffolding company to do so. This is a rescuedevice for raising or lowering people wearinga safety brace who have slipped and are thussuspended in mid-air. “After a fall, swift actionis crucial as the person concerned must berecovered within 15 to 20 minutes so as toavoid the risk of a trauma,” explains RainerZielke. For this reason, we have a “Gotcha”rescue kit available at all major sites. In addition,it must be taken to the place of deploymentin the case of special scaffoldingprojects.HIGH-LEVEL EXPERTISEAt the same time, employees must undergoregular tests on their knowledge of the scaffoldingmanual, which BIS arnholdt draftedin 2007 in compliance with site safety rules. Itcontains general safety rules, the precautionsto be taken to prevent falls, extensive assemblyinstructions, information on components,assembly alternatives, hazard assessmentsas well as checking controls and is systematicallykept up to date. Like special actionssuch as the poster campaign “Safe scaffolding”and the regular meetings of differentdepartments within the company, the testsof knowledge are a key element in effortsto maintain specialist skills and to heightenawareness of the importance of safety andquality in scaffolding.The transportation and examination of scaffoldingmaterials also play an important role.Thus, all the material handled by BIS arnholdtin Gelsenkirchen is checked to ensure that itis in proper condition. Only selected forwardersable to comply with the specified safetyrequirements are used to transport the materialto its destination. After it reaches thesite, it undergoes further visual examination.As well as this, BIS arnholdt has its own fleetcomprising a large number of vehicles andmachinery as well as specialist equipmentsuch as rough-terrain trucks for use at opencutmining sites. All necessary examinations,maintenance and repairs are performed bythe company’s own workshop. If it is necessaryto use equipment which is not held byBIS arnholdt itself or only authorised for usein certain plants, it is checked by means of amobile workshop vehicle.One key element of quality assurance at BISarnholdt is the use of a checklist to documentthe examinations performed as soonas the scaffolding has been completed. Thisinvolves the use of a special scaffolding slip.“We introduced a checklist-based examinationlong before this became standard practicefor scaffolding companies,” explains RainerZielke. “Even customers who do not stipulatesuch a check quickly come to realise thatit fulfils an important purpose and that theyultimately also benefit from it.”STRICT RULESVarious rules and regulations such as thePressure Equipment Directive and the OperatingSafety Regulation for pipeline constructionprescribe comprehensive documentationof all processes within the project. Thisis also reflected in the quality managementpractices at BIS Rohrleitungsbau GmbH,Bitterfeld. They are based on an integratedmanagement system complying with theISO 9001 (quality management) and SCC(safety management) standards, with the
NETWORKglobe 1/2010page 56latter also covering all environmental aspectsof relevance for piping. Implementation ofthis system is monitored on an ongoing basisby means of internal and external audits. “Fora quality management system to unleash itsfull effect, it must be supported effectivelyand constructively at the project realisationlevel,” explains Alexander Wrobel, head ofquality management at BIS Rohrleitungsbau.“To this end, we use various instruments suchas contract-management documents for ensuringquality assurance such as a testingschedule as well as welding plans and workinstructions for the specific project.”EXTENSIVE PREPARATIONSPrior to the commencement of work on thecontract, a project team is assembled andbriefed to the necessary extent. The membersof the team are required to documentthe completion of all defined activities in accordancewith the requirements stipulated.One key aspect of this is comprehensive documentationof the welding processes andrelated tasks such as checking, heat treatmentand surface protection. “This,” explainsAlexander Wrobel, “materially reflectsthe quality of our work and means that theproject manager and the welding and check-ing supervisors must have scope to exertinfluence on the production processes at alltimes. In addition, checking mechanisms areincorporated in the process, allowing us tomonitor the quality of our product by applyingacknowledged testing methods, includingwelding process checks to demonstratethat the welding process selected has beenmastered.All production and checking activities aredocumented in the checking schedule drawnup for the individual project. This scheduledefines the individual steps to be taken aswell as the criteria for acceptance. AlthoughIndustrial scaffolding makes high demands of all employees.Systematic quality assurance of the type pursued by BIS arnholdt therefore covers the entire project organisation.
Professional planning of the preparations for a construction site plays a crucial role in ensuring that the scaffolding is assembled effectively and securely.many pipe construction companies usechecking schedules these days, for manyyears it was far from being standard practice.“We started using such a document at a veryearly stage,” reports Alexander Wrobel. “Andin the course of the years we have steadilyadjusted it to incorporate new technical developmentsand the specific requirements ofthe trade so as to satisfy customer requirementseven more efficiently.”Accordingly, the welders permitted to workon these demanding types of steel areselected carefully on the basis of the resultsof welding seam tests and observation bythe welding supervisors. The weldersdeemed suitable for working on thesematerials then undergo professional trainingat the company’s own academy inBitterfeld, which, among other things, isan approved vocational training institutein accordance with Book III of the SocialSecurity Code and certified by TÜVRheinland. Currently, BIS Rohrleitungsbauhas 16 welders qualified to work onthese materials. “This,” explains AlexanderWrobel, “is unique in all of Germany.”MANUAL DEXTERITY SOUGHTBIS Rohleitungsbau attaches crucial importanceto training welders. In some cases, additionalqualifications are required for theindividual welding methods. In particular,welding of chrome steel types P 91, P 92 andX 20, which are frequently used in power stationconstruction but are very susceptible tothe risk of cracking, make high demands ofwelders’ dexterity and not everyone is capableof achieving the necessary results. Whatis more, notched-bar impact bending testsare necessary with these types of steel asproof that the welder has utilised the specialtechnology required. Notched-bar impactbending tests are a means of assessingthe tensile strength of the material, helpingto detect the cause of embrittlement, e.g.hollow spaces, inclusions, separation andaging.HEIGHTENED TRANSPARENCY THROUGH THE USE OF A DATABASETransparency is a key factor in quality assurance. In the United Kingdom, BIS IndustrialServices Ltd. records and maintains all scaffolding in a database. By entering all equipmentuniformly in the database, it is possible to monitor the scaffolding status, whichis updated once a week. The results are entered in the database and form the basis fordetermining the date of the next mandatory examination. This is of great advantageparticularly in the case of long-term scaffolding. In addition, the documentation of allchanges in the database means that details can be readily attached to the scaffoldingin question. At the same time, the database aids internal cost accounting as the dataprovides an indication as to whether the scaffolding is being used for a longer periodthan planned, thus meaning that corresponding reserves must be set aside. A similardatabase is currently also being implemented at BIS arnholdt, with 75 percent alreadyin place.
NETWORKglobe 1/2010page 58» Quality comes from qualificationsTHE BIS ACADEMY REFLECTS THE DIVERSITY AND QUALITY OF PERSONNELDEVELOPMENT WITHIN THE BIS GROUP WITH THE INTEGRATION OF FURTHERUNITS, PARTICULARLY THE INDUSTRIAL AND POWER STATION SERVICESPROVIDER MCE, VIRTUAL TRAINING AND SKILLS-DEVELOPMENT ACTIVITIESHAVE GAINED FURTHER DEPTH AND SCOPE, ENHANCING THE RANGE OFOFFERINGS PROVIDED BY THE BIS ACADEMY.The uniform family of symbols with theBIS Academy logo placed at the top ensuresimmediate recognition of all the activitiesperformed by the BIS Academy and, asa registered trademark, is a guarantee ofquality. “This underscores the benefits andthe qualities which set BIS training activitiesapart in the market place,” says SilviaHägele, personnel development officer. “It isan expression of the professional approachand sustainability of our training and skillsdevelopment activities.”The content of offerings available from theBIS Academy has been widened substantially.Modular training programmes for bothmaintenance and project business havebeen developed on the basis of the operatingcompanies’ requirements and ensureadherence to BIS standards. Known as “BISMaintainer” and developed in close consultationwith BIS Maintenance SüdwestGmbH, the first modular training coursehas been launched in a pilot project. Comprisingsix integrated modules, it seeks toheighten participants’ theoretical, methodicaland social skills. The “BIS Maintainer”course has a duration of around 18 monthsand is paving the way for further modulartraining courses for specific target groups.Managing director Franz Braun is convincedof the benefits of the programme: “Withthis investment in our staff we are able tosecure even greater quality for our clients.The superb collaboration with Central PersonnelDevelopment helps us to maintainand extend our high standards of quality.”TAILORED PROGRAMSSpecially tailored programmes ensure sustainedimprovements in skills. Examples includeFRUCIT and the “Fit for Managing”/“Fit forMarket” programmes. Targeted at variousmanagement levels in the financial area,FRUCIT aims to enhance theoretical and socialskills on a sustained and long-term basis andto prepare young high potentials for managementtasks within the BIS holding companyas well as at the subsidiaries. Initiated by managingdirector Günther Illig and coordinatedby Personnel Development, these programmeshave been utilised by BIS IndustrieserviceMitte over the last two years toenhance the communications, management,project management and sales skills of itsspecialists and executives.STRONG COMMUNITYThe BIS Networks form a material part of theBIS Academy and act as a platform for sharingexperience and best practices within theBIS Group on a cross-company/cross-borderbasis. They pool the strengths of a non-centralisedstructure with central support functionsand have thus become a successfulmodel. There are currently 14 thematic networkswith around 250 employees from theBIS Group, all of which are putting specialistknowledge to good use in specific projects.One example is the new edition of a manualfor thermal and refrigeration insulation,which was produced by the BIS InsulationNetwork. This book sets out the BIS Group’score skills and knowledge in a compressedform. Practitioners are able to use the application-orientedreference directly in theirday-to-day work. The new edition has beenextended with the addition of important new
NETWORKglobe 1/2010page 59UNIFORM QUALITY STANDARDSAll personnel development activitiesare linked and constantly enhanced underthe roof of the BIS Academy. Centraland local training offerings are targetedat management staff, young potentials,project/construction managers and employees.All activities are tailored to meetthe specific needs of the BIS employeesand subsidiaries, thus ensuring sharedsuccess at the individual and strategiclevel. The operating units have alwaysdisplayed considerable initiative of theirown when it comes to personnel development.Examples include the trainingand skills development centres for thetechnical employees operated by BISSalamis in the United Kingdom, BISIndustrier in Norway and BIS Multiserwisin Poland.The BIS Group has set itself the goal ofjointly defining cross-company/crossbordertraining standards. In this connection,the main emphasis is on guaranteeingthe defined quality levelsacross the entire Group by defining standards.To achieve this, the “BIS CompetenceCommittee” has been established.It forms part of the BIS Academy and iscomposed of representatives of the BIStraining centres, local and central personneldevelopment departments andmanagement staff from the operatingcompanies. By defining uniform BISstandards it is possible to ensure highquality in the training which BIS Groupemployees receive. In a preliminary step,competence profiles are defined. Lookingforward, there are plans to arrangefor external certification of these Groupwidestandards. What this means forthe BIS Group’s customers is heightenedtransparency and even greater qualityin planning and executing all industrialservices projects.areas, includes the latest changes to legal requirementsand standards and is suitable forinternational use. “This manual is a great advantagefor us in our own work and can alsobe put to very good use by our customers,”explains Michael Schmitz, head of PersonnelDevelopment at the BIS Group. “Accordingly, itis an excellent example of the results-orientedactivities and capabilities of the BIS Networks.”SUBSTANTIAL GAIN IN SKILLSBIS Networks are an ideal instrument for integratingacquired companies, particularlyalso the previous MCE companies. For onething, the BIS Networks are able to benefitfrom an influx of new members, while, foranother, the sharing of knowledge is enhancedthrough the addition of the newmembers’ knowledge. As well as this,effective social networks are establishedand extended. The same thing applies tothe Junior Management Team (JMT), whichhas been used successfully for many yearswithin the BIS Group as a means of developingyoung management talent. Now, it willadditionally be home to the high potentialsfrom the former MCE companies.“This,” says Timur Tavas, head of CorporateHuman Resources & Services, “constitutes adecisive competitive advantage particularlygiven the shortage of qualified managementstaff.”The personnel development activities of theformer MCE companies have strengthenedthe BIS Academy, additionally reinforcingits expertise. In this connection, a key contributionis coming from the MaintenanceSchool (IH-Schule), which has been providingtechnical staff and operatives at thekey maintenance sites with theoretical aswell as practical knowledge since 2005. Thisinformation is supplemented with practicaltips and suggestions from experienced industrialservice experts as well as externalspecialists and trainers. The advantages ofthe Maintenance School are not difficult tosee. Specialist skills are developed and enhanced,access to internal expertise ensuredand the quality of work enhanced in the interestsof the customers.Alongside main contract business, projectbusiness is also increasingly growing in importancewithin the BIS Group, particularlyin the new Plant Technologies Division. Toensure that the high expectations of qualityin this segment can be satisfied, the BISAcademy is offering project managers andemployees a range of training activitiesmeeting their specific requirements. Theseactivities have been assembled under the“Fit for Project” motto in consultation withthe operatives requiring them and undergoconsistent improvement.CUSTOMERS BENEFITINGAll told, the integration of MCE has resultedin a win-win situation in the personnel developmentarea as well. Our professional andsystematic personnel development activitiesreflect the Group’s leading position inthis still-young industry,” says Thomas Töpfer,a member of Bilfinger Berger’s ExecutiveBoard. “The range of services contributed byMCE is additionally enhancing our trainingefforts, not only benefiting our employeesbut also offering our customers clear addedvalue.”serer Mitarbeiter und unserer Beschaftenausgerichtet. So machene Erfolge möglich – auf individueltrategischerEbene.alle Fragen der PersonalentwickirIhnen kompetente Beratungzung. Unser Leistungsspektrumche Prozessschritte von der KoneUmsetzung bis zur QualitätssirMaßnahmen.
CREDITSPublished by:Bilfinger Berger Industrial Services GmbH,Munich, represented by itsChief Executive Officer,Dr. Michael HerbermannEditorial team:Ullrich Esser (responsible),Beate Kneuse and Susann Naumann (copy),Michaela Helm (assistant)Editorial address:Corporate Communications,Gneisenaustraße 15,D-80992 MunichTelephone +49 89 14998-135Telefax +49 89 14998-277E-Mail: ukomm@BIS.bilfinger.comInternet: www.BIS.bilfinger.comReprinting with indication of sourcepermitted.The globe is available in German andEnglish.