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State-of-the-art engineering · in-houSe production workShopS · experienced aSSembly Staff

Power. Vision.SucceSS.

bilfinger Vam anlagentechnik gmbh

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Bilfinger industrial technologiesBilfinger Industrial Technologies is an international specialist for industrial facilities and has approximately 8,000 employees – including over 4,000 engineers. The services range from consultancy and design, engineering and project management, through to manu facturing and installation. Bilfinger Industrial Technologies generates an output volume of approx­imately €1 billion. The 12 operating companies of the Group are active with their own branches in 25 countries worldwide.

Bilfinger VaM anlagentechnik Bilfinger VAM has been a leading edge company in industrial plant engineering and pipework construction as well as apparatus, vessel and tank for many decades. The company offers the entire range of services en­compassing engineering, fabrication, installation, and commissioning. Components and entire plants are manufactured for the sectors of pipework for industrial purposes and power plants, underground pipework, turbine installation, apparatus, vessel and tank, equipment assembly as well as Education & Training.

On top of these services, the company offers and provide skilled workers, nondestructive material testing, welding consulting as well as the training and further education of welding operators. Bilfinger VAM adheres to the high­est national and international standards. All stages of production are subject to the criteria of an Integrated Management System and comply with the standards pursuant to EN ISO 9001, EN ISO 14001 and the safety manage ment system according to SCC standards.

Bilfinger VAM AnlAgentechnik – A reliAble PArtner of industry

Products and serVices ‒ plant engineering ‒ pipework for industrial purposes ‒ pipework for power plants ‒ underground pipework ‒ apparatus, vessel and tank ‒ penstocks / hydraulic steel structure / turbine installation ‒ Steel structure ‒ equipment assembly ‒ education & training

2 Company

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CONTENT 2 Company 6 Pipework for industrial Purposes 9 Pipework for Power Plants 10 underground pipework 13 Apparatus / Vessel / tanks 14 Hydropower Plants 17 equipment Assembly 18 engineering 21 erection & Assembly services 22 welding and test engineering 25 education & training 26 our sites

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gas cooling, natural gas storage facility haidach, Salzburg, austriab _ headquarters of bilfinger Vam anlagentechnik, wels, upper austria

NET OUTPUT OF 845 MEGAWATTS – EFFICIENCY OF MORE THAN 59 %.The efficiency of thermal power plants approaches the magic 60 % threshold due to rising pressure and temperature. Special materials such as martensitic chrome steels E 911, P 91 and P 92 withstand temperatures around and above 600 °C thus creating the basis for the pipework required in cutting­edge plants.

Steam pipes at the gas and steam turbine powerplant irsching 5, bavaria, germany

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In the sector of metallurgy Bilfinger VAM operates branch offices including a workshop at each of the premises of voestalpine located in Linz and Donawitz. In close cooper­ation with the customer, Bilfinger VAM erects piping sys­tems and mechanical components in new plants. Existing plants are refurbished and inspected.

Moreover, Bilfinger VAM plans and delivers vessels and apparatuses as well as pipework of all common materi­als and dimensions for the chemicals and petrochemi­cals industry. Bilfinger VAM assembles all kinds of me­chanical equipment ranging from structural steelwork to vessels and apparatuses including all related pipe­work. Bilfinger VAM has a long­term tradition in manu­facturing pipework for the paper­ and pulp industry. The pulp factory in Pöls is one of a number of Bilfinger VAM bases in this field.

All common steels and materials such as titanium and glass­fiber reinforced plastics are processed. Apart from pipework erection, Bilfinger VAM also erects entire plants.

a _ modification evaporation plant, pöls, Styria, austriab_ booster station laim, bavaria, germanyc _ biomass power plant ulm, baden wuerttemberg, germanyd _ glass-fiber reinforced cooling water pipes at the gas and steam turbine power plant irsching 5, bavaria, germany

PiPework for induStriAl PurPoSeS tHe linking element

a b c

bilfinger Vam strives to contribute to the success, quality and efficiency of industrial plants by offering its experience and expertise. the services offered encompass design, planning, technical pre paration, delivery, erection, and commissioning of pipework and entire plants. highly skilled staff uses state-of-the-art techniques at work.

6 Pipework for Industrial Purposes

Products and serVices ‒ engineering (planning, design, calculation) ‒ manufacture and delivery ‒ Site supervision, erection and commissioning ‒ Quality assurance and documentation ‒ Service and maintenance

sectors ‒ metallurgy ‒ chemicals / petrochemicals ‒ paper- / pulp industry

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Project management starts with the preparation of project planning. Bilfinger VAM uses the software de­termined by the customer and works out a detailed planning according to specifications, pipe statics and support concepts. In close cooperation with the custom­er, employees of Bilfinger VAM strive to develop solu­tions that come up to the increasing challenges regard­ing efficiency, quality, safety and deadlines. Already during the planning stage, our site managers bring in their expertise when it comes to determining works and assembly seams. Pipe spools are prefabri cated and tested at the workshops of Bilfinger VAM located in Steti, Czech Republic, and Linz, Austria.

MAAS software developed by Bilfinger VAM is used for computer­aided procurement and management of materials and for progress control at the construction site. Welding operators and mechanics use sophisticated assembly concepts when mounting pipework. In close cooperation with the customer, Bilfinger VAM carries out the commissioning of piping systems.

a _ welding work on high-pressure pipes at the power plant Salzgitter, lower Saxony, germanyb _ district heating plant, Salzburg, austria c _ Steam pipes at the gas and steam turbine power plant irsching 5, bavaria, germanyd _ cooling water supply at the gas and steam turbine power plant köln knapsack, north rhine-westphalia, germany

PiPework for Power PlAntS sAfe And seCure At 600°C And 285 bAr

Products and serVices ‒ cad planning (autocad, pdmS) ‒ pipe statics (rohr 2) ‒ pre-assembly ‒ erection ‒ processing of all common steels (including e 911, p 91, p 92) and plastics

‒ commissioning ‒ documentation

the efficiency of thermal power plants approaches the magic 60 % threshold due to rising pressure and temperature. Special materials such as martensitic chrome steels e 911, p 91 and p 92 withstand temperatures around and above 600 °c thus creating the basis for the pipework required in cutting-edge plants.

Pipework for Power Plants 9

As your general contractor responsible for civil engineering and pipe fitting, Bilfinger VAM carries out the entire implementation of con­struction projects.

Bilfinger VAM has proven to be a reliable partner for piping systems as it specializes in pipe fitting. Bilfinger VAM provides its customers with detailed information about planning, layout, and design of all kinds of media pipes and advises them on the selection of pipe materials, valves and controlling devices, and all functional details of media supply.

underground PiPework – Power HigHwAy

a_ natural gas pipe storage facility, etziken, Switzerlandb _ district heating transport line, chur, Switzerlandc _ gas pipeline ontras dn 600, Staßfurt, Sachsen-anhalt, germanyd _ gas pressure control and measuring system thyrow, brandenburg, germany

Products and serVices Planning, delivery, and installation of: Pipelines

‒ for all kinds of media – gas, oil, chemicals and water

‒ for all pressure stages ‒ assembly of special structures

gas stations ‒ compressort stations ‒ branch pipies ‒ gas pressure control and measuring systems ‒ Services such as regulation service, Stop work, pressure tests pursuant to dVgw

gas storage facilities ‒ natural gas storage facilities of all dimensions and pressure ratings

‒ gate valves ‒ gas meter stations ‒ Volume and pressure reducing stations

district heating systems for all kinds of ‒ laying systems ‒ nominal diameters ‒ pressure stages ‒ temperatures

snow making systems Pipe-work related services for

‒ pump stations ‒ compressed air systems ‒ hydrants ‒ mains

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pipelines are essential for transporting liquid and gaseous media in an efficient manner over great distances. bilfinger Vam lays pipelines for all kinds of media such as water, gas, oil, chemicals, and district heating.

10 Underground pipework

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For decades, Bilfinger VAM has been executing contracts without any interface including statics and detailed engineering as well as non­destructive testing and has proven to be a reliable partner when implementing a large number of projects.

Components of single weights of up to 100 tonnes and diameters of up to 5,500 mm are fabricated at the work­shop in Wels. Components exceeding these dimensions are prefabricated and erected on site. Upon request, rolling­up of plates up to a thickness of 100 mm, bending with the new 1,600 tonnes press or welding jobs can be carried out as contract work.

a _ accumulator, linz, upper austriab _ bitumen tanks for an asphalt production plant, großmehring, germanyc _ column of a renowned german chemical group, bavaria, germanyd_ district heating accumulator, Jena, thüringen, germanye _ heat exchangers combined-cycle power plant mellach, Styria, austria

APPArAtuS / VeSSel / tAnkS sAfe And durAble

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Products and serVicescalculation, design, manufacture, and erection in the areas of:

apparatus ‒ pressure vessels ‒ tubular heat exchangers ‒ Sieve bottom and packing columns ‒ process vessels ‒ Special constructions

Vessel ‒ Storage tanks ‒ lpg tanks ‒ accumulator

tanks ‒ tanks for inflammable liquids ‒ dobule-shell tanks ‒ floating-roof tanks

components for exhaust gas purification systems ‒ evaporation cooling ‒ e-filter cases ‒ emission electrodes including framing

components for direct reduction plants ‒ Quench vessels ‒ flight separators ‒ air cooling conveyor ‒ Special constructions

Apparatus /Vessel /Tanks 13

despite being subject to static and chemical stress, industrial apparatuses, vessels and tanks have to be durable and safe as they are used in process engineering. this requires high quality manufacture.

The components prefabricated by Bilfinger VAM are transported to site where they are installed by pro­fessionals, sometimes under extremely difficult conditions. It might happen, that installation requires utilization of very special means like cablecar, inclined hoist or helicopter.

Calculation, design and manufacture of sophisticated bifurcations, manifolds, trash racks, closure devices such as emergency shut down gates, dam bottom outlet gates, weir flaps etc. is done at our headquarters in Wels.

Our target is a technical long­term value conservation and an extended life cycle of facilities.

Bilfinger VAM knows the way: As a manufacturer­independent specialist for installation and rehabilitation of all types of water turbines since many decades Bilfinger VAM has been successful in Europe and worldwide. Bilfinger VAM has left its technical „footprints“ at a high number of notable power plant projects and enjoys an excellent international repu­tation for fabrication and installation of penstocks as well as hydraulic steel structures like radial and roller gates, stoplogs, trashracks, etc.

hydroPower PlAntS from tHe worksHoP

into tHe roCk

Products and serVices calculation, design, manufacture, and assembly of: Penstock

‒ open type and underground penstock ‒ high pressure steel lining ‒ manifolds ‒ bifurcation pipes ‒ expansion stuffing boxes ‒ manholes ‒ plain bearings ‒ pipe bridges ‒ dismounting and extension pipes ‒ Surge chamber linig

hydraulic steel work ‒ filling and drain valves for locks ‒ emergency gates ‒ Stop gates and trash racks ‒ retaining weirs ‒ bottom outlet slide valves ‒ radial gates ‒ harbor locks ‒ intake gates

installation of turbine ‒ pelton / kaplan / francis turbines ‒ pumps and pump turbines ‒ related components and auxiliaries

a _ inside the draft tube, limberg ii, kaprun, Salzburg, austriab _ downstream steel lining, kops ii, Vorarlberg, austriac _ pelton runner at gerlos ii, tyrol, austriad _ installation of radial gates with flap at hydro power plant

lehen, Salzburg, austria

14 Hydropower Plants

penstock and high pressure steel lining are essential components when hydro power plants are built. for many decades, bilfinger Vam has been a competent and reliable partner in construction of hydropower plants.

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equipment Assembly combines experience, knowlegde and skills Equipment Assembly combines the experience gained in engineering, production and installation with future­oriented services on site. Bilfinger VAM offers installation and services for entire plants as well as for components at blast furnaces, steel plants, rolling mills and even for complete strip processing lines. Assisted by its in­house manufacturing facilities, Bilfinger VAM offers their customers full life cycle support for mechanical equipment and components. In this division Bilfinger VAM has several bases in Austria (Linz, Zeltweg, Donawitz, Graz) and in Switzerland (Würenlingen).

regeneration. revitalisation. refurbishment. Demanding steel constructions and special concepts require a reliable and experienced partner. Large­scale steel construction projects, such as the complete revitalisation of the main station in Frankfurt am Main or the restoration of parts of the historic Wuppertal suspended railway were carried out with a maximum level of expertise. Buildings that are trendsetting in terms of architectural design, must also meet the highest demands in terms of steel construction.

a _ hoisting / assembly of coilers 3 at voestalpine, linz, upper austriab _ rehabilitation palmenhaus Schönbrunn, Vienna, austriac _ refurbishment of the logistic centre of bilfinger gerätetechnik, wels, upper austria d _ blast furnace „a“ at voestalpine, linz, upper austria

equiPMent ASSeMBlyexPertise tHAt Counts

Products and serVicesconsulting

‒ consultancy services for customers ‒ developing ideas ‒ planning drafts ‒ preparing specifications ‒ estimating costs

engineering

‒ Static calculations ‒ implementation planning ‒ assembly planning ‒ construction scheduling ‒ construction site logistics ‒ crane studies ‒ development of assembly technolo-gies and special components

construction

‒ manufacturing and delivery ‒ dismantling work ‒ assembly work ‒ project execution (also as general contractor)

‒ coordination of other trades

Equipment Assembly 17

b c d

This attitude and its consistent implementation have turned Bilfinger VAM into one of the leading providers in its specialties. Based on their one hundred percent commitment, Bilfinger VAM teams work out complete solutions. Wide­ranging expertise allows solving even complex and demanding jobs on time and in a

technically perfect manner. As an engineering office for mechanical engineering, Bilfinger VAM offers planning and calculation services in pipework, apparatus and vessel as well as hydraulic steelwork. If required, engineering services are rendered at the customer’s premises or at the construction site.

a _ employee of the engineering divisionb _ 3d-model bop-Section, power plant Salzgitter, lower Sarony, germany c _ fe network for downstream bifurcation pipe, limberg ii, Salzburg, austriad _ 3d-design using Solid works

engineering – looking into tHe future

Products and serVicesPiping engineering

‒ basic and detailed engineering ‒ design of components and units ‒ dimensioning of parts ‒ generation of pipe material classes ‒ process diagrams ‒ engineering of operating platforms, temporary blow-off and pickling devices

‒ pressure test concepts ‒ Stress calculations of piping systems ‒ calculation of pressure loss / calculation of heat loss ‒ Support concepts and calculations ‒ calculation of fundament loads ‒ risk analysis and operating manuals ‒ final documentation ‒ technical project management ‒ pdmS: administration, catalogues ‒ provision of engineering-staff

apparatus and vessel engineering ‒ basic and detailed engineering ‒ Static and dynamic dimensioning of flat-bottom tanks, pressure vessels and heat exchangers including calculation for wind and earthquake loads

‒ evaluation of conformity according to ped ‒ thermal calculations ‒ planning of process control equipment ‒ Structural steelwork ‒ project management ‒ engineering and dimensioning of atmospheric heating accumulators acc. to “System hedbäck”, as well as pressurized heat accumulators.

‒ concepts and planning of the hydraulic integration of heating accumulators in district heating systems.

hydraulic steelwork engineering ‒ Static calculation pursuant to most recent standards and norms

‒ calculations using the finite element method ‒ 2d- and 3d-design ‒ planning of welding operation procedures ‒ project implementation including workshop planning and assembly / installation

‒ flow simulation by cfd

18 Engineering

Quality, expertise, and reliability are bilfinger Vam’s benchmarks for successfully performing engineering services. engineering is teamwork. highly qualified and committed engineers work together striving to develop successful solutions.

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SoftwAre ‒ ANSYS (FEM­Calculation) ‒ AVEVA PDMS / MDS / Diagramms / Global

‒ Autodesk AutoCAD / Inventor / NavisWorks

‒ Bentley Microstation / STAAD.Pro ‒ BHR FERO ‒ CoCreate Drafting / Modeling ‒ Dassault Systemes CFD / Solid Works

‒ Dlubal RSTAB ‒ Evonik EBSILONProfessional ‒ F.I.R.S.T. Conval ‒ GRAITEC Advance Steel ‒ IBM PROBAD ‒ Intergraph SmartPlant Isometrics (Alias I­Sketch) / Review

‒ LV­Software (AD2000, EN13455, ASME­Code)

‒ Leicad Software AutoSTRUCTURE ‒ PTC Mathcad ‒ Sigma ROHR2 / SINETZ / FESU ‒ WinShell (AD2000, EN13445) ‒ RCS Pipebuilder

b c da

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Complying with the highest safety and quality standards, Bilfinger VAM is active worldwide and assembles piping systems, apparatuses and vessels, steelwork, hydraulic steelwork, machinery and entire plants ready for service.

The key to success is close cooperation and exchange of experience between concept and design. Our professionals and the availability of Austria’s largest and most modern machinery and equipment guarantee efficient and cost­effective assembly.

a _ assembly of a lock gate, power plant wallsee, lower austriab_ Steelwork assembly, limberg ii, kaprun, Salzburg, austriac_ tig hot wire welding, cleuson-dixence, Switzerlandd_ assembly of fittings at the power plant Salzgitter, lower Saxony, germany

erection & ASSeMBly SerViceS – Visions beComing reAlity

Products and serVices

Worldwide assembly of: ‒ piping systems ‒ apparatuses and vessels ‒ Steelwork ‒ hydraulic steelwork ‒ machinery ‒ complete plants

revision work

survey technology

Worldwide provision of skilled workers

‒ assembly experts ‒ welding operators ‒ construction site managers ‒ Supervisors ‒ chief welding operators ‒ test engineers ‒ engineers

Erection & Assembly Services 21

during assembly, the creative ideas of designers become reality. bilfinger Vam employs excellent technical designers and has almost thousands of skilled assembly experts ranging from chief fitters to assembly specialists.

b c d

At the welding workshop, the welding operators are trained in the use of new techniques in a practically oriented way while existing knowledge is being consolidated; or the welders are prepared and trained for special jobs. Bilfinger VAM welding operators are tested and certified according to EN 287­1 and EN ISO 9606­2 and EN 1418.

International Welding Engineers, International Welding Technologists and International Welding Specialists ofBilfinger VAM are pleased to offer their welding consulting services.

In order to comply with the high quality requirements, our products are tested using non destructive testing (NDT) pursuant to the applicable product specifications. Our testing and inspection personnel have been certi­fied in stages 1, 2 and 3 pursuant EN 47321 / ISO 9712.

a _ Joint of an orbital weld, power plant limberg ii, kaprun, Salzburg, austriab_ magnetic particle testing at the power plant cleuson dixence, Switzerlandc_ welding work on the natural gas pipeline, redlham-offenhausen, upper austriac_ mechanical ultrasonic testing of a straight bead, power plant

cleuson-dixence, Switzerland

welding And teSt engineering sAfely linked

Products and serVices training of welding operators / Welding consulting

Welding processes ‒ manual arc welding ‒ metal active gas welding / gas-shielded metal inert gas welding

‒ tungsten inert gas welding ‒ Submerged arc welding ‒ plasma arc welding ‒ gas welding

certification ‒ bilfinger Vam is certified pursuant to national and international standards and regulations.

‒ bilfinger Vam welding operators are tested and certified according to en 287-1, en iSo 9606-2 and en 1418.

nondestructive material testing ‒ Visual inspection (Vt) ‒ dye penetrant testing (pt) ‒ magnetic particle testing (mt) ‒ radiographic testing (rt) ‒ ultrasonic testing (ut) ‒ hardness testing (ht) ‒ positive material identification (pmi) ‒ Vacuum testing

new materials, new ways of processing and ever more demanding working conditions require excellent welding and testing engineering. this is why bilfinger Vam gives top priority to the training and further education of welding operators.

22 Welding and Test Engineering

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educAtion & trAining QuAlifiCAtions Are gAining ConstAntly imPortAnCe

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a_ training electro pneumatics, Sri lankab _ completion of instructor training, Vietnam c _ laboratory for electro pneumatics, Sri lankad_ training center, Serang, indonesia

Education & Training 25

the education & training division specialises in providing international qualifications for people who believe that their future lies both in traditional and yet future-oriented jobs in industry. for decades, the dual training system of bilfinger Vam has combined theoretical knowledge with practical training.

Bilfinger VAM offers a combination of various training concepts and specific practical experience in the following areas:

‒ Electrical engineering ‒ Electronics ‒ Mechanical engineering ‒ Welding engineering ‒ Automotive engineering ‒ Mechatronics ‒ Individual training concepts

The services of Bilfinger VAM range from planning, engineering, delivery of equipment and training software up to the construction of turnkey training centres.

Financial consulting is also part of its range of services. Bilfinger VAM, in co­operation with renowned experts, training institutes and universities, makes a significant contribution towards offering higher qualifications in industry. International training centres in China, such as the Panzihua University and the Heilongjiang Institute of Science & Technology, the Uni­versities of Sarajevo and Zenica in Bosnia­Herzegovina and the Ministry of Higher Education in Sri Lanka rely on the experience of Bilfinger VAM.

theory and pratice combinedMore than 50 years of experience and more than 60,000 participants in industrial training courses speak for themselves. Bilfinger VAM training programmes have been implemented successfully in various parts of the world including China, Indonesia, Libya, Jordan and Saudia Arabia, Vietnam, Sri Lanka, as well as Bosnia­Herzegovina.Internationally recognised certificates are a guarantee for the quality of the programmes. Tailor­made to meet the customers‘ needs, the Dual Vocational Training Programme allows the trainees to develop their technical, language and social competence. Special „Train the trainer“ concepts in Austria and on site promote the international exchange of experience and knowledge in industry.

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bilfinger industrial technologies

bilfinger Vam anlagentechnik gmbhDieselstraße 2 4600 Wels, Austria Phone: +43 (0)7242 406-0 Fax: +43 (0)7242 406-320 info.vam@bilfinger.com

www.vam.bilfinger.comwww.industrial.bilfinger.com