rhi consultant engineering

Setting the Standard In Cement Excellence

Company Capabilities Presentation

Engineers, Builders & Operation Professionals for the Cement Industry

RHIReliance Heavy Industries


RHI was established, in response to an increasing regional demand for a world class integrated services provider, that focuses exclusively on serving the cement industry. In the past 6 years alone, RHI has been directly involved in the Engineering, Consultancy construction, modernization, as well as plants operation adding over 24 million tons per year to the market capacity.

RHI leadership is asserted through the wealth of knowledge and experience of our carefully selected, trained and continuously developed, cement industry expert works force, providing innovative, forward thinking, and effective solutions to all our client’s needs. Working closely with our customers, and by partnering with major designers and equipment manufacturers, RHI seasoned project teams, provides on time, and with-in budget projects, that are executed to our clients’ full satisfaction.

Our commitment to sustained customer satisfaction, through exceeding customer expectation providing refined products and services, has always our major asset.



Our Vision

To Assert and further expand our regional leadership, through

becoming the integrated service provider of choice, for all major

Cement Manufactures, converting our unmatched knowledge of the

industry, into best value innovative, forward thinking solutions,

satisfying all our clients needs.



Our Mission

• We -the RHI’s team- pledges to assert our regional leadership of the cement industry

integrated services through striving to provide the following parameters :

•Best value service to all our clients through, sustainable development and setting the

industry customer satisfaction standard.

•Personal and professional development of RHI team members, through providing excellent

growth opportunities and training.

•Commitment to compliance with health, safety and environmental regulations as well as

exceeding all our customer’s expectations through the relentless pursuit of excellence in

everything we do.

•Ethical and moral conduct in all our relations with clients, suppliers and each other.



RHI Divisions

1- Consultancy & Feasibility Study Division

2- Engineering & Design Division

3- Raw Materials Investigation & Mining Division

4- Operation & Maintenance Integrated Services Division

5- Projects Management Division

6- Construction & Overhauling Division



Consultancy and Feasibility Study Division

• Raw Materials Assessment & Study

• Establishing Design Basis of New Cement Production Lines

• Plant Conceptual Design, Layout and Flow Sheet

• Project Economics (Capex, Fixed & Variable Costs)

• Tender Documents & General conditions Preparation

• Project Technical Specifications Development

• Bids Evaluation and contracts Negotiations

• Alternative Fuels Study



Engineering & Design Division



• Reinforced Concrete Structural Design and DetailingStructural Steel Design and Detailing

• Existing Structures appraisal, modifications design and retrofits

• Auditing and Validation of design works

• Site supervision and site quality control

• Architectural design

• Surveying and roads design Works

Civil & Structural Engineering Section

• Review and Verification of Mechanical-Civil designs compatibility



• Basic process design of equipment including

Crushing pyroprocess ,grinding, transport and

handling equipment, filters, etc.

• Flow sheets.

• Heat and Mass balance.

• Refractory and Insulation Material selection.

• Basic and detail design of equipment

• Auditing and Technical evaluation of existing

plants and equipment for retrofits, modernization

and upgrading projects.

• Plants Engineering review and validation.

• Plants optimization and improvement studies.

• Start up and commissioning support.

Process and Equipment Engineering Section



• Transport and handling equipment design.

• Auxiliary equipment sizing and selection.

• Detailed design of plate work for all

equipment, ducts, and chutes.

Mechanical Engineering & Facility Design Section

• Environmental Emissions Assessment.

• Emissions reduction and control.

• Filters upgrading, engineering and design.

Environmental Engineering including

• Plants engineering and general arrangements for

new designs and existing systems

modifications.• Piping network systems of Industrial water,

compressed air, fuel oil, gas and fire fighting.



• Single Line diagram.

• Schematic and Wiring diagrams.

• Electric power distribution equipment

specification and evaluation

• Specifications and data sheets of electrical

equipment.

• Cables sizing layout and routing diagrams.

• Communication and lighting systems.

• Power management systems

Electrical Design Section



Instrumentation Design Section

• Instrumentation Equipment specifications,

data sheets and evaluation.

• Logic / loop diagrams and termination

drawings.

• Hook-up and installation drawings.

• Control room layout and arrangement

drawings.

• Panels specifications and arrangement

drawings.

• DCS and ESD specifications including

programming And FAT Tests.



Project Management Division


• Procurement, supply and expediting services

• Project administration & cost control

• Project budgeting, planning& progress monitoring

• Bid packages preparation & evaluation



• Construction supervision

• Project schedule acceleration & recovery management

• Commissioning, start-up & performance testing management

• Quality Control plan development & execution management

• Vendors & suppliers shop inspections & test witnessing

• Project value engineering



Construction & Overhauling Division

Construction & Overhauling Division

• Turn Key Design, build projects.

• Heavy Industrial plants overhauling, and shut-

down.

• Heavy Industrial plants Erection, and

Maintenance.

• Environmental Equipments Erection, and

Maintenance.

• Upgrading, and Process Modernization of

cement and Heavy Industrial Plants

• Major Piping, and Utility Projects, execution.





Raw Materials and Mining Division



Phase 0: Reconnaissance Study

Phase I : Preliminary Raw Materials Investigation

Phase II: Overall geological Investigation

Phase III: Detailed Investigation & Mining Planning

Raw Materials Study



Geological Mapping

Drilling & Logging

Sampling, Chemical & Physical testing

Geological Studies Scope

Data Treatment and Interpretation

Data computation by SURPAC



Selection of the quarry site

Quarry design features &configuration

Quality planning by SURPAC

Mining Studies Scope

Directionof

Advance

Directionof

Advance

Cut

Cut

Cut

Wheeldirection of

Travel

Wheeldirection of

Travel

Wheeldirection of

Travel

Directionof

Advance

Full Block Mining

Terrace Cutting

Face Block Mining

Mining process technique

Quarrying Orientation



Quarry Operations Management



Original TopographyBefore Crusher Start Up1 years after3 years after5 years after10 years after

Short & Long Terms Quarry Progress Planning

Quarry Opening

Reliance Heavy Industries

RHI

Production Benches preparation

Roads opening

Sub-Benching

Overburden Removal


Quarrying Operations


RHI

Blasting & Extraction

Loading and Hauling

Feeding


Operations Assessment and continuous improvement


RHI


Dolomite

Limestone

Limestone

Raw Materials Monitoring



Operation & Maintenance Division



Operation & Maintenance Division

Operation & Maintenance Technical Assistance

OMTA

• Supply and Management of Technical

Assistance team to support owners O & M

team

• Meeting the targeted production plan

• Technical assistance for meeting key

performance indicators of the plant

• Training, technology transfer and

succession planning implementation for

owners team.

• Technical assistance in spare parts

management and control.

Operation & Maintenance Integrated services

OMIS

• Full responsibility for supply and

management of complete O & M team

• Full responsibility for meeting

production plan

• Full responsibility for maintaining

key performance indicators of the

plant

• Supply of spare parts (optional).

Option 2 Option 1



RHI OMIS Phases

Phase I: Dry Run Testing And Commissioning Support

• Assisting client for achieving timely acceptance

• Erection and commissioning punch list preparation,

• Ensuring compliance with contractual terms and industrial norms,

Phase II: OMIS (Operation and Maintenance

• Taking over the complete operation and maintenance of the plant, starting from issuance of provisional acceptance certificate,

• Monitoring of KPI’s

Phase III: Continuous Improvement

• Bench Mark for sustainable improvement,

• Continuous improvement of all OMIS operation

Phase IV: Plant Operation Transfer

• Handing over the plant to client in accordance with the agreed on plan.


RHI Scope Of Services For Phase (I) Includes:

• Validating all mechanical, electrical and instrumentation works executed.

• Ensuring that all testing and commissioning procedures, parameters and protocols are according to latest relevant industry standards.

• Detailed review of Operation and Maintenance procedures and manuals provided by equipment suppliers and contractors.

Phase I: Dry Run Testing and Commissioning Support

• Punch lists development.




• Identifying potential sources of plant bottle necks , complications and inadequacies and with rectification recommendations to clients.

• Recording and Bench Mark cross referencing of all plant Performance Guarantee figures.

• Reviewing and providing advice in regards to spare parts.


RHI Scope Of Services For Phase (I) Includes:




RHI Technical Support From Head Office

• State-of-the-art testing and commissioning protocols used in similar plants.

• Performance Guarantee standards of similar plants.

• Most recent industry Bench Marks and Norms.

• Any additional resources project may require .

• Test procedures followed in other projects and by different equipment suppliers.





Phase II: Operation & Maintenance Integrated Services

RHI Scope Of Services For Phase (II) Includes:

• Complete plant technical management.

• Clinker and cement production in accordance with agreed on production plan.

• Health, Safety & Environment Management.

• Total quality control and laboratory management.






• Spare parts supply, control and management.

• Optimum utilization of plant resources and utilities.

• Carrying out Planned Shutdown, based on a jointly approved maintenance plan.

• Establishing and the Implementation of preventative and predictive maintenance.





RHI Scope Of Services For Phase (II) Includes:• KPI’s for Production:

• TPD / TPH• Raw Mill residues• Clinker Free-lime• Cement fineness & Residues• kWh/t

• KPI’s for Safety:• Loss time Injury• First Aid Injury• Near miss • Fatality






• KPI’s for Maintenance:• Reliability %• No. of Stoppages• Maintenance Cost Versus Budget




• During the initial phase of plant operation, RHI “OMIS” team conducts a detailed assessment

of all factors influencing the KPIs’ of each plant process and division.

Phase III: Continuous Improvement of the Plant

RHI Scope Of Services For Phase (III) Includes:

• Once assessment is made, detailed action plans are formulated for improvement in each

process and division.




Upon successful completion of OMIS contract term, RHI will hand over the complete plant to client , based on a jointly approved , seamless handover plan, with all plant machinery in good working condition.

Phase IV: Plant OMIS Contract Transfer

RHI Scope Of Services For Phase (IV)




Information Management System

“IMS”




IMS(Information Management System )

RHI manages and controls it’s plant OMIS through an automated Information Management System that is tailored to meet plant specific needs covering the following modules:-

• Plant KPI’s and continuous improvement projects implementation and control.

• Laboratory and Quality Control Management.

• Production reporting .

• Work order system for Maintenance.

• Spare parts management, control, and replenishment system.

• Projects and Maintenance planning.

• HSE Policy Implementation.





OMIS Operations Quality Control



“OMIS Operations Quality Control”

RHI Quality Control Department reporting directly to RHI Managing Director, strives daily to ensure that all RHI plants produces consistent quality that meets defined end user demands.

RHI Quality Control department works hand in hand with Client Management team on research and development projects as well as sustainable development initiatives, according to customer and market demands.



Projects Reference List Extracts





RHI References In Cement Industry

Raw Materials Investigation and Mining Division

1- Arabian Cement Co, Ramliya Plant 2x6000 tpd- Owner: Cementos La Union - Location: Suez- Egypt- Project: Raw Materials Investigation

Quarry Opening, Operation and Crusher feed for line 1 & 2 (Ten Years)

Supply of Clay

2- El Sewedy Cement Plant 1x6000 tpd

- Owner: El Sewedy Group - Egypt- Location: Suez- Egypt- Project: Raw Materials Investigation

Mining plan, Quarry Opening and Quarry Operation (Ten Years )

3- Wadi El-Nile Cement Plant 1x6000 tpd- Owner: Wadi El-Nile Cement Co.- Location: Beni Suef- Project: Raw Materials Investigation

Limestone & Clay Quarries Operations (Ten Years)




Raw Material Investigation and Mining Division

4- GOE Cement Plant, Gabal Libni 2x6000 tpd- Owner: Egyptian Ministry of Defense- Location: Sinai - Egypt- Project: Detailed Raw Material Investigation and Mining Planning (2007)

Supervision of Quarry opening (Limestone and Clay)

5- Rabak Cement- Owner: Al Kharafy Group- Location: State of White Nile - Sudan- Project: Reconnaissance and Preliminary Raw Material Investigation (2008)




Feasibility Study Division1- OMRAN CEMENT

- Owner: Omran Misr Group- Location: North Cost - Egypt

- Project: Green Field Cement Plant, 5000 t/d technical Feasibility Study for the project.

2- FAYOUM Clay Brick Plant- Owner: ABU DHABI BANK- Location: El-Fayoum - Egypt- Project: Techno-Economical Feasibility Study for acquisition of a clay brick plant

3- WATANIA CEMENT- Owner: El-Wattaneyah Cement Group- Location: Suez - Egypt- Project: Technical Feasibility Study for 1.5 MIO t/y Cement Plant

4- Technical Feasibility Study- Owner: MISR Cement Company- Location: Beni-Suef - Egypt

- Project: Detailed technical feasibility study, including recommendation of optimum

production capacities, technical project aspects, as well as human resources

development.




Operation and Maintenance Integrated Services (OMIS)

2- Ameriya Cimpor Cement Co.- Owner: Cimpor Cement Group-Portugal- Location: Alexandria - Egypt- Project: Operation and maintenance of Packing Plant

3- Spanish - Egyptian, Cement Co. (OMTA)- Owner: SHOURA Group- Location: Port Said - Egypt- Project: Technical Management(OMTA) of cement grinding and packing facility 1600 t/d

4- Qattamiya Cement Plant - Egypt- Owner: Ital-Cementi- Location: Suez - Egypt- Project: Maintenance for packing plant

1- Arabian Cement Company- Owner: Cementos LA union-Spain - Location: Suez - Egypt- Project: Operation & Maintenance Cement Grinding & Packing Line I & II




Engineering & Consultancy 1- Government of Egypt

- Owner: MOD Engineering Authority- Location: North Sinai (Egypt)

-Project: Consultancy Services Engineering Review, Supervision of Construction and Operation during warranty support for 2 x 1.6 Million tons Year Cement Plant.(Turnkey Project).

2- El-Nahda Cement Plant Project- Owner: El-Nahda Cement Co.- Location: Qena Governorate (Egypt)

-Project: Engineering & Consultancy Service for 1x600 T/day Turnkey Cement Production Line.

3- Tabuk Clinker Production Line Project (302-C)- Owner: Tabuk Cement Company- Location: Saudi Arabia Tabuk

-Project: Consultancy of Bidding phase for the Construction of One production Line producing 5000 tpd of Clinker.

4- Sinai Cement Co. – Line2 4500 tpd - Owner: Vicat (France), Sinai Cement (Egypt)- Location: Sinai (Egypt)- Project: Consultancy and engineering for 2nd production line (2006)





2- Sinai White Cement Co. – Line2 1300 tpd - Owner: Aalborg International Group-Denmark- Location: Sinai (Egypt)

Project: Consultancy and Project Management with turnkey contractor responsibility for

2nd production line (2007)

3- Wadi El-Nile Cement Plant 6000 tpd - Owner: Wadi El-Nile Cement Co.- Location: Beni Suef (Egypt)- Project: Consultancy & Project Management for one 6000 tpd

line

1- Sinai Cement Project- Owner: Sinai Cement Company- Location: Sinai Cement Plant (Egypt)

-Project: Engineering & Project Management for Construction of a 120 Ton/Hour Cement Grinding Mill.

4- El-Sewedy Cement Plant 6000 tpd - Owner: El-Sewedy Cement Co.- Location: Ein Sokhna (Egypt)- Project: Consultancy & Project Management for one 6000 tpd line




Construction & Maintenance Division

1- Misr Beni Suef Cement Plant – 2nd line 5000 tpd- Owner: Misr Beni Suef Cement Company- Location: Beni Suef (Egypt)- Project: Local components manufacturing and electromechanical erection of the new line

(2006)2- Upgrading of Rashadiya Cement Plant Line1 & 2

- Owner: Jordan Cement Factories - Lafarge- Location: Rashadiya (Jordan)

-Project: Supply & Erection of Mechanical Equipment and Structural Steel for Line 1 & 2.

(2006)

3- Sinai Cement Co. – Cement Grinding plant #4- Owner: Vicat (France), Sinai Cement (Egypt)- Location: Sinai - Egypt- Project: Electro-mechanical Erection (2009)

4- Sinai White Cement – Line I-Upgrade- Owner: Vicat France-Sinai Cement (Egypt)- Location: North Sinai - Egypt- Project: Turnkey design build project for converting line I To grey cement production

Setting the Standard In Cement Excellence

Thank You


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