Over 2014, Fives upgraded the two Gas Treatment Centers at the Alba Line 5 in Bahrain. This project was established as a major challenge for Fives’ teams, from the engineering studies in France to the turnkey implementation of the solutions on site. As part of its Line 5 pot amperage increase, Alba has awarded Fives with a contract to modify the two Gas Treatment Centers supplied in 2005, in order to comply with gas and alumina flow rate increase. The contract consisted of the supply and installation of one additional exhaust fan including existing duct modification, new airlifts installation and the replacement of the existing fan impellers. This project has been executed in collaboration with Fives Middle East in Dubai and Fives Services Gulf based in Bahrain, that provided assistance for the local sub-contracting and site construction. Among the major challenges faced, was the simultaneous deployment of over 100 Fives’ sub-contracted personnel at the GTC yard area which is actually considered part of Alba potline 5. Alba expects zero tolerance in non-compliance on its safety standards; hence arranged intensive training on safety induction, on awareness of potroom hazards (DC hazards), on working in confined spaces as well as working at height for all Fives’ personnel. Alba‘s strict requirements on 100% compliance to usage of personnel protective equipment like HF masks, fire retardant clothing were fully met during the project execution. On the way ahead, another big challenge was executing the project when pots were in operation. Installing new equipment for the upgrade called for shutting down the whole GTC. Alba’s team and Fives’ site management team had to therefore call for well-planned and coordinated GTC shutdowns so as to achieve maximum installation work within short periods. Moreover, as the existing plant was ten years old, replacing a piece of equipment by another one was not as simple as it seems. Especially because the main pieces of ducts were 10 m long and had to be handled at a height of 20 m, between two potlines where space was congested and limited. Safety analysis, 1 ALBA - GTC 3 & 4, A SUCCESSFUL PROJECT INTERVIEW Health, Safety and Environment are among the main objectives of the Group to focus on when executing projects all over the world. Today, Fives aims at moving towards a strong safety culture shared by each and everyone, and at continuing along path of progress achieved over the past five years. The presence of a HSE coordinator helps us to put HSE on top of our priorities. Audrey Duport has been working as HSE Coordinator for the Aluminium business line for two years. She answers three questions to explain her role within the organization. What is the mission of the HSE Coordinator at Fives? My role is to ensure that, at the end of a working day, Fives’ employees and our contractors are as fit and healthy as when they started it. To reach this objective, we first need to comply with any applicable regulations, standards and best practices and to ensure that we meet all our customers’ requirements. I work in collaboration with our Managers and staff in defining and implementing adequate control measures for the activities under their responsibilities. Our HSE management system has been completely revised by using the principles of the OHSAS 18001 international safety standard. In the past few years, many procedures have been reviewed to ensure better control of our site activities. For instance, a yearly audit planning has been set to make sure that regular HSE audits are carried out on all our projects. Practical actions have been taken: integrating HSE supervision for night shift personnel on site, implementing safety awards for individuals on site and modifying the design of some pieces of equipment for safety purposes. Last year, we completely reviewed our standard construction HSE plan to be up to date with the latest best practices and to ensure a better control of site activities. This revised plan has been implemented on the GTC modification project for Alba 5. Can you tell us more about Fives’ ambition in terms of safety? During the past few years, we have worked with clients renowned for their high HSE policy. Being in contact with these clients on a daily basis has been a very valuable experience for our teams. We have met their expectations and achieved excellent safety records. Our ambition is to become fully independent from our customers to reach equivalent standards, whatever their expectations are. Our zero-accident policy must not be an objective but rather a certainty whatever the context of the project is. How is safety integrated in all phases of a project? At the very early stage of the project, the commercial team takes into account safety requirements in its offers including for revamping and expansion projects. Safety is also one of the main criteria to select our construction and commissioning contractors. When the contract is awarded, Fives defines a project specific HSE construction plan that includes local statutory, existing constraints and client’s requirements. It draws up in details what the HSE organization will be on site. This construction HSE plan is then passed on to the Site Manager and HSE Manager before the construction phase starts, in order to ensure that they are both aware of their responsibilities and familiar with the rules and procedures to be applied, including the emergency protocol specific to the project. This plan will evolve as the project moves on. At the end of each project, Fives’ management team reviews the safety performance and feedbacks from the site team. This process is essential to ensure that all deficiencies will be corrected for the next projects and to identify what must be reproduced to reach optimal safety performance. HSE is a continuous improvement process. SAFETY AT FIVES, A DRIVER OF OPERATIONAL EXCELLENCE Copyright © 2015 - Fives - All rights reserved. FIVES GOOD NEWS FOR YOU, the newsletter of Fives Solios SA – 25-27 boulevard de la Paix – 78100 Saint-Germain- en-Laye France – Phone: +33 (0)1 30 87 45 50 – Director of Publication: Hugues Vincent – Editor: Alain Périers – Editorial Committee: Thierry Allegrucci, Stephen Augostine, Bernard Cloutier, Bijan Cour – Writers: Hélène Bachellerie, Fabienne Virieux – Thanks for their collaboration: Lee Allen, Pasquale Calo, Mamak Chiron, Audrey Duport, Mathieu Frainais, Hien-Tin Huynh – Execution: Christophe Cocquet – Printing: TPI - 34, rue Jean-Lefèbvre - 95530 La Frette- sur-Seine – Registration of copyright and ISSN: 2109-280X. Printed in 500 exs. Editorial After several years of primary aluminium production overcapacity, the demand in 2014 has finally exceeded the supply, the stocks have decreased and the metal price has started to increase. This situation suggests some improvements in the 2015-2016 horizon and new investments may emerge. However, in 2014, the aluminium producers mainly focused on reaching full capacity in their new smelters or on improving overall efficiency in their existing installations. In this context, Fives mostly received contracts for equipment modifications and services. The revamping of GTC 3&4 at Alba 5, in Bahrain, was a successful project despite the challenge in terms of schedule and site conditions. Fives was also engaged in the final execution and commissioning of the Hindalco and Vedanta smelters in India, while completing the Rusal Boguchany smelter construction. As a supplier of pioneering technologies, Fives has further enhanced and marketed Genios, its electromagnetic metal moving system. Fives’ commitment and strength to fully assist and proactively help its clients to maximize the performance of their industrial plants in operation has been further demonstrated. As a key lever for the Group’s opera- tional excellence, Safety is at the heart of Fives’ corporate social responsibility and HSE management is becoming fully integrated into our project execution process. Lastly, in 2014, all companies of the Aluminium Division of Fives have been renamed and now present their offer under the Fives brand. Hugues Vincent, C.E.O. Fives Solios Newsletter - March 2015 Aluminium What’s new in Aluminium? Gas Treatment Center 13,000,000 man-hours without LTI respectively at Ma’aden and Qatalum Audrey DUPORT IN BRIEF On 1 st January, 2015, Solios Carbone and Solios Environnement SA in France merged and changed their company name to Fives Solios SA. Similarly Solios Thermal in the UK and Solios Environnement Inc in Canada were respectively renamed Fives Solios Ltd and Fives Solios Inc. Our services subsidiaries in Bahrain and South Africa were respectively renamed Fives Services Gulf Spc and Fives Services Southern Africa Proprietary Ltd. Visit our website www.fivesgroup.com to know more about the Aluminium business line.