Technical Presentation January 2014 Aguilar y Salas 2014.
Technical Presentation
January 2014 Aguilar y Salas
2014.
01. HIGHLIGHTS
02. HISTORY
03. HUMAN MEANS
04. EQUIPMENT
05. MATERIALS
06. TECHNICAL MEANS
07. WELDING POSSIBILITIES
08. INTERNAL BORE WELDING
09. QUALITY CONTROL & QUALITY ASSURANCE
10. ENGINEERING DEPARTMENT
11. DESIGN CODES
12. SOFTWARE
13. CERTIFICATES
14. APPROVALS
15. LOCAL CUSTOMER SERVICES
16. REFERENCES
03. 02. 08. 06. 01. 04. 05. 07. 09. 10. 11. 12. 13. 14. 15. 16.
Copyright © 2014. Aguilar y Salas, s.a. All rights reserved www.aguilarysalas.com
01. HIGHLIGHTS
Copyright © 2014. Aguilar y Salas, s.a. All rights reserved www.aguilarysalas.com
Aguilar y Salas is specialized in the design and fabrication of equipment by the application of the
most advanced manufacturing technologies and quality procedures
The main products which the company designs and manufactures are:
>Heat Exchangers
> Reactors
> Columns / Towers
> Vessels
> Modules and Skids
Highlights:
>Focused on quality and special equipment . Maximum 200 tones, 80m length and 8m diameter.
> Revenues 2013 = 35 m €.
> More than 200 employees worldwide distributed in 3 Production Units.
> More than 80% of turnover are exports.
Geographical distribution of
turnover 2012 – 2013 (m€)
Distribution of turnover by customer
2012 – 2013 (m€)
Distribution of turnover by sector
2012 – 2013 (m€)
USA; 36%
SPAIN; 12% BRAZIL; 11%
AUSTRALIA; 8%
UNITED ARAB
EMIRATES; 4%
Resto; 26%
51% 49%
37%
57%
6%
Chemical
Oil & Gas
Others
Engineering
Industry
01. HIGHLIGHTS
A
C
B
Barcelona (Spain) Porto de SUAPE, PE (Brasil) Casablanca (Morocco) A B C
Nowadays the group has 3 Production Units:
Copyright © 2014. Aguilar y Salas, s.a. All rights reserved www.aguilarysalas.com
Aguilar y Salas begins its activities as
manufacturer and designer of stainless
steel equipments.
Aguilar y Salas moves to Barcelona
to a larger workshop 3500m2
(37674 sq ft).
Aguilar y Salas starts manufacturing
equipments made out of titanium, nickel
special alloys and other materials.
Aguilar y Salas exports its first
equipments through an European
engineering.
Aguilar y Salas opens a new plant in Les
Franqueses del Vallès. 23.000m2
(247570 sq ft) under roof. 10.000m2
(107639 sq ft) of facilities.
02. HISTORY
1947
1964
1975
1977
1998
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Aguilar y Salas develops a specific
production planning system:
MDM (Manufacturing Database
Management).
02. HISTORY
2004
2006
2007
2010
2013
Aguilar y Salas opens a new plant in
Morocco. 5000m2 (53820 sq ft) of
facilities.
Construction of “Clean Area” with
1000m2 (10764 sq ft) for special
equipment.
Aguilar y Salas starts the implementation
of a new business unit in Brazil.
At the end of 2013 the facilities in Porto
de SUAPE (PE, Brazil),
are fully operational.
Copyright © 2014. Aguilar y Salas, s.a. All rights reserved www.aguilarysalas.com
Aguilar y Salas staff is made up by more than 200 people, distributed in 3 production units
> 10 Senior Engineers
> 12 Technical Intermediate
> 40 Welders
> 2 EWE (European Welding Engineers)
> 1 CWI (Certified Welding Inspector)
> 11 Administration
> 10 Sales
> 3 Logistics
> 9 Quality Control
> 6 Purchase
> 6 Planning
> 135 Production
Continued training and adaptation to
new technologies and advances.
03. HUMAN MEANS
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04. EQUIPMENT
Copyright © 2014. Aguilar y Salas, s.a. All rights reserved www.aguilarysalas.com
Reactors
> Lined Reactors
> Tubular Reactors
> Outer Half Pipe Coil Reactors
> Inner Coil Reactors
> High Pressure and High
Temperature Reactors
> Agitated Reactors
> Lined and Cladded Reactors
Columns
> Distillation and Rectiflying
Columns
> High and Low Presure and
Temperature Columns
Heat Exchangers
> Shell Heat Exchangers
> Coil Heat Exchangers
> Trufin Type Finned Tubes Heat
Exchangers
> High and Low Presure &
Temperature Heat Exchangers
> Internal Bore Welding,
> Hairpin Heat Exchangers
> Double Plate Heat Exchangers
> Higa FluxTM tubes Heat
Exchangers
04. EQUIPMENT
Copyright © 2014. Aguilar y Salas, s.a. All rights reserved www.aguilarysalas.com
Vessels
> Pressure Vessels
> Heated Vessels
> Mixing Vessels
> High Pressure Vessels
> Storage Vessels
> Dilution Vessels
> Isothermal Vessels
> Sterile Vessels
Modules and Skids
Heat Exchangers
04. EQUIPMENT
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Reactors
04. EQUIPMENT
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Columns
04. EQUIPMENT
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Vessels
04. EQUIPMENT
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04. EQUIPMENT
Copyright © 2014. Aguilar y Salas, s.a. All rights reserved www.aguilarysalas.com
Modules and Skids
> Stainless Steels
> Heat - Resisting Steels
> Highly Alloyed Stainless Steel
> Duplex, Super Duplex
> Carbon Steels
> Low Alloy Carbon Steels
> Special Alloys (Inconel®, Hastelloy®, Monel®, Incoloy® etc.)
> CuproNickel, Copper Alloys
> Aluminium
> Nobles Metals (Nickel, Titanium, Tantalium, Zirconium)
> Clad Materials
05. MATERIALS
Copyright © 2014. Aguilar y Salas, s.a. All rights reserved www.aguilarysalas.com
Facilities
06. TECHNICAL MEANS
Barcelona (Spain) Porto de SUAPE, PE (Brasil) Casablanca (Moroco)
Premises : 23.000m2
(247.570 sq ft)
Under roof: 10.000m2
(107.640 sq ft)
Premises : 65.000m2
(699.654 sq ft)
Under roof: 11.000m2
(118.403 sq ft)
Premises: 3.000m2
(32.292 sq ft)
Under roof: 3.000m2
(32.292 sq ft)
Copyright © 2014. Aguilar y Salas, s.a. All rights reserved www.aguilarysalas.com
> 1 Bridge cranes 50tn
> 3 Bridge cranes 32tn, 30m span
> 2 Bridge cranes 20tn, 30m span
> 14 Semi gantry cranes 10tn, 10m span
Elevation means
06. TECHNICAL MEANS
Barcelona (Spain) Porto de SUAPE, PE (Brasil) Casablanca (Morocco)
> 1 Bridge cranes 50tn, 30m span
> 1 Bridge cranes 16tn, 30m span
> 1 Bridge cranes 16tn, 20m span
> 1 Semi gantry crane 15tn, 15m span
> 1 Semi gantry crane 10tn, 12’5m span
> 2 Semi gantry cranes 10tn, 10m span
> 4 Bridge cranes 5 tn
Copyright © 2014. Aguilar y Salas, s.a. All rights reserved www.aguilarysalas.com
Water jet cutting machine. Plate cutting shear.
> State of the art Water Jet Cutting Machine (CNC)
with a capacity of 12 x 3.5 m (39.5 x 11.5 ft)
without thickness limitation.
> Plasma Cutting Machine with capacity of 12.2 x
3.15 m (40 x 10 ft) plates.
> Bending cylinders up to 90 mm (1-1/2 inches) with
a maximum width of 3000 mm (10 ft).
> Thicker materials can be rolled subcontracted
nearby.
> Plate cutting shears.
> Folding machines.
> Bevelling machines.
> Profile bending machines.
> Half pipe coil profile shaping machine.
Water jet cutting machine. Water Jet cutting control panel.
06. TECHNICAL MEANS
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Bending cylinder. Radial drill.
> Two 3500 x 1500 x 900 mm (138 x 59 x 35,5 in)
numerical control milling machine (CNC) for
machining, drilling and reaming tubesheets for heat
exchangers up to 5000 mm (196 in).
> Radial drills.
> Lathes.
> Millers.
Numerical control mlling machine.
06. TECHNICAL MEANS
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Warehouse.
Other Facilities
> Radiographic bunker.
> Sand blasting area.
> Warehouse.
> Testing area.
> Finishing (pickling and passivation).
> Pneumatic test zone.
Radiographic bunker. Testing area.
06. TECHNICAL MEANS
Copyright © 2014. Aguilar y Salas, s.a. All rights reserved www.aguilarysalas.com
> GTAW, GMAW, FCAW, SMAW, SAW (single and twin arc), Submerged Arc Strip Cladding and Electro Slag Strip
Cladding welding proccess.
> Automatic GTAW and GMAW pulsated arc welding equipment.
> Columns for SAW and GMAW.
> Vacuum chamber for titanium and other exotic material welds.
> Welding head for tube to tube welds.
> 2 Weldings heads for tube to tube welds with inert chamber (for Ti applications).
> Automatic circle welding of nozzles ≥ 10 in to shell and heads.
> GTAW orbital and automatic welding equipment for tube-to-tubesheet welds.
> Automated installation for joining tubes to tubesheet exchangers.
07. WELDING POSSIBILITIES
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GTAW orbital and automatic welding
equipment for tube-to-tubesheet welds.
Automatic column for GTAW & GMAW
weld oververlay inside nozzles ID ≥ 38
mm (1 ½ in).
Robot for tube-to-tubesheet welding
(under construction).
Strip 60 x 0,5 mm (TP347) 5 mm layer thickness (special flux).
Simulation with th robot fot tube-to
tubesheet welding.
07. WELDING POSSIBILITIES
Copyright © 2014. Aguilar y Salas, s.a. All rights reserved www.aguilarysalas.com
SAW machine adapted for nozzles.
> In order to avoid oxidation between the tube sheet and the tube, the tubes are welded gap less on the
rear side of the tubesheet of the Heat Exchanger.
> Orbital welding is the unique possibility to weld this type of weld seam design.
> With or without filler material.
Internal Bore Welding joint design examples
08. INTERNAL BORE WELDING
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Weld seam configuration. Inside butt Weld. Weld seam aspect. Weld lance for small I.D.´s.
> 2 EWE (European Welding Engineers).
> 1 CWI (Certified Welding Inspector).
> 7 Engineers.
> PMI, Hardness, Roughness, Ferrite check control, Dye penetrant, pressure and vacuum test performed by A&S.
> Magnetic particles, gamma ray, X-radiographic, ultrasonic, TOFD and laboratoty testing subcontracted.
> PMI (Possitive Material Identification) performed by A&S using a portable NITON.
> Radiographic control of tube-to-tubesheet welds.
> Spectrotest (Portable Optic Spectrometer) subcontracted for check
> Helium leak test (up to 10-4 standard cc/sec).
NITON XLt Helium leak test Helium leak test
09. QUALITY CONTROL & QUALITY ASSURANCE
Copyright © 2014. Aguilar y Salas, s.a. All rights reserved www.aguilarysalas.com
> 6 Project engineers.
> Mechanical design.
> Thermal design (design, rating and simulation).
> Nozzle loads using WRC or FEM.
> Wind and seismic calculations in accordance with international standards and Country Regulations.
> Fatigue calculations.
> Vibration analysis in Heat exchangers.
10. ENGINEERING DEPARTMENT
Copyright © 2014. Aguilar y Salas, s.a. All rights reserved www.aguilarysalas.com
Aguilar y Salas designs using the following design codes …
> ASME VIII Div. 1 & 2 – ASME I.
> TEMA.
> AD 2000 Merkblatt (German Code).
> CODAP 2000 (French Code).
> Rules for Pressure Vessel (Dutch Code).
> British Standard PD 5500.
> EN 13445 (European Code).
> PED (Pressure Equipment Directive).
> API 605 & 660.
> UBC / ASCE / IBC / NBC / AS …
> Other Seismic & Wind Country Regulations (Spain, France, Germany, Brazil, CFE Mexico, etc).
> Designs for special services as H2, H2S, Sour Water, Amine, Lethal Service.
> 3D Drawings and Designs – INVENTOR (consult Smartphone/ tablets).
11. DESIGN CODES
Copyright © 2014. Aguilar y Salas, s.a. All rights reserved www.aguilarysalas.com
12. SOFTWARE
Copyright © 2014. Aguilar y Salas, s.a. All rights reserved www.aguilarysalas.com
… and using the following software:
- ASME Sect VIII Div. 1 & 2
- ASME UHX – Heat Exchangers
- TEMA Exchangers
- FEA Nozzle
- Nozzle/PRO
- ASME Sect. VIII Div. 1 & 2
- British Standard PD 5500
- EN 13445
- Heat exchangers Thermal design
- Thermal and mechanical design
- ANSYS Workwench
- Design Modeler
- Fatigue Module
- LANTEK Flex3D 5X
- Autodesk AutoCAD
- Autodesk Inventor 3D
- OPEN MIND HyperMILL 5 AXIS
ERP Management Program (Enterprics Resource Planning) developed as control: Planning, Production, Management,
Sales, Purchasing, Technical Department, Quality Control, Planning, Production, Warehouse, etc..
> HTRI
> COMPRESS
> COADEPV Elite
> ASPENTECH
> ANSYS
> LANTEK
> AUTODESK
> HYPERMILL
ISO 9001:2008
13. CERTIFICATES
Copyright © 2014. Aguilar y Salas, s.a. All rights reserved www.aguilarysalas.com
ISO 9001: 2008
L.R.Q.A.
Number: SGI 3953527
Since: September 1996
Expires: September 2014
Spain Brazil Morocco
13. CERTIFICATES
Copyright © 2014. Aguilar y Salas, s.a. All rights reserved www.aguilarysalas.com
Group certificates
NB
Manufacture License Special
Equipment People’s Republic of China
The National Board of Boiler &
Pressure Vessel Inspectors
Since: 2000
Expires: March 2016
Approval of the manufacturing
of High pressure vessels and
equipment.
Number: TS2200637-2010
Since: 2002
Expires: June 2014
U2 - Stamp
ASME Certification
SEC. VIII, DIV 1
Number: 34.426
Since: 2004
Expires: March 2016
U- Stamp
ASME Certification
SEC. VIII, DIV 1
Number: 30.150
Since: 1995
Expires: March 2016
PED 97/23/EC
Module H
Number:
038/PED/MAD/0106
Since: January 2004
Expires: October 2016
Lloyd’s Register
PED 97/23/EC
Module H1
Number:
038/PED/MAD/0107
Since: January 2004
Expires: October 2016
Lloyd’s Register
14. APPROVALS
Copyright © 2014. Aguilar y Salas, s.a. All rights reserved www.aguilarysalas.com
Group approvals
PETROBRAS
Number: 023128
Since: October 2011
Expires: October 2014
KNPC
Certificate of Approval
KNPC
Since: December 2006
V/C-V4558-05-3095L
Certificate of Approval
ARAMCO
Number:
107000039918
Since: August 2006
V/C-V4558-05-3095L
ARAMCO
Sabic Engineering & Project
Management
SABIC
TAKREER
Takreer
Number of
certificate: 905841
Since: 2000
15. LOCAL CUSTOMER SERVICES
Copyright © 2014. Aguilar y Salas, s.a. All rights reserved www.aguilarysalas.com
16. REFERENCES
Copyright © 2014. Aguilar y Salas, s.a. All rights reserved www.aguilarysalas.com
Final Customers:
ANHYDRO
APOTEX
AIR LIQUIDE
AIR PRODUCTS
BASF AG
BAYER
BOEHRINGER GROUP
BP
CELANESE
CEPSA
CLARIANT GROUP
CT ENVIRONMENT UK
DSM RESINS FRANCE
DUPONT DE NEMOURS
DOW CHEMICAL
EMS-CHEMIE AG
EMS SERVICES
ENAP CHILE
EVONIK GROUP
EXHEAT
FERROSTAAL AG
FERTIAL
GIVAUDAN
GULF PETROCHEMICAL INDUSTRY CO
HOVIONE
INVENTA FISCHER
INEOS
KEMIRA
KLÖPPER THERM
KÖRTING HANNOVER AG
LANXESS
MERCK GROUP
NAMHAE CHEMICAL CORP
PEERLESS EUROPE LTD
PEMEX
PETROBRAS
PETROLEOS DEL PERU
REPSOL GROUP
RVT RÜHR-UND VERFAHRENSTECHNIK
SOLVAY GROUP
SAMIR
SAUDI ARAMCO
SHELL
SONATRACH
Engineeries:
AKER SOLUTIONS
BERTRAMS CHEMICAL PLANTS LTD
BUSS CHEMTECH AG
CAMBI
DEDERT CORPORATION
FLUOR
INTECSA
INITEC
JACOBS ENGINEERING
KVAERNER PROCESS
LINDE AG
MESSO AG
MITSUBISHI HEAVY INDUSTRIES
SENER
SULZER CHEMTECH
TECHNIP GROUP
TECNICAS REUNIDAS
TOYO ENGINEERING CORP
UHDE GMBH
UOP LLC
WABAG
Sales Office: 17, Place Charles Nicole, Appt 2 Etg 7 20100 Casablanca (Maroc) Tel: + 212 0522592264 [email protected]
Workshop: Parc Industriel Bouskoura CFCIM 109 lot 53 20100 Bouskoura (Maroc) [email protected]
Pol. Ind. Pla de Llerona C/Irlanda, s/n 08520Les Franqueses del Vallès Barcelona (Spain) Tel: +34 93 861 70 70 [email protected] www.aguilarysalas.com
Sales Office: Rua Barão do Triunfo, 520, 15º andar – Cj 152 CEP: 04602-002 Brooklin Paulista São Paulo - SP (Brasil) Tel:+55 (11) 5051 7626 [email protected] Workshop: Complexo Industrial ZL-3 Gleba Leste Engenho Mercês CEP: 55590-000 Ipojuca - PE (Brasil) Tel:+55 (11) 5051 7626 [email protected]