Creusot Forge. Oil & Gas Petrochemical. Know-how Innovation Expertise

Transcription

1 Creusot Forge Oil & Gas Petrochemical Know-how Innovation Expertise

2 World leader in the supply of forgings The flexibility of a company on a human scale, supported by the power of a large international group Creusot Forge, a 100% subsidiary of the AREVA group, manufactures forgings and castings destined mainly to the energy market. Our know-how, capacity for innovation and highest quality standards enable us to develop and supply products which match the exact needs and specifications of our clients. Creusot Forge is globally acknowledged to have the ability to supply large quantities of products within challenging delivery time, thanks to its extensive machining capacity. Products at the heart of the integrated strategy of the company Creusot Forge is part of Areva s industrial presence in France, and is dedicated to the design and manufacture of the heavy components used in the oil & gas and nuclear markets. Providing the key components of large oil & gas and chemical projects End user Process licensor Engineering company Pressure Vessel Manufacturer Creusot Forge Manufacturing and delivering worldwide thick wall shells, rings and tube sheets Products main transportation routes Le Creusot 2

3 We manufacture the thick metal wall of high pressure reactors for your refineries Gas Recovery Burner Fuel LPG (Heating/Cooking) Petrochemicals (Plastics/Fibers) Alkylation CRUDE OIL Atmospheric Distillation NAPHTHA JET/KEROSENE DIESEL Hydrotreating Catalytic Reforming Gasoline Jet/Kerosene Diesel/ Heating Oil GAS OIL Hydrocracking Vacuum Distillation Hydrotreating Coking Lubes Processing Fluid Catalytic Cracking Lubricants Coke RESID Asphalt, Power Generation & Marine Fuel High pressure reactors locations Courtesy by GE Oil&Gas and Larsen and Toubro 3

4 Our markets Our products are incorporated into more than 240 high pressure reactors and more than 50 heat exchangers throughout the world More than 70 reactors in Europe More than 60 reactors in the Americas More than 55 reactors in Asia More than 30 reactors in the Middle East Location of our products since 2005 CANADA Northwest oil opti Canada inc USA Motiva VENEZUELA PDVSA FRANCE TOTAL PORTUGAL GALP GERMANY CONOCO PHILIPS KUWAÏT KNPC EQUATE SAUDI-ARABIA SAUDI ARAMCO POLAND LOTOS INDIA IOCL QATAR QATAR GAS RAS GAS SOUTH-KOREA SK ENERGY GS CALTEX CHINA SINOPEC PETROCHINA Our commitments To offer the best technology and reliability in regard to: Reduced amount of pressure retaining welds Integrated internal build-up for internal support rings Optimized dimensions (reduction of circumferential welds amount) The largest-possible forgings sizes - up to 8 m diameter - up to 5 m high - up to 450 mm thick - up to 150 tonnes unit weight To be the acknowledged leading forging supplier for high pressure reactors To continue to fulfill the needs and specifications of our clients in the oil & gas market Courtesy by Kobelco and GE Oil&Gas 4

5 Our products Reactor For oil refineries Creusot Forge is one of the few forging companies in the world which are qualified and capable of providing large heavy wall shells, heads and Y-rings dedicated to the fabrication of high pressure reactors located in oil refineries. Our market is focused on high pressure reactors such as: Conventional hydro-cracking and any other kind of hydro-conversion units And medium pressure vessels with extra-large inside diameter for application such as: High pressure hydro-desulphurization units Moderate pressure hydro-cracking units Head Shells with integrated nub / Build-up Machining of shell We can supply our products according to any major process licensor: Chevron, ExxonMobil, Axens, UOP, Shell For power plant heat exchangers / GTL / Reactor-Exchangers Creusot Forge has built-up a high reputation in supplying large tube sheets for heat exchangers. Its market is focused on large single pieces, seamless tube sheets for demanding customer looking for high quality products with long lasting lifetime. Y-ring Tube sheets for heat exchangers Creusot Forge is also known for its stainless steel know-how and its large capabilities which enable us to supply large diameter combined with heavy thickness. For gas plant Compressor casing Creusot Forge is one of the very few forgers in the world to supply monobloc extra heavy casing for gas compressors. Our machining capabilities enable us to provide forgings with complex internal machining compatible with cavities for compression chambers. 5

6 Our manufacturing processes: an unrivalled know-how Starting from a hollow ingot to a forged shell A shell is a forged cylinder, which can exceed 5m in diameter and up to 450mm in wall thickness. This shell is the main constituent of many large high pressure reactors. Drawing on a mandrel Re-heating of ingot prior to forging Shaping (forging) Digital simulation Ingot pouring Heat treatment Steel casting in an electric furnace (recycled automobile scrap) Ladle refining Finished part ready for delivery Machining 6 Non-destructive inspection

7 Experts for more than 200 years Creusot Forge is one of very few forges in the world capable of making the ultra heavy pressure retaining parts and essential components for critical equipment production. The first industrial activity started in Le Creusot in Our deep-rooted skills and know-how have played a leading role both in the worldwide nuclear power and oil & gas programs. View of the plant Renovated 7,500 tonne press Since the 60 s, we have supplied more than 2,300 forged parts for oil & gas installations and for nuclear primary islands throughout the world: USA, Saudi Arabia, India, Kuwait, Qatar, Russia, Germany, China, Brazil, South Africa, Switzerland, Finland, Belgium, South Korea, France... From Creusot Loire to AREVA 1782 Start of foundry activities in Le Creusot 1876 Establishment of the forging shop in Le Creusot. The biggest forging hammer in the world is put into operation (500 tonnes) 1956 New 7,500 tonnes press 1979 Installation of a new 11,300 tonnes press 1993 New facility for larger diameter shells (up to 5,6 m) 1995 Development of the 2,25 Cr Mo Vanadium modified Steel grade (SA 336M F22V) 2003 Investment in heavy hollow ingots (250 tonnes) for higher shell weight 2006 Assimilation of Creusot Forge into the AREVA group 2007 Expansion of the machining shops 2008/ Complete revamp of 7,500 and 11, tonne presses Forging shop capacity increase Typical forged shell 7

8 A state-of-the-art production facility forging shop 2 hydraulic presses completely revamped in 2008 and tonnes tonnes numerous automatic gas heat-treatment furnaces capable of following detailed temperature curves in order to yield the desired mechanical properties of particular grades of steel. gas re-heating furnaces capable of bringing parts up to forging temperature (> 1200 C) within a few hours (these furnaces are amongst the most powerful in the world). Machining shop More than 50 machine tools equipped with the latest generation of NC controls (vertical lathes, horizontal lathes, milling and boring machines) allowing precision machining to very close tolerances. In the Creusot Mécanique machine shop, we carry out precision finish machining on large components, thanks to a range of machine tools of exceptionally large size and accuracy and to the technical skills of our operators. 8 Competitiveness Compétitivité Project

9 Certificates and qualifications ASME since 1980 ISO 9001 (2008) ISO in progress ohsas in progress RCC-M NNSA Quality and reliability Throughout the entire fabrication process, we carry out inspections either on the components themselves or on samples in our laboratory. Finished products always carry with them appropriate documentation as proof of their quality and their compliance with customer s specifications. Objective: to guarantee the highest level of quality From top to bottom, ASME, NNSA and ISO certificates Inspections Our inspection procedures are underpinned by an exhaustive range of techniques which are independent from production: non-destructive: ultrasonics, eddy current, magnetic particles examination, laser telemetry destructive: tensile testing, toughness testing, hardness, Pellini tests. Objective: to guarantee zero defects Safety It is an absolute priority for us to ensure the health and safety of our own staff and of the workers of our partner companies. We have established a demanding and efficient system of safety management which has as its aim the permanent reduction of risks: management observation of safety, safety visits, risk assessment, training... Frequency Rate 2006 : 4, : 3,16-31% (national average > 25) Objective: zero accident The teams at the heart of our success The men and women of Creusot Forge put their energy and technical skills at the service of their customers on a daily basis. They work to the most demanding standards in terms of quality, safety and economic performance. More than twenty skill groups are represented on the site: fitters, furnacemen, project managers, inspectors, quality coordinators, forge masters, milling machine operators, R&D engineers, press operators, machinists Through our dynamic policy of recruitment and training, we make sure that these skills are developed and kept up-to-date. Objective: to pass on and strengthen our knowledge and know-how management Expérience Respect Attention des to deadlines délais 9

10 Growing industrial capacities Increase in production capacities Increase in steelworks capacity: ingot weight > 250 tonnes and an annual increase in tonnage to 50,000 tonnes. Revamp of the presses with increases in their capacity and reliability. Increase in machining capacity: acquisition of 6 vertical lathes and upgrading of all machines to numeric command control. Additional reheating and heat treatment capacities (650 tonne furnace with regenerative burners) and improvement in their performances. Establishment of a new testing laboratory. Extension of the forging shop. More than 150 MD have been invested since 2006 in order to optimize our industrial capacity. Strategic new developments Automation of dimensional measurement of hot forgings (laser) In order to improve efficiency, Creusot Forge has recently developed in-house a three dimensional measuring system dedicated to its forging presses. This none-contact measuring system, based on laser technology, is more accurate, more rapid and more reliable than traditional systems. Hollow ingots for the production of high pressure vessel shells Creusot Forge is the only company in the world to have developed a hollow ingot process, which is at the heart of the manufacture of our nuclear shell forgings. These ingots allow a considerable reduction in the manufacturing time of a shell and provide better gift to cladding operation. Our strategic R&D partnerships Creusot Forge, together with the Le Creusot Centre for Metallurgical Research (CRMC) and other laboratories and universities, is leading research programmes aimed at the development of new processes for the manufacture of grades of steel, at improving our forging processes and developing new products. The signing of an agreement between Creusot Forge and ArcelorMittal in the presence of Nicolas Sarkozy, President of the French Republic, Anne Lauvergeon, Chief Executive Officer of AREVA and A. Mittal, Finance Director of ArcelorMittal. 10

11 Our next challenges Continuing investments to increase our production capacity in order to respond better to the needs of our customers. Development of new leading-edge technologies. Recruitment and training: transmission and development of knowledge. Intensification of our efforts to continuously improve: economic growth socially responsible enterprise respect for the environment The environment of Le Creusot is also our environment Creusot Forge is committed to the ongoing process improvements of the AREVA group. As shown by our self imposed efforts in the reduction of discharges and waste, we undertake to ensure that the effects of our activities on the surrounding populations are negligible. 11

12 All over the world, AREVA provides its customers with solutions for carbon-free power generation and electricity transmission. With its knowledge and expertise in these fields, the group has a leading role to play in meeting the world s energy needs. Ranked first in the global nuclear power industry, AREVA s unique integrated offering covers every stage of the fuel cycle, reactor design and construction, and related services. In addition, the group is developing a portfolio of operations in renewable energies. AREVA is also a world leader in electricity transmission and distribution and offers its customers a complete range of solutions for greater grid stability and energy efficiency. Sustainable development is a core component of the group s industrial strategy. Its 75,000 employees work every day to make AREVA a responsible industrial player that is helping to supply ever cleaner, safer and more economical energy to the greatest number of people. Groupe AREVA Creusot Forge 56, boulevard Clémenceau Le Creusot France Phone: + 33.(0) contactforge@areva.com Energy is our future, don t waste it! September Photos credits: copyright AREVA, Hors Normes - E. Seguier - P. bourdon - R. Quatrain - C. Moreau - Conception et réalisation : - Certified ISO 14001