INTERNATIONAL STANDARDS,

FAMILY VALUES

Al Zamil Heavy Industries Ltd.

This critically acclaimed family business – which was the first organisation within its industrial sector to achieve the ISO 9001 certification, followed by the ASME ‘U’, ‘U2’, ‘PP’, ‘S’, ‘A’, and the National Board’s ‘NB’ and ‘R’ technical accreditation stamps – has cultivated a reputation for quality, and thanks to its investment in state-of-the-art machinery, network computer systems, engineering and design software, fabrication control systems and specialised industrial equipment, has the capabilities to meet all customer demands.

Managing Director Mr Ibrahim Saleh Al Zamil took the time to speak to Endeavour magazine to tell us more about the story of his company.

As the worlds leading oil producing nation, and with a world-class natural gas and petrochemicals sector, Saudi Arabia is well known across the world as an economic, cultural and military juggernaut. Buoyed by great increases in oil prices, Saudi Arabia has seen its economy take great strides since 2000, and has increasingly invested huge sums of capital into virtually every corner of the country.

The Jeddah based Al Zamil Heavy Industries Ltd (ZHI) specialises in the design, supply, manufacturing, assembly, construction, installation and maintenance of the capital equipment that serves Saudi Arabia’s oil, gas, petrochemical and process industries. In serving these world-class industries, this 100% privately owned Saudi Arabian business offers its clients a reputation for quality, and has earned technical accreditation such as ISO 9001-2000 and recognition from the American Society of Mechanical Engineers. And with a list of customers including the Saudi Arabian Oil Company (Saudi Aramco), Saudi Arabian Basic Industries Company (SABIC), ABV Rock Group, Bechtel, Ballast Nedam Groep N.V., Mitsubishi Heavy Industries, Stone & Webster Engineering Corporation, ABB Lummus Crest, Chiyoda Petrostar, Hitachi Zosen to name but a few,

As a company with a rich heritage in providing turnkey engineering services for the oil, gas, petrochemical and process industries, Al Zamil has thrived in recent years.

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Al Zamil Heavy Industries Ltd.

it is possible to gain an idea of just how highly regarded Al Zamil Heavy Industries Ltd really is.

However the beginning of the story for this $100mn valued company was quite different according to Mr Ibrahim Saleh Al Zamil,

“The company was formed in 1977 under the trade name SaudiMetalco for the purpose of manufacturing dump-truck bodies, together with water and asphalt trucks in support of its mother company, the Alharamain road construction business. Alharamain’s owners (50%-50%) were my father Shaikh Saleh Ibrahim Al Zamil (the current major shareholder of ZHI) and Shaikh Abdulrahman Al-Howaish.”

SaudiMetalco initially operated as a fabricator of the above equipment solely for its owners, but over time the company gradually began fabrication for Alharamain’s competitors in an effort to become more financially self-sufficient. However, SaudiMetalco was unsuccessful in the pursuit of these business ventures, and the company was then entirely bought out by Ibrahim’s father from Alharamain, who facilitated its operation through his brother Mr Abdullah Ibrahim Al Zamil. The company then began to specialise in the fabrication of industrial warehouse buildings, process structural steel buildings and then shop-built water and gasoline storage tanks instead; a move which ultimately proved to be the making of the company’s future success.

Following this change in strategic direction for the business – which then changed its name to Al Zamil Heavy Industries in accordance with new Islamic law - the company also decided to begin targeting new foreign clients over its

more risky traditional client base, in an effort to improve business turnover. The resultant growth in turnover allowed the company to flourish and with the backing of reliable, repeat customers such as Saudi American Oil, ZHI entered into a rich vein of company growth which further allowed the family business to consolidate its existing markets, while expanding into new ones.

Today the company is divided into several distinct branches, with the Steel Fabrication division acting as the crown jewel of the organisation, having more than 29 years worth of experience in its field. With the capability to design and manufacture a large range of products, such as pressure vessels, reactors, storage tanks, oil-fired heaters, steam-generating plants, incinerators, heat exchangers, HRSG’s and silos, this particular facet of the business continues to enjoy much in the way of successful trade.

Al Zamil’s renowned emphasis on quality and safety is well known among its client industries. The business first sought to acquire and implement a quality system recognised to major foreign contractors, and as a result achieved the ISO 9001 accreditation in 1994. The company went on to seek – Saudi Aramco pressure vessel accreditation and achieved approval for up to 19mm-thick vessels, followed by a further approval covering up to 38mm-thick vessels in a span of four years.

“We also attempted, on several occasions, to obtain SA accreditation on pressure vessels for the next-to-largest level (between 38 and 76mm thickness) and were not successful due to the fact that we were in a Catch-22 situation. To be qualified for greater than 38mm thick vessels, thus allowing for vessel inquiries and potential orders, we needed to demonstrate over a live contract that we were building such vessels. In 2005 we received temporary approval for this, and in 2008 the temporary approval became permanent with the completion and full delivery of orders from the Khursaniyah Gas Plant, whose 42 vessels are all beyond the 76mm shell thickness

We have the capability to roll pressure vessels from 500mm to 12m in diameter, and up to 180mmplate thickness in carbon, alloy and stainless steel within our modern fabrication complex using the latest rolling, welding, cutting, shearing and breakpress techniques. Larger pressure vessels and storage tanks are pre-rolled and site-erected by our experienced workforce throughout Saudi Arabia.”

To compliment Al Zamil’s excellent fabrication capabilities, the company oversees an engineering department that has the ability and experience to produce design calculations and working drawings to all international standards, with state-of-the-art CAD and design analysis software. Its skilled project managers and engineers closely manage all customer contracts, and ensure the smooth progress of operations from the inception of each project, and then through each subsequent phase of engineering, procurement and fabrication, prior to delivery. The project management system is in strict accordance with the ISO 9001-2000 certification.

Another primary component of Al Zamil’s is its Industrial Cranes division which has been granted exclusive licensee and fabrication rights for Munck Cranes, of which it builds four specific models. The Standard Overhead Travelling Cranes, which are available in capacities ranging from 1/2 ton to 60 tons, and with a span of up to 40 metres are custom built, pre-engineered cranes, which incorporate standard proven parts.

Al Zamil Heavy Industries Ltd.

Goliath Cranes are made for numerous types of applications such as container handling, coil operation and the handling of sewage and various bulk materials. Capacities of these are from two tons to 150 tons, with up to 60-metre spans.

Heavy Cranes are engineered and built to handle heavy loads up to 200 tons for such applications as turbine buildings, shipyards and power-generation equipment. Marine

Offshore Cranes are provided for efficient handling of loads on board ships and at ports, including oil field applications. The equipment is designed to operate in extreme environments and allows for minimum maintenance.

The company also has a lucrative Oil and Gas division, which was formed in 1985 to provide professional services for the petrochemical industry in Saudi Arabia. The key to the company’s success is quite simply its ambition to be the best, and its unyielding customer focus according to Mr. Al Zamil, who said:

“We pride ourselves in having achieved, and continuing to maintain, the highest levels of globally recognised industrial standards ensured by the insight and inspiration of highly qualified and leading-edge management teams, and their supporting specialists.

Knowing the importance of teamwork, we have established, and continue to maintain, dynamic long-term relationships with our customers and suppliers. These partnerships are built on a mutual understanding of overall business objectives, specific project requirements, joint trust and constant communication.

From project conception to installation and operation,

ZHI and its partners combine their talents to provide turnkey services to our customers.” With growing capabilities, an ever increasing list of services to offer and satisfied clients, Mr. Al Zamil is anticipating a prosperous 2013.

This year, Al Zamil has been commissioned to begin work on 39 pressure vessels at Saudi Aramco’s Khursaniyah Gas Plant Project over the coming two years, six of which are the Khursaniyah Natural Gas Liquids bullet storage vessels. These six vessels will weigh in at more than 1,000 tonnes each, with a diameter of 6.6 metres, an overall length of 67.7m, and a wall thickness of 82mm. The scale of the project is such that it will truly test ZHI to the very limits of capabilities.

However Al Zamil’s answer to this engineering challenge is to build and heat-treat the vessels on-site, which would be the first time this kind of manufacturing job has been performed at a Saudi Aramco site by a Saudi manufacturer.

With tight deadlines to contend with, as well as a global shortage of steel, this job is certain to pose challenges. To heat–treat the vessels on–site, Al Zamil’s has assembled a large furnace to be placed over the 68-metre vessels, which will utilise electric and gas heaters to raise the vessel temperature to 690°C and perform a seven day thermal treatment process on it.

The Saudi Aramco project management team first explored the idea of on-site manufacturing with local manufacturers during the projects initial planning phase; and it is telling that Al Zamil was the only company willing to take on the challenge.

Al Zamil Heavy Industries Ltd.www.zhiltd.com+966 699 2411

Written by Djamil Benmehidi

www.littlegatepublishing.com