Elsewedy Towers Manufacturing Wind Turbine Towers Towers.pdf · ELSEWEDY ELECTRIC TOWERS (EET) WIND...

Elsewedy TowersManufacturing Wind Turbine Towers

Elsewedy Towers

About EET ................................................................................................................................. 2

Location ..................................................................................................................................... 3

Our Vision ................................................................................................................................ 4

Production Process ........................................................................................................... 6Material Collection Stage ............................................................................................ 6Cutting (edge beveling) ............................................................................................... 7Rolling and Forming ...................................................................................................... 8Fit Up .................................................................................................................................... 9Section Welding (SAW) .................................................................................................. 10Door Frame Welding ..................................................................................................... 11Fitting & Welding of Internal Parts ........................................................................ 11Flange Milling And Easy Laser Machine ................................................................. 12Stud Welding ..................................................................................................................... 12Shot Blasting ..................................................................................................................... 13Painting ................................................................................................................................ 14Mechanical and Electrical Internal Mounting ..................................................... 15lifting & Transportation facilities ............................................................................. 15Storage & Shipping ........................................................................................................ 16

Certifications ........................................................................................................................... 17

INDEX

3

ELSEWEDY ELECTRIC TOWERS (EET)WIND TOWER MANUFACTURER

Elsewedy Electric Towers (EET) was founded in 2008 as an Egyptian –German joint venture between Elsewedy Electric Group and SIAG Schaaf Industries under the name of SIAG ELSWEDY TOWERS for producing Towers for Wind Turbines. Since 2015, EET is totally owned by Elsewedy Electric Group.

EET is now a member of Elsewedy Electric. Our headquarters enterprise is located in Cairo - Egypt and manufacturing enterprises located in El Ain EL Sokhna. Over the past 6 years, EET Company has grown to become one of the leading wind turbine towers manufac-turers in the Middle East & Africa We have supplied wind turbine towers for projects in following counties: Germany, Italy,Poland, Cyprus, Egypt and USA. Our strategy seeks to reinforce our position as a member of renewable energy industry in order to provide a competitive product quality while helping to meet global wind energy demand in a responsible way.

Elsewedy Electric has become a significant contributor to the economic growth in Egypt through its development into a well-established group with extensive holdings, both locally and beyond borders in several other Middle Eastern & African countries as well as in European & Asian countries.

The group has succeeded in becoming, a global leader in cables manufacturing, a regional leader (MEA region) in terms of energy solutions and its related services. All these in addition to: intro-ducing the concept of Energy Management in order to improve energy efficiency and reduce energy use, thereby reducing costs.

About Us

4

Location & Area• AinSoukhna / Suez Governorate, Egypt.• EET is located near the biggest harbors in Egypt (AinSokhna, Adabia, Suez ).• Also close to Zafarana & Gabal El-Zait (the biggest wind farms in EGYPT).

Place Area / m2

Land

Covered Area

Storage Area

Non-Utilized

250,000 m2

40,000 m2

85,000 m2

125,000 m2 (rest for Phase II)

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Our Vision

Production Capacity

Range of production

Our Mission

• The current capacity in average is 400 sections / year, i.e. 140 Tower / year• Average production per week 10~12 sections

To be a strategic wind towers manufacturer in the Middle East , Africa , Europe and America’s East Coast

Building long term relationships with customers and providing them with high quality products that exceed their expectations

Tower Diameter/meter

Tower Thickness, m

Section Length, m

Annual Production/tons

Weekly Productions, Sections

Up to 50

Up to 35

15,000

10 ~ 12

Min: 2m Max: 5m

6

Production Process& Machine Facilities

7


Different raw material are being received in well prepared areas to maintain its quality and prevent de-preciation; whereas different stores are available for each raw material types. Quality control inspects the raw materials and releases the approved items for processing.

Production Process

Material Collection Stage

8

Cutting (edge beveling)Using modern CNC cutting machines and software, steel plates are perfectly cut and prepared in a reliable and accurate process.Two advanced ESAB CUTTING MACHINES are capable of producing high quality cuting besides the additional portable flame cutting machines.

Marking, Cutting & Beveling Number of Units

CNC Flame Cutting & Beveling Machine (L:35m W:3.1m and T(max): 100 mm, Max. wt.15 tons for plates acc. to available lifting tools can be increased to 20 tons)

Portable Flame Beveling Machines

Cranes that service this area (20 tons)

2

2

3

9


• Cut and beveled plates are rolled into conical or straight shapes using two rolling FACCIN machines.• Diameters are adjusted according to drawings during bending and using pre-prepared gauges. The edges are carefully aligned to ensure that ends meet properly. Tack-weld is performed after the completion of bending process (GMAW), followed by root pass using gas metal arc welding process and applied by a certi fied welder. Quality inspector instead checks diameter, misfit and ovality according to standards.

Production Process

Rolling and Forming

Roll-Bending Number of Units

Faccin four rolls (Max. 50 mm thick x 3,100 width)

Faccin(Max. 30 mm thick x 3,100 width)

Cranes that service this area (20 tons)

1

1

2

10

Fit Up• Shells need to be perfectly aligned & rotated to allow welding in the flat position.• Its performed using hydraulic stations, capable of assembling section up to 150 tons per each.

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Production Process

Longitudinal welding stations ESAB equipped with tandem submerged arc welding machine . Non-destructive testing is used to examine the internal soundness of welds followed by visual inspection.

The assembled cans are tacked and root pass is welded us-ing GMAW machine, then submerged arc welding machines are used to produce circumferential welds. The welding of seam is followed by Non-destructive testing to examine the internal soundness of welds followed by visual inspection.

Section Welding (SAW)A - Longitudinal Welds (LSAW) B - Circular Welds (CSAW)

CSAW (Tandem Wire welding) Number of Units

Max. diameter that can be welded outside is 6000mm and max. reach is 6000mm

Assembly pay-1, Cranes (2x30 tons & 1x 20 tons)

Assembly pay-2, Cranes (2x40 tons & 1x 20 tons)

5

3

3

LSAW (Tandem Wire welding) Number of stations

Maximum reach inside that can be welded with boom is 3500mm 2

12

Gas metal arc welding (GMAW) Number of Units

GMAW process is used for welding of the internal attachments

Cranes (2x40 tons & 1x 20 ton)

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2

Door Frame Welding Fitting & Welding of Internal PartsDoor frames opening are cut according to drawings using oxy-fuel flame cutting tools then welded using semi-auto-matic Gas Metal Arc Welding process.

The fitters start attaching internal parts to the body of the section according to the drawings using take welds, then the welders weld it according to a qualified welding procedure specification and using the (GMAW) process. Magnetic particle inspection is the NDT test that reveals the quality of welds.

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Production Process

As the flanges are critical parts, there for the flatness and taper of flanges are measured using EASY LASER SYSTEM.We use The milling machine as per customer request according to fabrication specifications.

• For the foundation segment, it is necessary to attach studs to give good adherence with concrete.• This requirement is fulfilled through stud welding process.• NELSON welding machine is used to perform this operation.

Flange Milling And Easy Laser Machine

Stud Welding

14

Blasting cabin (SLF Origin) Number of Units

Dimension (7x6.50x36 m)

Weather Condition

Roughness Meter

2

1/ Elcometer

2/ Needle Gauge

Shot BlastingSections are moved by rail into a blast booth. Abrasive material (iron grit) is used to clean the surface and produce the required roughness. Two blasting cabins are used to perform the work and safe the environment from pollution through a filtration system. Each cabin is equipped with abrasive recycling system to avoid contamination. The atmospheric condition is monitored through measuring devices from Elcometer.

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Production Process

The application is through a set of airless machines, three cabins are in service for this operation.The cabins are equipped with filtration systems to keep the product quality and the environment clean. Sections are mounted on special rotating devices to keep them free from the ground.

The weather conditions are controlled and monitored using special devices.Paint quality is measured in wet and dry conditions, gloss measurements, adhesions testing and RAL Number are also measured and monitored.

Painting

Painting Cabin Number of Units

Dimension (7x6.50x36 m)

Air recycle system

Airless Machine

Comb Gauge (WFT)

Rotating Parts

Dew Point Meter

Dry Film Thickness Meter (DFT)

RAL Number

Gloss Meter

Adhesive testing

3

6

5 pairs

One per each cabin

6/ Elcometer

1/ Elcometer

2/ Elcometer

Check 11+

1/ Electrometer

1/ Electrometer

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Mechanical and Electrical Internal Mounting

lifting & Transportation facilities

Mounting of internal accessories includes ladders, cable chains, platforms, fall arrest, lift service, cabling, lights and power cables, lightning tools... among others, are performed in a professional way in order to save the paint from damage. Required inspection is performed before dispatching.

• A set of means of transportation are available.• Forklifts of different capacities.• Mobile cranes of 70 tons, overhead cranes are capable of lifting max 80 tons section.• Section loading through a special car which is capable of loading up to 60 tons / section.

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Production Process

Storage & ShippingLarge flat areas for product storage, around 80,000 m2 are used for keeping the product in a safe condition till loading.

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Our Clients

Certifications

EET holds different certificates for:

• Quality Environment certificate - ISO 14001:2004• Management system - ISO 9001:2008,• Occupational Health and Safety Management - OHSAS 18001:2007• Welding certificate according to EN ISO 3834-2 and EN 9010-1 &2.

• Conformity of the factory Production Control - 2451-CPR-EN1090-2015.0817.00• GSI SLV - Production welded compnents - certificate no. : 2535.2015• GSI SLV - DIN EN ISO 3834-2• GSI SLV -Welding quality requirements - EN ISO 3834-2

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Factory Address: EET - EL Sewedy Electric Towers S.A.E Ain Sokhna, South of the Economic Zone, Northwest Gulf of Suez, EgyptTel. : (+2062) 92 04 250 Fax : (+2062) 92 04 255Email : [email protected]

Head office Address: Plot 27 1st District, 5th Settlement, New Cairo - Egypt.Tel. : (+202) 275 99 700/ 01/ 02/ 03Fax : (+202) 275 99 731

Elsewedy TowersManufacturing Wind Turbine Towers

Elsewedy Towers Manufacturing Wind Turbine Towers Towers.pdf · ELSEWEDY ELECTRIC TOWERS (EET) WIND...

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