Elsewedy Towers Manufacturing Wind Turbine Towers

Elsewedy Towers Manufacturing Wind Turbine Towers

INDEX About EET... 2 Location... 3 Our Vision... 4 Production Process... 6 Material Collection Stage... 6 Cutting (edge beveling)... 7 Rolling and Forming... 8 Fit Up... 9 Section Welding (SAW)... 10 Door Frame Welding... 11 Fitting & Welding of Internal Parts... 11 Flange Milling And Easy Laser Machine... 12 Stud Welding... 12 Shot Blasting... 13 Painting... 14 Mechanical and Electrical Internal Mounting... 15 lifting & Transportation facilities... 15 Storage & Shipping... 16 Certifications... 17 Elsewedy Towers 3

ELSEWEDY ELECTRIC TOWERS (EET) WIND TOWER MANUFACTURER About Us 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 manufacturers 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 wellestablished 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: introducing the concept of Energy Management in order to improve energy efficiency and reduce energy use, thereby reducing costs. 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 / m 2 Land Covered Area Storage Area Non-Utilized 250,000 m 2 40,000 m 2 85,000 m 2 125,000 m 2 (rest for Phase II) 5

ELSEWEDY ELECTRIC TOWERS (EET) WIND TOWER MANUFACTURER Our Vision To be a strategic wind towers manufacturer in the Middle East, Africa, Europe and America s East Coast Our Mission Building long term relationships with customers and providing them with high quality products that exceed their expectations Production Capacity The current capacity in average is 400 sections / year, i.e. 140 Tower / year Average production per week 10~12 sections Range of production Tower Diameter/meter Min: 2m Max: 5m Tower Thickness, m Section Length, m Annual Production/tons Weekly Productions, Sections Up to 50 Up to 35 15,000 10 ~ 12 6

Production Process & Machine Facilities 7

ELSEWEDY ELECTRIC TOWERS (EET) WIND TOWER MANUFACTURER Production Process Material Collection Stage Different raw material are being received in well prepared areas to maintain its quality and prevent depreciation; whereas different stores are available for each raw material types. Quality control inspects the raw materials and releases the approved items for processing. 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 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) Number of Units 2 Portable Flame Beveling Machines Cranes that service this area (20 tons) 2 3 9

ELSEWEDY ELECTRIC TOWERS (EET) WIND TOWER MANUFACTURER Production Process Rolling and Forming 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. Roll-Bending 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) Number of Units 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. 11

ELSEWEDY ELECTRIC TOWERS (EET) WIND TOWER MANUFACTURER Production Process Section Welding (SAW) A - Longitudinal Welds (LSAW) 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. B - Circular Welds (CSAW) The assembled cans are tacked and root pass is welded using 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. LSAW (Tandem Wire welding) Number of stations Maximum reach inside that can be welded with boom is 3500mm 2 CSAW (Tandem Wire welding) 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) Number of Units 5 3 3 12

Door Frame Welding Door frames opening are cut according to drawings using oxy-fuel flame cutting tools then welded using semi-automatic Gas Metal Arc Welding process. Fitting & Welding of Internal Parts 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. Gas metal arc welding (GMAW) GMAW process is used for welding of the internal attachments Cranes (2x40 tons & 1x 20 ton) Number of Units 18 2 13

ELSEWEDY ELECTRIC TOWERS (EET) WIND TOWER MANUFACTURER Production Process Flange Milling And Easy Laser Machine 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. Stud Welding 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. 14

Shot Blasting Sections 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. Blasting cabin (SLF Origin) Number of Units Dimension (7x6.50x36 m) Weather Condition Roughness Meter 2 1/ Elcometer 2/ Needle Gauge 15

ELSEWEDY ELECTRIC TOWERS (EET) WIND TOWER MANUFACTURER Production Process Painting 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 Cabin Number of Units Dimension (7x6.50x36 m) Airless Machine Rotating Parts Air recycle system Comb Gauge (WFT) 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 16

Mechanical and Electrical Internal Mounting 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. lifting & Transportation facilities 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. 17

ELSEWEDY ELECTRIC TOWERS (EET) WIND TOWER MANUFACTURER Production Process Storage & Shipping Large flat areas for product storage, around 80,000 m 2 are used for keeping the product in a safe condition till loading. 18

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 Our Clients 19

Factory Address: EET - EL Sewedy Electric Towers S.A.E Ain Sokhna, South of the Economic Zone, Northwest Gulf of Suez, Egypt Tel. : (+2062) 92 04 250 Fax : (+2062) 92 04 255 Email : info-eet@elsewedy.com Head office Address: Plot 27 1st District, 5th Settlement, New Cairo - Egypt. Tel. : (+202) 275 99 700/ 01/ 02/ 03 Fax : (+202) 275 99 731 Elsewedy Towers Manufacturing Wind Turbine Towers