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SELF INTRODUCTION
OF
NIIGATA CONSTRUCTION CO., LTD.

NIIGATA CONSTRUCTION CO., LTD.

Tokyo, Japan

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INTRODUCTION

It is our pleasure to introduce you to our activities in plant maintenance

and repair services

Niigata

Construction

Co.,

Ltd.

was

established

in

1954

as

an

independent plant construction and maintenance organization within the

NIIGAT A

GROUP

rationalization

to

which

could promote greater development

maintenance

engineering

in

the

petroleum

and
and

chemical industries.

The record and talents of the Niigata Construction Co., Ltd. have made
the company one of the most experienced maintenance engineering
contractors in Japan, specializing in the engineering, procurement and
construction of petrochemical plants, petroleum refineries and other
chemical plants.

We are confident that our skilled services, based upon our technological
knowledge and rich experience, will meet your strict standards in every
respect.

We hope to be able to participate in your maintenance engineering

activities to give more reliability and efficiency to the running of your
plant, and we earnestly look forward to the honor of being awarded the
opportuni ty to serve you.
Niigata Construction Co., Ltd.

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CONTENTS

Article 1.

Article Z.

Article 3.

NIIGATA CONSTRUCTION CO., LTD.

1.1

Name of Company

1.2

Established

1.3

Capital

1.4

Addresses

1.5

Number

1.6

Board of Directors

1.7

Lines of Business

1.8

N11GA T A GROUP

1.9

3-Year Financial Review

of

Employees

ORGANIZATION AND MANAGEMENT

2.1

Head Office

2.2

Branch Offices

2.3

Liaison Offices

2.4

Technical Center

CAPABll..ITIES
3.1

Engineering Work Pattern

11

3.2

Broadening Our Capabilities

13

3.3

Procurement

15

3.4

Construction

17

3.5

Operation

17

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CONTENTS (cont'd)

Article 4.

4.1

Daily Maintenance

19

4.2

Shut-down Maintenance

20

Article 5.

RECONSTRUCTION

5.1

The Piece Supporting Method

23

5.2

Storage Tanks and Sealing Systems

27

5.3

Save-Energy for Plant

29

Article 6.

PROJECT MANAGEMENT SYSTEM

6.1

Project Team

31

6.2

Duties and Responsibilities of Principal Members

31

EXPERIENCE

36

Article 7.

,.-.

MAINTENANCE

-II-

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Article 1.

NIIGATA CONSTRUCTION CO., LTD.

1..1

Name of Company
Niigata Construction Co., Ltd.
(hereinafter referred to as NCC)

1.2

Established
June 7,1954

1.3

Capital
300,000,000. (As of March 31, 1982)

1.4

Addresses
Head Office
2-4, Shiba Koen, Minato-ku, Tokyo, Japan
Phone:

03-433-8231

Telex:

2227111 NITETO J HINT-l

Technical Center
14-10, 3-chome, Tamachi, Kawasaki-ku
Kawasaki City, Kanagawa, Japan
Phone:

1.5

044-288-5036

Number of Employees
Engineers & Supervisors

405

Craftsmen

187

Clerks & Administrators

131

Total

723

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1.6

.d o

Board of Directors
President:

Yoshio Yasukawa

Managing Directors:

Tetsukichi Fukuhara
Mikio Moriyama

Directors:

Tomio Nojima
Yokichi Hirano
Masayuki Sato
Tadashi Obara
Tetsuo Uchiyama
Tomiji Fujimura

1.7

Standing Auditor:

Tadao Kazama

Auditor:

Mitsugu Shatari

Counsellor:

Sadao Naka

Lines of Business
1)

Planning,

design,

construction,

periodical

reconditioning and maintenance of plants, such

as

petroleum

refineries,

petrochemical,

pharmaceutical manufacturing, food processing,

iron and steel mills.
2)

Design, manufacture and installation of towers,

storage

tanks,

heating

furnaces

and

heat

exchangers.
3)

Steelwork design, manufacture and erection.

4)

Installation of air conditioning systems, thermal

insulation, piping, electrical services, machinery
and associated equipment.

5)

Civil engineering and building construction work.

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1.8

NIIGATA GROUP
NCC is a member company of the NIIGATA GROUP,
which is

led by Niigata

Engineering

Co.,

Ltd.

Established in 1954 by separating the Chemical Plant

Division from the parent company, NCC was set up
as

an

independent

maintenance
rationalized

plant

organization
effective

construction

to

develop

approach

to

the

and

more

specialist

techniques of plant maintenance and construction.

NCC works in close harmony with the following
companies in the NIIGATA GROUP.
1)

2)

Niigata Engineering

ce.,

Ltd.

Incorporated:

June 17, 1910

Capital:

14,166,000,000.

Niigata Converter

ce.,

Incorporated:

December, 1952

Capital:

500,000,000.

Main products:

Torque

Ltd.

converters,

couplings,

power

hydraulic
shift

and

marine gears
3)

Niigata Worthington

ce.,

Ltd.

Incorporated:

November, 1953

Capital:

500,000,000.

Main products:

Pumps,

compressors,

steam

turbines and automatic control

devices
4)

Niigata Masoneilan

ce.,

Ltd.

Incorporated:

August, 1974

Capital:

500,000,000.

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Main products:

.d o

Masoneilan automatic control

valves,

level

controllers,

meters
and

and
other

automatic control devices

1.9

3-Year Financial Review

(unit: One million yen)

42th

43th

44th

April 1978

April 1979

April 1980

March 1979

March 1980

March 1981

Orders received

16,647

19,712

25,522

Sales

16,346

19,575

23,789

170

162

250

Profit (After tax)

Profit rate of total capital (%)

Profit/share ()

Dividend/share ()

Net assets/share ()

11. 4

9. 6

13. 3

2. 8

2. 7

4. 2

50

50

50

2,670

2,825

3,128

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Article 4.

MAINTENANCE

All

maintenance

needs,

including

modification

and

reconditioning work, can be fully met with the daily and

shut-down maintenance schedules prepared by NCe, and
offered in the form of a Contract Maintenance Service.

With

this

contract

maintenance

service

system,

the

customer who has entered into the contract agreement will

be supplied with complete package, including specialist
engineers,

equipment

and

materials,

precisely

in

accordance with his instructions.

The customer can then rest fully assured of efficient, safe
and trouble-free plant operation at a reduced operating
cost once the plant is back into service.
When

required,

testing

services

can be

offered,

and

recommendations for future planning can also be made.

4.1

Daily Maintenance
With the daily maintenance service, the necessary
number

of

maintenance

personnel

to

match

the

characteristic features of the customer's plant are

stationed on the site to deal with every phase of the
daily maintenance requirements.
Accordingly,

the

following

advantages

for

the

customer can be realized:

a)

Rationalization in maintenance services can be

achieved by the contract maintenance service
system, as it unifies all the complicated ordering
processes.

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b)

Those engineers and service personnel engaged in

the

maintenance

work

can

be

pooled

and

controlled in a stable manner, thereby ensuring

their better assimilation of knowledge about the
plant, equipment and installation methods.
c)

The work load produced in the course of day-today

plant

operation

can

be

dealt

with

in

accordance wi'th a planned maintenance schedule

which

allows

the

daily

work

volume

to

be

averaged to a reasonable level.

This enables the plant owner to economize on
labor costs and incidental expenses under the
improved

operational

efficienty

of

expert

maintenance service personnel.

d)

All these features usually result in an overall

cost reduction for the maintenance program.

4.2

Shut-down Maintenance
In

the

case

of

shut-down

maintenance,

all

the

maintenance requirements arising from the specific

area of shut-down in the plant are contracted in a lot
under the principal of integrated maintenance work
control.

In this, preparation is normally started

6 months

before

the

commencement

of

actual

maintenance work and the results of studies by NCC

engineers are submitted to the customer as they
become available for his review and approval.
Two

months before

the

start

of

the

shut-down

maintenance service, the outline of the maintenance

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work items is finalized to conclude the agreement of

"the shut-down maintenance service contract.
Before initiating the maintenance service, further
studies

are

conducted so

that

we

can

be

well

prepared for possible additional work items which can

be

anticipated

to

take

place

after

commencement of the contracted work.

the

The shut-

down maintenance service offered by NCC after

completion of all these preparations provide the
customer with the following advantages:
a)

The

in-depth

studies

made

before

the

commencement of shut-down maintenance under

a contract concluded in advance enable work to
proceed smoothly and will involve the minimum
operational losses from the workforce and from
valuable items of equipment.
b)

All the work items within the specific shut-down

maintenance
integrated

area

can

manner

be

controlled

and

any

in

an

temporary

installations can be utilized in the most efficient

way.
c)

The work volume can be averaged for optimum

results with consequent higher work efficiency
and overtime costs.

d)

Working safety can be better ensured with an

established

safety

control

organization,

incorporating not only NCC people, but also the

subcontractor's
personnel.

- 21 -

and

the

customer's

own

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e)

The net result of all these advantages is a

shorter work period with reduced maintenance
cost.

One item worthy of special mention in shut-down

maintenance services is the maintenance of heat
exchangers, which requires considerable man-hours
and further serious consequence resulting should they
fail.
With this in mind, NCC has solved the problem of
maintenance rationalization for heat exchangers and
labor needs for such work.
Through the extensive use of tubular staging for
elevated work sites,

greater

mechanization with

impact wrenches, hydraulic tube boundle extractors,

et c., and inspection by the eddy current method and
other

techniques,

the

exchangers can now be

maintenance
carried

out

of

heat

under

high

working efficiency with enhanced working safety to

the full satisfaction of the customers.
Shut-down maintenance service expertise is one of
NCC's greatest strengths and a very large number of
successfully completed contracts with oil refinery
and petrochemical manufacturing customers attest to
the high international repute of NCC.

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Article 5.

RECONSTRUCTION
NCC possesses high levels of technology backed up by
successful

service

records

in

the

construction

and

maintenance of storage tanks.

In the maintenance of storage tanks particularly, a variety

of services are offered, such as the overhaul, inspection
and cleaning of tanks required under the established code
of operation, replacement of tank bottom plating and
improvements to the sealing characteristics.
This work is undertaken by the company on the basis of
extensive accumulated technical skills and a number of
patented working methods have been developed by the
company to ensure the greatest efficiency and highest
quality of our work.
Outstanding service records have been established in oil
refinery and many other plants on the basis of NCC
efforts.

5.1

The Piece Supporting Method

The Piece Supporting Method was introduced by
NCC,

and

represents

most

advanced

art

in

construction period and cost.

In

this

newly

developed

maintenance

method,

replacement of the entire area of the tank bottom

plating (which may be necessary because of excessive
corrosion or other serious reasons) can be performed
without recourse to lifting and holding operations by
means of hydraulic jacks.

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With this method, the bottom belt of the existing

tank shell plating and annular plating are cut in
carefully defined lengths, the cut out segment of
bottom plate and annular plating are taken out
sideways, then a new segment of annular plate is
inserted.
In the course of this replacement work, support
pieces are fitted to the bottom belt of tank shell
plating to support the load of the tank, and the
existing annular plating is progressively removed.
After inserting the new segments of anuular plate,
the

support

pieces

are

removed

in

carefully

controlled sequence to transfer the load of tank on to

the newly laid annular plating.

In this way, the tank shell is lowered on the new
annular plating without creating any undue stresses
and

without the need for extensive jacking and

reinforcement of the jacking points.

a)

Cutting off procedure for the bottom belt of the

tank shell plating and annular plating
In conventional replacement work for the whole
bottom plating of large storage tank, the load of
the tank shell plating is often supported by
means of jacks.
With this now-outdated method, the preparation
of large number of jacks and

their

control

devices, reinforcements to the tank foundation

for these jacking units, and the provision of

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reinforced jack mounts fixed to the tank are

normally required.
In the Piece Supporting Method, the bottom belt
of the tank shell plating and annular plating are
cut

in

precisely

controlled

lengths

so

that

segments of the annular plates can be removed.

In this way, openings are created to allow the
replacement plate segments to be inserted as
shown in Figs. 1 and 2.
b)

Supporting the shell plating and replacement of

the old annular plates
In the Piece Supporting Method, replacement of
the entire area of the tank bottom plating is
carried out without involving the risk of buckling
or local distortion of the tank shell plating by
the introduction of special support pieces.
These support pieces are welded at the correct
interval to the tank shell plating as shown in
Fig. 3.
The load that would otherwise be imposed on the
opening of the tank shell plating is now born by
these

support

pieces

which

rest

on

the

replacement bottom plate annular segments.

c)

The final lowering operation and welding

The tank is effectively resting on a large number
of short stilts when all the replacement plates
and support pieces have been installed as shown
in Fig. 4.

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Plate replacement work is carried out safely and

securely in a sequence as below:

Adjoining area
to be opened

<1

,r - - - /' ,:: I -

Opening

"

1'1"

"
-

Adjoining area
to be opened

~
)__ - -

-:r\- i r

"

'I

"'

.,,.,

New annular plate

~-----------~---,

Annular plate

Support piece
Fig. 2

Fig. 1

Tank shell plate

Support piece

Support plate

Support piece

Annular plate
Annular plate
Fig. 3

Fig.4

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The tank shell plating is lowered on to the new

annular plating by sequential cutting out of the
support pieces.
After verifying that the entire circumference of
the shell plating has settled on to
annular

plating,

the

welded

the new

connections

are

made, all surfaces cleaned up and all joints

carefully inspected.
The job is then complete.
d)

Features

and

advantages

of

the

"Piece

Supporting Method"
With this method, the load of the tank during
annular plate replacement is easily supported by
the use of support pieces of simple construction.
These support pieces are removed progressively
around the circumference of the tank to settle
the shell plating on to the new bottom plates.
As a result, no abnormal load or uneven stress
distribution is imposed on the tank shell plating,
which

eliminates

the

distortion of the plating.

risk

of

buckling

and

The job can be done

safely and easily at lower construction cost and

in a shorter work period when compared with old
method using the jack-up procedure.

5.2

Storage Tanks and Sealing Systems

The aim to ensure the safe and wasteless storage of
precious petroleum products can be said to be the

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need of the age in this time of global conservation of

energy and natural resources.
Floating roof tanks play an important part in meeting
this and are categorized as the floating roof type and
the covered float type.
NCC's

storage

tanks

are

designed

against

the

following criteria:
1)

Sloshing response

2)

Seismic buckling

3)

Seismic collapse

NCC's storage tanks are constructed with carefully

selected materials on the basis of the years of
experience

developed

through

tank

maintenance

servicing.
For corrosion-resistant materials and the best rust
prevention measures, the rich technical data and
information accumulated within the company is best
utilized and allows NCC

to adapt itself to any

specific customer requirement.

NCC's storage tanks are fabricated using welding
techniques which are controlled to give the best
welding results. NCC realizes that welding technique
is the major factor in assessing the best features of
storage tank construction work, and consequently has
set up a Technical Center for welding techniques.
NCC's storage tanks are fitted with patented T.W.
Seals and leakage past the floating roof is minimized.
"The

T.W. Sealing

Construction

ce.,

System

Ltd."

- 28 -

developed

by

Niigata

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In deference to the significant importance of the

.sealing characteristics in floating roof tanks, NCC
developed a new sealing system commercially called
the T.W. Seal.
With its unique sealing mechanism, the T.W. Seal
effectively contains oil vapor within the storage tank
with the minimum leakage.

5.3

Save-Energy for Plant

NCC has taken a lead in promoting measures for
saving

energy

and

better

conservation

of

the

environment.
a)

Pollution prevention equipment

NCC has extensive experience in the setting up
and maintenance of a wide variety of plants
based

on

the

concepts

of

environmental

engineering.
This work has necessitated the development of
improved
capable

monitoring
of

systems

controlling

to

and

equipment

minimum

the

environment effects of air pollution, effluent

pollution, noise and vibration.
A variety of industrial waste incineration plants
industrial

waste

gas

disposal

systems

are

designed and manufactured by NCC.

b)

Energy conservation methods

The very first step to be taken in a plant to
promote better conservation of natural resources

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and energy is to identify and eliminate any

leakage of steam, gases, air and oil.
This

must

be

considered

one

of

the

most

important items in plant maintenance.

NCC, in addition to this basic criterion, has been
engaged in the study and research of recycling
systems for utilizing waste gases and steam, and
other forms of waste heat.
The company has developed various types of
industrial heat recovery systems and is

now

offering these systems and equipment for the

benefit of all our customers.

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Article 6.

PROJECT MANAGEMENT SYSTEM

6.1

Project Team
To create the most effective running of a project,
NCC sets up a full time project team within the
Engineering & Construction Headquarters.
This team works only for the project and for the
necessary period of time in the appropriate location.
The principal members of a project team are the
Project Manager,
Procurement

Engineering &

Manager

and

Design Manager,

Field

Construction

Manager.
The Project Manager is given authority similar to
that

of

General

Manager

in

relation

to

the

performance of the project assigned to him.

The project team will execute, manage, control and
coordinate the project for the best work performance

utilizing personnel from

the existing organization

specially assigned to the project.

6.2

Duties and Responsibilities of Principal Members

The

following

details

show

the

duties

and

responsibilities of the principal members who will be

involved in the Project Team and who control the
major functions in the execution of the project.
a)

Project Manager
Reports to:

The General Manager

Supervises:

The project team, consisting of the

Project Engineer & Construction
Manager

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Duties and Responsibilities:

1)

Responsible for the successful performance of

the project contract within the terms specified,
with emphasis on job cost, completion schedule
and meeting the planned profit performance
wherever possible.

2)

Selects and organizes the project team personnel

with the assistance of the managers of the
relevant departments.

3)

Controls the preparation, release and placing of

material

and

equipment

requisitions

with

vendors.
4)

Controls and approves the preparation of the

Master Project Schedule.

S)

In the primary customer contact on all project

matters including the negotiation of any Change
Orders.

6)

Reviews

project

compliance

with

performance
scope,

cost

to
and

insure
schedule.

Initiates corrective action as required.

7)

Draws upon department staff for assistance and

counsel

(Procurement

Department

and

Construction Department).
8)

With the Field Construction Manager and Project

Engineer

determines

the

scope

of

the

subcontracting required.
Reviews

subcontract

subcontract awards.

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negotiations

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Through

personal

optimum

communication

contact

establishes

among

the

the

project

teams.
10)

Assigns one of the personnel as agent in case of

the Project Manager's absence from his office.

11)

Prepares job scope letters,

monthly progress

reports and other data as established in the job

specification.
b)

Project Engineer
Reports to:

The Project Manager

Supervises:

The Home Office Engineer

Duties and Responsibilities:

1)

Is responsible for all engineering design works

associated with the project.

"' ,

2)

Reviews all engineering works.

3)

Is

the

primary

customer

engineering matters in

contact

cooperation

for

all

with

the

Project Manager.

..

4)

Reviews

the

Master

Project

Schedule

and

ensures that detailed schedules are prepared for

the engineering and drafting activities.
5)

Maintains a record of man-hour expenditure and

any other pertinent engineering costs to balance
against budget allocation for performance of the
work.

6)

Reviews
vendor

purchase
lists

equipment.

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for

requisitions
all

and

itemized

proposed
temporary

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7)

Reviews bid analysis reports prepared by the

staff of the Procurement Department.

S)

Maintains cost control in his scope of activities

and keeps a record of financial value for such
commitments.

Distributes

this

record upon

request.
9)

Reviews goods receiving reports to ensure that

the material is in its proper condition.

Follows

up to ensure correction of any defficiencies.

c)

Field Construction Manager

Reports to:

The Project Manager

Supervises:

The Supervisors

Duties and Responsibilities:

1)

Reviews project data and coordinates with Staff

Services

Department

to

develop

detailed

construction plans and schedules for the Project

Manager's approval.
2)

Administers

industrial

policies

maintain

to

relations
proper

and

safety

discipline

and

morale.
3)

Conducts

periodical

planning

meeting

to

coordinate the work of various crafts and ensure

the

availability

of equipment,

materials and

manpower.
4)

Reviews and approves cost and progress reports.

5)

Coordinates

with

the

subcontractor's

representatives to insure that construction plans

are properly integrated.

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