PROZAP 50 years of experience in design and execution of industrial - - PowerPoint PPT Presentation

50 years of experience in design and execution

• f industrial investment projects

PROZAP

• About PROZAP

– General information – Certificates and awards – Major clients – Design process – Risk Management – Safety

• Major projects:

– Fertilizers: ammonia, urea, AN, AS – Caprolactam and melamine – Off-sites – UAN Production and Storage – Environment protection – Chemicals – Product handling and storage facilities

Agenda

• Almost 50 years of experience in design and engineering

services for chemical industry: over 40 thousand designs for over 100 clients

• Highly qualified engineers and technical staff for professional

project design and execution

• Resources to provide sophisticated and technologically

advanced design in all disciplines and a variety of accompanying services

• Employment: 110, average professional experience:
• ver 10 years
• Customer oriented, tailored engineering services

PROZAP Sp. z o.o.

• al. Tysiaclecia P.P. 13

24-110 Puławy, Poland prozap@prozap.com.pl www.prozap.com.pl

• Tel. +48 81 473 16 00

Fax +48 81 886 25 59

PROZAP – 50 years of experience

Since 1970 - Almost 50 Years of History

• 1970 – Engineering Department of Zakłady

Azotowe Puławy is created

• 1988 – PROZAP Sp. z o.o. is established
• 1990 – first implementation of PDS

(comprehensive, intelligent computer-aided design/engineering CAD/CAE application) in Eastern Europe

• +40 thousand designs within the framework of more than
• +30 thousand jobs for over
• 100 clients

Certificates and Awards

• Certified Quality Management System ISO 9001, 14001, 18001
• Title of Best Design Company of the Year 2013.
• I Prize in the Modernization of the Year 2011 competition

for Urea Plant Revamping Project acc. to Basic Design by Urea Casale in Zakłady Azotowe Puławy S.A.

• Nomination in the Modernization of the Year 2012

for „Revamping of the Co-generation Plant by retrofitting

• f Flue Gas Desulphurisation Plant in Grupa Azoty PUŁAWY
• Nomination in the Modernization of the Year 2013 for

Modernization of vehicle scales in Grupa Azoty PUŁAWY

• Gold Medal of Rynek Inwestycji Magazine for comprehensive

conversion engineering company into an EPC contractor.

PROZAP has been awarded the title of Best Design Company of the Year 2013 Certificate of Appreciation by Office of Technical Inspection for high standards in technical safety and security.

• Ammonia
• Urea
• Ad Blue
• Sulphuric acid
• Sulphur and its compounds
• Nitric acid
• NOx, SO2 , NH3 emission abatement
• Prill tower off- gas dedusting
• Melamine
• Ammonium nitrate
• Caprolactam
• Peroxides
• Units based oil processing
• Waste & Water treatment
• Bulk and liquid fertilizer storage

– inland and harbour

• Heat/power plants
• Bioethanol

Major Reference Projects

Domestic

Anwil S.A. Polfa Tarchomin SA International Paper Kwidzyn SA Metalko Z.Ch. Luboń Polfa SA Grupa Azoty Siarkopol

• Z. Ch. Siarkopol

Organika Sarzyna PCC Rokita Grupa Azoty ZAK Wratislavia-Bio Carbon Black Polska Elektrownia Rybnik SA Bałtycka Baza Masowa Lotos SA Grupa Azoty Police Orlen SA Boryszew SA Mostostal Puławy SA Cersanit SA Grupa Azoty Tarnów Synthos Dwory 7 Sp. z o.o. S.K.A.

Key Partners

Overseas

 Achema  Agro Linz  Air Liquide  Casale Group  Chematur Engineering Group  Evonik Carbon Black  Gea Messo AG  GSFC  Khimtekhnologya  LIWA  Lurgi Zimmer  Marsulex  Petrochemishe Anlagen  Rhodia Chemie  Ruwais Fertilizer Industries (FERTIL)  Samsung Engineering  GS Engineering & Construction  SABIC  Sulzer Chemtech  Tecnimont  ZAO Polus

• Market Study
• Feasibility Study
• Selection and transfer of technology
• License Management
• Cost Estimation
• Civil Design
• Basic Engineering
• Detail Engineering
• Cost Control
• Procurement
• Project Execution
• Author’s Supervision
• As-built Documentation
• Training of operating personnel
• Plant operation and maintenance
• Plant optimisation
• Plant upgrading

Commissioning Construction Design Project Definition

Specialty Services

At every stage of a project life-time EPC Contracts

„Turn-key” PMC Project Management Consultancy

Specialty Services

for Investors and EPCs

• Consultancy regarding local regulations and/or

representation (Power of Attorney)

• Environment Impact Report
• Civil Design as required by Polish Law
• Building Permit application
• Integrated Permit
• Permit to Use
• Local Safety and Security Rules compliance
• Local authority engineering and coordination
• Negotiations with authorities
• Obtaining required decisions and approvals
• Management of contractors
• Large database of proven Polish suppliers
• Possibility to hire local contractors contributing to

local community

EPC Services

Integrated Project Execution The whole project from one hand

• Fewer changes and less implementation work
• Optimized cost effectiveness
• Optimized scheduling and smooth performance
• Increased quality and compliance with requirements
• Increased safety and security
• Improved operability

Off-sites and auxiliary facilities

• Waste and effluent disposal systems
• Water preparation and treatment plants
• Product conveying, storage, packaging and loading/unloading facilities
• Site utilities connections
• Steel and concrete structures, process and auxiliary buildings,
• Electrical power / steam systems
• Process water / air systems
• Cooling and heating systems
• Roads, yards and railway
• Communication, security and surveillance systems
• Site and field lighting
• Personnel facilities and sanitary installations
• Various engineering services: optimization studies, debottlenecking,

capacity increase, etc.

Projects Oriented HR

Disciplines Project 1 Project 2 Project 3 Process Piping Mechanical Instrumentation Electrical WSS&HVAC Civil Engineering General Plot Plan Environment Protection Safety Considerations

PROCESS ENGINEERING PIPING MECHANICAL VESSELS & MACHINERY INSTRUMENTATION WATER / SEWAGE SYSTEMS & HVAC ENVIRONMENT PROTECTION GENERAL PLOT PLAN CIVIL ENGINEERING, ROAD AND RAILWAY SAFETY CONSIDERATIONS ELECTRICAL

Matrix System

Appointing PMs and discipline leaders to prepare the quotation Receiving of the inquiry / ITB Acquiring the basic information to produce the quotation. Defining the scope

• f inquiry

Settlment with the client regarding the final scope of design Preparing the quotation

• acc. to PROZAP’s internal

regulations Signing the Agreement Issuing the Project Schedule, appointing the Project Team and assigning tasks

Design Process

Inquiry processing Agreement and execution

• f the project

Forwarding the documentation Periodical project check-ups Final, formal review Technical measures Execution of the Project External expert opinion Ad hoc consultations

Project Control

The Project Control and Supervision address specifically:

Following the Project Schedule

• Conformity with the Agreement
• Conformity with the Basic Design
• Conformity with local/state regulations
• Information flow between disciplines

Periodical meetings:

• PM and discipline leaders,
• Following the Project Schedule
• Interdisciplinary settlements
• Delay counter-measures
• Minutes of the meetings available

for all involved Final, formal review:

• Completeness of the documentation
• Formal requirements

Technical measures: Automated, immediate check-ups for collision / interference (civil, framework, piping, equipment) External expert opinion: Documentation approval by the relevant institutions and authorities Ad hoc consultations / reviews:

• Discussion over design solutions to be used
• Interdisciplinary settlements
• PM reviews of the produced portions of the

documentation

Periodical project check-ups Final, formal review Technical measures Execution of the Project External expert opinion Ad hoc consultations

and Verification

Progress Reports

• Monthly / weekly reports - as required by the client / agreement
• To monitor and report all major activities, arising issues and their solutions
• Report contents:

– Summary / Synopsis: major facts summarized and commented – Work to date: reached milestones, progress percentages by activities – Issues arising – Issues solved – Actions to prevent delays – Work planned for the next period (month/week) – Contract / order status – Invoice status

Project Control

CAD / CAM Systems

ChemCAD+CCTerm, ASPEN TASC+ Process Piping & Vessel Forte, Norma Pro MS SQL, Oracle, Access MS Project Instrumentation & Electrical Civil, Water, Sewage and HVAC Cost est. Database Project Visual Vessel Design, Probad Design Calcs PDS 3D Isogen EPLAN, SEE Electrical Expert, Intools, ETAP Smart Plant Review Triflex MicroStation, AutoCAD CAD Autodesk ROBOT Structure Analysis Professional, RM Win, Ventpack, BOCAD 3D, Adv. Concrete

State-of-the-art Design Techniques

SmartPlant P&ID Instrumentation 3D Basic Integrator

Risk Management

RISK

Technical Financial Market Social & Political Environment

Safety Management

Safety First

• Safety audits
• Safety assessment
• Safety Task Assignment
• Hazard Elimination
• Lessons learned
• Training
• Safety survey and processing of results

Selected reference projects

Fertilizers, chemicals, environment protection

UAN Plant and storage faciliteis Liquid ammonia storage Ammonia plant revamping Urea plant revamping Nitric acid plant Granulated fertilizer AN plant

Grupa Azoty PUŁAWY Scope of work

Preparing of technical documentation

• Map and Civil Engineering
• Detail Engineering in all disciplines
• Purchasing documentation: ITBs, bid analyses,

technical attachments to contracts

• Operation manuals and registration files
• Evaluation of completeness of Process Design
• Coordination, participation in commissioning,

supervision

AN Based Fertilizer Plant

Status: in progress

Scope of Work

• Complete technical documentation:
• Civil Design
• Area classification
• Multi-discipline Detail Engineering
• Tender documentation: inquiries, technical proposal

evaluation, technical attachments for contracts

• Equipment registration files
• HAZOP and SIL
• Plant start-up and operating manuals
• Supervision, evaluation of equipment documentation,
• Participation in coordination meetings and

commissioning.

1000 MTPD Nitric acid plant

Construction of a new production plant (thyssenkrupp), Grupa Azoty PUŁAWY – in progress

Scope of Work

• Tender documentation:
• technical evaluation of proposals
• preliminary concept with cost estimate
• technical attachments to the contracts
• Environmental Impact Report
• Preparation of Material Requisition

Nitric acid

Pre-design work for modernization of existing nitric acid plant project, Grupa Azoty PUŁAWY – in progress

UAN plant and storage facilities

„AGROCHEM ” Sp. z o.o., Człuchów, Poland ( 2014)

Project at a glance

• EPC, Turn key project execution
• Conceptual Design
• Comprehensive Engineering in all disciplines
• Supplies
• Project Management and coordination with

subcontractors

• Supervision

Production Plant and Storage Facilities

• f UAN liquid fertilizers, Grupa Azoty ZAK S.A ( 2015).

Project at a glance

• EPC, Turn key project execution
• Conceptual Design
• Comprehensive Engineering in all disciplines
• Supplies
• Project Management and coordination

with subcontractors

• Supervision

Liquid Ammonia Storage

Scope of work

• Concept
• Detail Engineering in process, civil,

electrical, mechanical and instrumentation

• Procurement Management
• Authority Engineering, preparation
• f documents required to obtain permits
• Preparation of technical attachments to contracts
• Other engineering services

Capacity15 000 t. with loading-unloading facilities ( 2015 )

Scope of Work

• All documentation necessary to implement the

technology by Marsulex,

• Supervision over execution of contracts with

equipment vendors

• Obtaining required permits,
• General concept and spatial layout,
• Civil engineering design
• Detail engineering in all disciplines
• Operating manuals
• As-built documentation
• Supervision over construction

Flue Gas Desulphurisation

Innovative wet, ammonia process in Puławy, Poland PROZAP: PMC & General Design and Engineering Company

Prill Tower Emission Control

Scope of work

• Basic Engineering
• HAZOP Study
• Detail Engineering
• Procurement
• Supervision + Training
• As-built documentation
• Cooperation with GEA Messo,

provider of the crystallization technology

Urea dust and NH3 emission abatement, SABIC, Saudi Arabia

Other reference projects:

• Grupa Azoty PUŁAWY
• Anwil S.A., Poland
• Agrolinz, Austria
• Grupa Azoty ZAK

TGU Bulk Loading Facility

Al-Bayroni, SABIC, Saudi Arabia

Project at a glance

• Basic Engineering
• Detail Engineering in all disciplines
• As-Built Documentation
• Supplying of equipment
• Supervision services

Status: in progress

FEED Study

For New Bagging & Truck Loading Facility in Ruwais Fertilizer Ind., UAE

Project at a glance

• Comprehensive study and and

conceptual design for construction

• f a new bagging and loading

facility project

• Front End Engineering Design in

all disciplines

Solid Fertilizer Plant

with storage, handling and loading facilities in Grupa Azoty Zakłady Azotowe Puławy

Project at a glance

• Civil Design
• Environmental Impact Report
• Procurement Management
• Detail Engineering in all

disciplines for the storage and loading complex

• Supervision

PROZAP’s Scope of Work

• Civil Design
• Detail Engineering
• Process Manual
• Procurement management
• Concept of integration of the

new plant with existing units

• n site

Air Separation Unit

Two separate trains of overall capacity  1,700 MTPD Integration with existing plants

Project at a glance

• Goal: capacity increase and other

improvements

• Basic Design by Urea Casale
• PROZAP’s scope of work:

– Civil Design – Detail Engineering – Other engineering services

Urea Plant Revamping

Capacity increase to 1.215.000 MTPY

Scope of work

• Civil Engineering
• Detail Engineering
• Environment Impact Report
• Environment protection approvals
• Product handling

AdBlue production plant

Capacity increase to 100,000 MTPY, Zakłady Azotowe Puławy S.A., Poland

Bulk Fertilizer Storage

and UAN terminal, Gdynia Port, Poland Project at a glance

• UAN storage capacity: 27 000 tonnes
• Bulk Fertilizer storage capacity: 140 000 m3
• Loading/Unloading capacity – 2 000 MTPH
• PROZAP’s scope of work:

– Civil Design – Detail Engineering – Other engineering services

Project at a glance

• CAN storage with transport, handling, storage, weighing, packing, loading facilities

and roads and yards,

• General concept and spatial layout,
• Process design
• Preliminary impact on environment report
• Civil Engineering Design
• Inquires for handling and packing equipment
• Multi-disciplinary Detail Engineering
• Author’s supervision

CAN Storage

Capacity 25,000 t., Wloclawek, Poland

• Pre-design
• Civil Engineering
• Tendering procedures for purchasing
• Detail Engineering and tank registration files
• Detail Engineering
• As-Built Documentation
• Process Manual
• Supervision services
• Other engineering services: inventory, mechanical and

process commissioning documentation, coordination with Notified Bodies

Chemicals Dosing Station

PKN ORLEN S.A., Płock, Poland Scope of work

• Basic Design
• Civil Engineering
• Detail Engineering

Selection and installation of a soda tank

Inowrocławskie Zakłady Chemiczne Soda Mątwy S.A. Scope of work Project description

Installation of the soda tank including conventional and pneumatic conveying systems with conveying scales for railway car loading of capacity 60 t/hr.

Polyethers Production Capacity Increase

30 000 MTPY, PCC Rokita SA, Brzeg Dolny

• Civil Design including Environment Impact Report to
• btain a building permit,
• Detail Engineering in all disciplines: process, piping,

civil, instrumentation, HVAC, electrical, mechanical and cost estimation,

• Tendering procedures for the purchase of machinery,

equipment and materials,

• Detail Engineering and commissioning

documentation for vessels and pipelines

• Supervision services

Project characteristics

TDI complex

Job description

• Pre-design work including inventory,
• Civil Engineering Design with

Environment impact report,

• Complete Detail Engineering
• Process/operating manuals
• Procurement of machinery and equipment,
• Participation in start-ups and approvals
• Supervision and as-built documentation
• Managing engineering subcontractors, coordination and control

Capacity increase to 60,000 MTPY, Zachem, Poland

Job description

Designs and engineering in all disciplines:

• Civil Engineering,
• Detail Engineering,
• Registration Files,
• As-built documentation
• Author’s supervision.

The revamping was carried out without shutting down of the plant and using only short maintenance periods. During test runs of the extended TDI plant, all the technical, quantity and quality parameters of the product guaranteed by PROZAP were achieved.

TDI complex

Capacity increase to 75,000 MTPY, Zachem, Poland

General Engineering Contractor:

• Pre-design work including inventory
• Cooperation with Basic Design Provider
• Civil Engineering Design with the

Environment impact report

• Complete Detail Engineering in all disciplines
• Participation in bidding/contracting
• HAZOP Study
• Participation in start-ups and approvals,
• Process/operating manuals
• Supervision

130 000 MTPY Methanol Plant

„New Second-hand Plant Formula: application of existing equipment ACHEMA, Lithuania, 2006

Biodiesel plant

Job description

• Environment impact report with an integrated permit application
• Civil Engineering Design with building permit
• Detail Engineering in all disciplines
• Railway system development project
• Feedstock/products storage, loading

and unloading system

Wratislavia-Bio, Wroclaw, Poland

Polyols (Polyols 4) Production Plant

PCC Rokita SA, Brzeg Dolny Project characteristics

• Capacity: 30 000 tonnes / year
• PROZAP's scope of work:

– Technical evaluation of the project, including the investment cost estimates, – Civil Engineering – Environment Impact Report – Design basis documentation for the equipment and vessels – Obtaining a building permit, – Detail Engineering including tendering documentation, – Detail Engineering and commissioning documentation for equipment and pipelines – Supervision services

Sulphonated Chemicals Plant

30 000 MTPY, PCC Rokita SA, Brzeg Dolny

PROZAP - General Designer Company

• The design documentation for the storage and production

parts

• Civil Design including obtaining a building permit,
• Detail Engineering
• Tender and contracting procedures for both parts,
• Supervision services
• As-built documentation of the storage area.

Project characteristics

Melamine Plant

Job description

• Predesign and preparatory works
• Civil Engineering Design
• Environment impact report
• Complete Detail Engineering in all disciplines
• Procurement of machinery and equipment,
• Participation in start-ups and approvals
• Supervision and as-built documentation
• Process/operating manuals
• Managing engineering subcontractors, coordination and control

Capacity 30,000 MTPY, Puławy, Poland

• Civil Engineering
• Tendering procedures for purchasing including

technical attachments to contracts

• Detail Engineering in all disciplines
• Supervision services
• As-Built Documentation

Dry salt plant capacity increase

Soda Polska CIECH, Janikowo, 2016 Scope of work

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