PROZAP 50 years of experience in design and execution of industrial investment projects
Agenda • About PROZAP • Major projects: – General information – Fertilizers: ammonia, urea, AN, AS – Certificates and awards – Caprolactam and melamine – Major clients – Off-sites – Design process – UAN Production and Storage – Risk Management – Environment protection – Safety – Chemicals – Product handling and storage facilities
PROZAP – 50 years of experience • 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: 1 10, average professional experience: over 10 years • Customer oriented, tailored engineering services PROZAP Sp. z o.o. Tel. +48 81 473 16 00 prozap@prozap.com.pl al. Tysiaclecia P.P. 13 Fax +48 81 886 25 59 www.prozap.com.pl 24-110 Puławy, Poland
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 of Flue Gas Desulphurisation Plant in Grupa Azoty PUŁAWY PROZAP has been awarded the t itle of • Nomination in the Modernization of the Year 2013 for Best Design Company of the Year 2013 Modernization of vehicle scales in Grupa Azoty PUŁAWY • Gold Medal of Rynek Inwestycji Magazine for comprehensive conversion engineering company into an EPC contractor. Certificate of Appreciation by Office of Technical Inspection for high standards in technical safety and security.
Major Reference Projects Domestic • Ammonia Bałtycka Baza Masowa Lotos SA • Urea • Ad Blue Grupa Azoty Police • Sulphuric acid • Sulphur and its compounds International Paper Kwidzyn SA • Nitric acid Metalko • NO x , SO 2 , NH 3 emission abatement Anwil S.A. Orlen SA Boryszew SA Z.Ch. Luboń • Prill tower off- gas dedusting Polfa Tarchomin SA • Melamine Mostostal Puławy SA • Ammonium nitrate Cersanit SA • Caprolactam Grupa Azoty Siarkopol PCC Rokita Z. Ch. Siarkopol • Peroxides Wratislavia-Bio Organika Sarzyna • Units based oil processing Grupa Azoty ZAK Polfa SA • Waste & Water treatment Elektrownia Rybnik SA • Bulk and liquid fertilizer storage Grupa Azoty Tarnów Synthos Dwory 7 Sp. z o.o. S.K.A. – inland and harbour Carbon Black Polska • Heat/power plants • Bioethanol
Key Partners Overseas Achema Marsulex Agro Linz Petrochemishe Anlagen Air Liquide Rhodia Chemie Casale Group Ruwais Fertilizer Industries (FERTIL) Chematur Engineering Group Samsung Engineering Evonik Carbon Black GS Engineering & Construction Gea Messo AG SABIC GSFC Sulzer Chemtech Khimtekhnologya Tecnimont LIWA ZAO Polus Lurgi Zimmer
Specialty Services At every stage of a project life-time • Training of operating personnel EPC • Plant operation and maintenance • Plant optimisation Contracts Commissioning • Plant upgrading „ Turn-key ” • Project Execution • Author’s Supervision • As-built Documentation Construction • Civil Design PMC Project • Basic Engineering Management • Detail Engineering • Cost Control Consultancy Design • Procurement • Market Study • Feasibility Study • Selection and transfer of technology • License Management Project Definition • Cost Estimation
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 Matrix System Disciplines Project 1 Project 2 Project 3 PROCESS ENGINEERING Process PIPING Piping Mechanical MECHANICAL VESSELS & MACHINERY Instrumentation INSTRUMENTATION Electrical WSS&HVAC ELECTRICAL Civil Engineering WATER / SEWAGE SYSTEMS General Plot Plan & HVAC Environment Protection CIVIL ENGINEERING, ROAD AND RAILWAY Safety Considerations GENERAL PLOT PLAN ENVIRONMENT PROTECTION SAFETY CONSIDERATIONS
Design Process Agreement and execution Inquiry processing of the project Receiving of the Signing the Agreement inquiry / ITB Issuing the Project Schedule, Appointing PMs appointing the Project Team and discipline and assigning tasks leaders to prepare the quotation Technical measures Periodical project check-ups Execution of the Project Acquiring the basic Settlment with the client information to produce External expert opinion Ad hoc consultations the quotation. regarding the final scope of design Defining the scope of inquiry Final, formal review Preparing the quotation acc. to PROZAP’s internal Forwarding the documentation regulations
Project Control and Verification Periodical meetings: • PM and discipline leaders, Technical measures Periodical project check-ups • Following the Project Schedule • Interdisciplinary settlements Execution of the Project • Delay counter-measures External expert opinion Ad hoc consultations • Minutes of the meetings available for all involved Ad hoc consultations / reviews: Final, formal review • Discussion over design solutions to be used • Interdisciplinary settlements • PM reviews of the produced portions of the documentation The Project Control and Supervision address specifically: External expert opinion: Documentation approval by the relevant institutions and authorities Following the Project Schedule Technical measures: • Conformity with the Agreement Automated, immediate check-ups for collision / interference (civil, framework, • Conformity with the Basic Design piping, equipment) • Conformity with local/state regulations Final, formal review: • Information flow between disciplines • Completeness of the documentation • Formal requirements
Project Control 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
CAD / CAM Systems State-of-the-art Design Techniques SmartPlant P&ID Instrumentation 3D Basic Integrator Process Smart ChemCAD+CCTerm, Plant Visual Vessel Design, Probad ASPEN TASC+ Triflex Review Design Calcs Piping & Vessel PDS 3D EPLAN, SEE Electrical Expert, Intools, ETAP Isogen Instrumentation & Electrical Autodesk ROBOT Structure Analysis Professional, RM Win, Ventpack, BOCAD 3D, Adv. Concrete Civil, Water, Sewage and HVAC MicroStation, AutoCAD CAD Forte, Norma Pro Cost est. MS SQL, Oracle, Access Database MS Project Project
Risk Management Technical Environment Financial RISK Social & Market Political
Safety Management Safety First • Safety audits Safety assessment • • Safety Task Assignment Hazard Elimination • Lessons learned • • Training Safety survey and processing of results •
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