we make ideas work - Tebodin BV

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we make ideas work - Tebodin BV
OCTOBER 2014 / VOLUME 56
EDITION 4
3D MODELLING FOR BEHN MEYER
PHARMA PLANT EXTENSION
FOR ASPEN
‘TEAMING‘ IN DYNAMIC
PHARMACEUTICAL MARKET
03
05
06
WE
MAKE
IDEAS
WORK
DELTA focuses on energy efficiency
02
REDUCING ENERGY USE IN INDUSTRIAL PROCESSES CAN HAVE A SIGNIFICANT IMPACT
ON THE BOTTOM LINE. DUTCH ENERGY COMPANY DELTA PROVIDES TANGIBLE VALUE TO
ITS CLIENTS WITH THE HELP OF TEBODIN.
The principles of lean manufacturing
have been widely adopted over the
past decades, but the efforts were
mostly aimed at waste reduction and
output growth. DELTA wants to be
more than an energy provider to its
industrial clients. As part of a
framework agreement, Tebodin
identifies the best efficiency
opportunities.
Based in the Southwest of the
Netherlands, DELTA is an independent
multi-utility company specializing in
energy, grids and networks, and waste
management. In addition to electricity
generation and energy trading, it
supplies gas and electricity to private
and corporate clients. The company’s
network division is the regional grid
operator, responsible for management,
construction and maintenance. Other
areas of expertise include high-voltage
applications and metering technology.
01
Energy Quick Scan
‘The tracking and mapping of the
energy used in every process is the
starting point for any company serious
about saving energy’, says Energy
Consultant Mr. Sander Tensen. ‘DELTA
wants to support its industrial clients
in developing a sustainable value
proposition, and it believes in the
tailor-made approach. Industrial
companies often find it difficult to
identify the real bottlenecks, says
Mr. Maarten Seghers, the marketing
manager for the B2B energy market at
DELTA. ‘Tebodin is for us the right
partner to accomplish this’.
The process starts with an Energy
Quick Scan to determine the
possibilities. ‘We also carry out
comprehensive energy audits and
feasibility studies with regard to
investments. In my experience, direct
‘Joint Venture of the year’ award for STS-Tebodin
DURING THE FOURTH EDITION OF THE OIL AND GAS YEAR (TOGY) IN OMAN AN AWARDS
CEREMONY TOOK PLACE. ONE OF THE PRESENTED AWARDS WAS THE ‘JOINT VENTURE OF THE
YEAR’ AWARD THAT WAS PRESENTED TO JOINT VENTURE SPECIAL TECHNICAL SERVICES AND
TEBODIN & PARTNER (STS-TEBODIN).
STS-Tebodin is the largest private
sector oilfield employer of Omanis in
2013. The joint-venture is specially set
up for the Engineering and
Maintenance Contract (EMC) for
Petroleum Development Oman (PDO).
This 7 year framework contract, with a
possible extension of another 3 years,
was awarded by PDO in February 2011.
The contract includes all on-plot
engineering, procurement services,
construction and commissioning of all
green and brown field projects and
subsequent maintenance and
management services for PDO’s Oil
and Gas surface facilities throughout
the company’s northern concession
area in Oman.
The number of Omanis working for
STS-Tebodin is around 2,500 at
different work categories.
TOGY is an annual report on the
sultanate’s energy industry, produced
in partnership with Oman’s Ministry
of Oil and Gas and Oman Society of
Petroleum Services.
More info:
Mr. Salim Al Kindy
Managing Director Oman
[email protected],
+968 246 280 00
savings of around ten percent are
almost always possible without major
investments or process changes. For
larger savings, the cost recovery and
return of investment are usually a
matter of just a few years’, says
Mr. Tensen.
Sustainable production
Recent quick scans took place at two
metal processing companies. Tebodin
also developed a sustainability
proposition for a salt mining company,
in which the identification of energy
savings was combined with a broader
exploration of sustainable production
methods. ‘We use a heat camera to gain
further insight in energy losses and find
additional saving opportunities.’
Savings are not only to be found in the
latest technology or smarter processes.
01_ Mr. Sander Tensen: ‘A heat
camera, used to gain insight in
energy losses’
02_ DELTA’s Biomass, Nuclear and
Coal Power Plant EPZ in Borssele
An often-overlooked opportunity is the
active involvement of employees in
energy saving initiatives.
Mr. Tensen: ‘We arrange workshops to
create and deepen staff commitment to
sustainability and efficiency. These are
done on-site with everyone relevant
present, from management to the
technical department. DELTA also
participated.’
More info:
Mr. Björn Erkens
Director Netherlands West
[email protected], +31 181 65 17 07
New member Board of Directors Tebodin
The Executive Board of Bilfinger SE has
appointed Mr. Niels van Rhenen B.Eng.
MBA as member of the Executive
Management of Tebodin B.V. as of
September 1, 2014.
Since 2010, Niels van Rhenen (50) has been
working for Tebodin in the position of
director Tebodin Netherlands B.V.. He will
hold this position next to his new position in
the Board of Tebodin B.V.
The Executive Management of Tebodin B.V.
consists of Jack Overkamp (Chairman),
Robert Claasen, Niels van Rhenen and
Arjan Rougoor
OCTOBER 2014 / PAGE 2
A SELECTION OF OUR VARIOUS
CURRENT PROJECTS
Demolition
cost analysis for
‚
Nuon s power plants
TEBODIN ASSESSED THE DEMOLITION COSTS OF ALL POWER PLANTS OWNED
BY NUON AND ADVISED THE DUTCH ENERGY COMPANY WITH REGARD TO THE
DEMOLITION OF TWO PLANTS, IN AMSTERDAM AND PURMEREND.
Several major upgrades of power facilities for chemical clients for/with Ritter
Starkstromtechnik in the Netherlands
Scope: Detailed engineering and consultancy services
The Nuon power plant Hemweg 7 was
decommissioned in January 2013. By
then it had been replaced by a more
efficient Combined Heat & Power (CHP)
plant called Hemweg 9, located on the
same site in Amsterdam. Hemweg 7 had
been in service for 34 years and will
now be partially demolished in order to
use the gas turbine for peak moments in
electricity demand.
Purmerend, just north of Amsterdam,
is the most prominent district heating
city in the Netherlands, with over
24,000 households and 1,000
companies connected. The Nuon
CHP plant that provided 64 Mw of
heat for many years is going to be
replaced by a biomass power plant,
rendering the current installations
obsolete.
Stack of Nuon's Combined
Cycle Gas Turbine (CCGT) in
Purmerend, the Netherlands
Mass balance
Nuon wanted a thorough assessment
of the demolition costs. Tebodin found
that these costs are largely
determined by the amounts of steel
and concrete in the buildings. After
visiting the sites and collecting data
on the materials, construction and
local circumstances, they produced a
first draft of the ‘mass balance’.
Gaps identified
In consultation with Nuon, data gaps
were identified and the initial mass
balance was enriched with the
missing information on the equipment
and buildings, either through
documented data or based on
assumptions and measurements. The
final result is an elaborated steel and
concrete mass balance, which
provides Nuon with a detailed insight
into the quantities and characteristics
of the materials, and which will serve
as the basis for negotiations and
agreements with the demolition
company.
Study for Abu Dhabi Ports Company (ADPC) for the offloading facilities for
ADNOC Distribution’s Multi-Product Terminal in Khalifa Port, Abu Dhabi.
Scope: Location selection study and hazardous identification study for jetty
and pipeline routes.
More info:
Mr. Björn Erkens
Director Netherlands West
[email protected], +31 181 65 17 07
More than 30 years in Dubai
Revamping project of the blending vessel vent gas of Smit & zoon’s plant in
Nanjing Chemical Industrial Park, China.
Scope: Feasibility study report & detailed design service
‘WORKING FOR 18 YEARS WITH TEBODIN IN THE MIDDLE EAST HAS BEEN
A WONDERFUL EXPERIENCE, AND THE MAIN REASON FOR THAT ARE THE
PEOPLE,’ SAYS MR. GANGADHARAN KUNIYIL, PUBLIC RELATIONSHIP
OFFICER IN DUBAI. TEBODIN OPENED ITS DUBAI BRANCH IN 1981 AND,
OVER THE YEARS, MR. KUNIYIL HAS SEEN THE OFFICE GROW FROM FOUR
PEOPLE AT THE START TO 73 TODAY. THREE DECADES OF CAREFUL WORK
HAVE LED TO REMARKABLE RELATIONS AND PROJECTS.
Remarkable projects
Reconstruction of two compressor stations (Břeclav and Kouřim) for Net4Gas in
Czech Republic. The objectives of the project comprise modernizing the
equipment, meeting higher safety standard requirements, and making the
remote control from a Prague based control center possible.
Scope: Concept, FEED (basic design) with the option of tender documentation.
The Sheikh Zayed Road was one of
office Dubai’s earliest projects, and it
was quite spectacular. It was the first
cooling plant project in Dubai, ever,
serving all buildings along a three
kilometer road in the city center. It
was awarded to Tebodin by Tabreed,
an important provider of cooling
infrastructure for the nation. One of
the most important aspects of the
project was its contribution to reduce
energy consumption and the protection
of the environment by cutting carbon
dioxide emissions.
Located close to the Crowne Plaza
Hotel on Sheikh Zayed Road, the plant
serves many luxury hotels, residential
apartments and office towers. It is
perhaps Tebodin’s best known project in
Dubai, and it was done with only a
handful of people.’
The cooling plant system has important
advantages over traditional costly and
Tabreed’s
current
cooling plant
Development of OSII platform including subsea pipeline and composite
cable for Bunduq in Abu Dhabi
Scope: Project Management Consultancy
noisy air conditioning, as it helps
to reduce energy consumption
and protects the environment by
cutting carbon dioxide emissions.
Vision to reality
After the cooling plant, the
projects and teams got bigger:
working on a 62 kilometers
pipeline and on a 106 kilometers
manmade canal, with about 15
people. In the past number of
years Tebodin in Dubai has been
busy with projects which are now
of vital importance to the 2020
Expo, which will be hosted by the
United Arab Emirates in Dubai.
More info:
Mr. Maxim Stovpnik
Office Director Dubai
[email protected],
+971 456 72 700
Partnering on plant extension
Moving towards
projects improvement
IN RESPONSE TO THE MARKET DEMAND FOR ITS PRODUCTS, STEPAN COMPANY DECIDED
TO DOUBLE THE PRODUCTION CAPACITY OF ITS PLANT IN BRZEG-DOLNY, SOUTH-WESTERN
POLAND, BY INSERTING OF A SECOND REACTOR AND ASSOCIATED EQUIPMENT INTO THE
PRODUCTION LINE.
AS PER JULY, MR. JAN KLEIN WOLTERINK
STARTED IN THE NEW POSITION OF DIRECTOR
PROJECT IMPROVEMENT AT TEBODIN.
‘CREATING THIS POSITION AT CORPORATE LEVEL
ALREADY SHOWS THAT APPARENTLY THERE IS
A NEED. WE ONLY HAVE TO LOOK AROUND US
TO SEE WHY,’ MR. KLEIN WOLTERINK SAYS.
The company’s Project Manager, Mr.
Cameron Hammond put a tender out
for the preparation of FEL-2 (‘Front-End
Loading’ phase 2) multidiscipline
documentation for the extension of the
plant. In June, Tebodin’s office in
Warsaw, Poland was awarded the
engineering services contract.
Stepan, founded in 1932 in Northfield,
Illinois, USA, is a major global
manufacturer of specialty chemicals
used in a broad range of industries.
Stepan Poland manufactures basic and
intermediate chemicals, including
polyurethane polyols and special
ingredients for the food, supplement
and pharmaceutical markets.
disciplines, including process, piping,
mechanical, electrical, construction
and architectural engineers. One of
the most challenging parts of the
project is the design of the new
reactor. In order to assure troublefree operation of the vessel in
temperatures between 50 and 300 °C,
the vessel will be subjected to stress
analysis according to EN-13445-3. The
analysis, based on pressuretemperature profiles, will include 3D
FEA (Finite Elements Analysis).
Stress analysis
Mr. Janusz Iwanowski
Tebodin’s team, headed by Project
Manager, Mr. Janusz Iwanowski,
consists of nine engineers from many
Completion of this phase of the
project is scheduled to be completed
by the end of September. But there is
more in store, Mr. Iwanowski says.
‘We expect to participate in the next
stages of the project, including
permitting, detailed engineering and
construction management.
Meanwhile, the documentation we
have created will be used for the
expansion of a similar plant in the
United States. As Stepan has more
plants in Europe, we are looking
forward to continuing our cooperation
in future projects.’
More info:
Mr. Jaroslav Hrabĕ
Managing Director Poland
[email protected], +48 22 334 43 11
Many clients increasingly rely on us,
because they have trimmed down their
own organization and capacity to
prepare, execute and manage projects.
Markets have changed considerably
compared to ten years ago. The
competition has not been sitting idle.
Also, now we have more international
operating clients compared to our client
base a decade ago. Those clients expect
from Tebodin a similar service level and
uniform way of working wherever they
seek our services.
Working smarter
‘The changing world around us forces us
to get better at what we do. That alone is
already a challenge. What adds to the
complexity is that we have mature offices
and offices that recently started, big
projects and small projects, multi-year
framework contracts and one-off
projects. Executing projects is hard
work,’ Mr. Klein Wolterink remarks.
Improving project execution is even more
difficult, but it is not about just working
harder. It is about working smarter.
Achieve improvement
Getting projects done successfully
requires first and foremost the right skills
always close
OCTOBER 2014 / PAGE 3
and competence of our people. But
equally important are tools and systems
that we use as well as work processes
and procedures we apply. It is definitely
possible to achieve improvement in all
three areas and everyone I have spoken
with over the last few weeks recognizes
that. It is a challenge, but a very
interesting one. Not only because
Project Improvement obviously is
directly related to the daily buzz in
projects in all countries and offices
where we operate, but also because it
has links with IT, Finance, Quality and
Human Resources.
What are the expected overall results?
‘Well, that at least is an easy one,’ Mr.
Klein Wolterink smiles. ‘Being more in
control of what we do will lead to better
project delivery, which no doubt will
improve our reputation with our clients.
But it will also lead to better and more
predictable project results for Tebodin.
Actually, it looks like a win-win to me.
So, here we go.’
More info:
Mr. Jan Klein Wolterink
Director Project Improvement
[email protected]
+31 70 348 18 17
3D modelling for Behn Meyer
CHEMICAL COMPANY BEHN MEYER IS BUILDING A GREENFIELD WAREHOUSE AND OFFICE BUILDING,
LOCATED IN VIETNAM SINGAPORE INDUSTRIAL PARK (VSIP). TEBODIN PROVIDES EPCM SERVICES AND
3D MODELING IS USED TO COMMUNICATE PROJECT DECISIONS WITH THE STAKEHOLDERS. .
Catering to growing needs
The Behn Meyer project is located in
VSIP Bac Ninh, about 20 kilometers
from Hanoi. This park integrates
commercial and residential zones with
community facilities including schools,
sporting facilities, medical center and
other utilities, with industrial park
development. Singapore Senior
Minister Goh Chok Tong said at the
opening: ‘VSIP Bac Ninh is not only a
Singapore-style industrial park but also
a township that caters to Vietnam’s
growing needs for affordable quality
housing and improved urban
infrastructure.’
3D modelling
Since May 2014, Tebodin’s Project
Manager from Hanoi, Mr. Cao Van
Thanh, and his team of twelve, take
care of basic engineering, detailed
engineering, permitting, procurement
services and construction management
for the new warehouse and office of
Behn Meyer.
01
Mr. Cao Van Thanh: ‘We apply a BIM
(Building Information Modeling) solution
in this project. With Autodesk BIM, we
create an intelligent 3D model. Design,
visualization, simulation, and
02
01_ Representatives of Behn Meyer and Tebodin at the groundbreaking ceremony
02_ 3D view of Behn Meyer‘s warehouse and office building
collaboration with BIM provide greater
clarity for all stakeholders across the
project life cycle. It makes it easier to
achieve project and business goals.’
For Behn Meyer, Chief Representative
in Hanoi office, Mr. Bui Chi Kien
supervises the project. In Vietnam,
Behn Meyer specializes in specialty
and fine chemicals, fertilizers and crop
protection. The company chose
Tebodin because of its longtime
experience in chemical factory
projects. This project is scheduled to
be finished in April 2015.
More info:
Mr. Ronald de Vries
Managing Director Singapore, Vietnam
and Myanmar
[email protected]bodin.com, +65 929 79 275
OCTOBER 2014 / PAGE 4
Office Ahmedabad:
Booming with quality
Supporting methanol
‘TWO PEOPLE STARTED THE OFFICE A YEAR AGO WITHOUT A PARTICULAR JOB IN HAND. NOW
OUR TEAM OF THIRTY HANDLES OVER TEN PROJECTS,’ SAYS MR. ONDREJ STERBAK, OFFICE
DIRECTOR OF TEBODIN IN AHMEDABAD, INDIA. AND THE BOOM CONTINUES: ‘SATISFACTION OF
EXISTING CLIENTS HAS STARTED REPETITIVE PROJECT AWARDS, CREATING A SHARP RISE IN
OUR NEW BUSINESS DEVELOPMENT.’
TEBODIN & PARTNER IN OMAN HAS BEEN AWARDED A TWO-YEAR
CONTRACT TO PROVIDE A RANGE OF ENGINEERING SERVICES AT THE
METHANOL PRODUCTION FACILITY OF SALALAH METHANOL COMPANY
LLC (SMC).
The production facility is located in
the Salalah Free Zone in Oman, near
the Port of Salalah. Founded in 2006,
the plant is wholly owned by Oman
Oil Company and produces methanol
out of sweet natural gas.
Engineering services will be
provided for all parts of SMC’s
methanol facility: the methanol plant
itself and all off-site and utility
structures.
Important footprints
The focus of Tebodin in Ahmedabad is
on the chemical, food and industrial
sectors. Mr. Sterbak: ‘We have already
made important footprints in
companies such as Huntsman,
Arkema, Mapei, Chipita, and Omya.
Huntsman was especially satisfied
with our work, and we have done a
series of projects with them, including
support in different countries.’
‘For a client in the chemical sector,
for example, we are designing multiple
buildings in an 100.000 m² area, and
developing over 60 piping and
instrumentation diagrams.
We also started to work for our sister
company Bilfinger Water Technology
preparing the concept, master
planning and preliminary budget
estimation for their new factory.
Intense start-up
With such projects, the first year was
intense, tells Mr. Sterbak: ‘It was
absolute challenge, but we went with
it all together. The amount of sacrifice
from each staff-member was huge. We
spent countless nights and weekends
at work. I am still amazed by the moral
of our entire team: what needed to be
done was done, on time and quality,
no matter what. I have great gratitude
towards my dear colleagues.’
The office is also supported by the
international Tebodin network.
Mr. Sterbak: ‘Whenever we need
any advice or guidelines, we get it
immediately. For example, when we
needed a design review, our team in
Thailand was able to execute it within
hours.’
Expanding expertise
The accelerated pace continues: ‘We
know that we will need to have at least
50 employees in the next six months
to cover our contracted work. But
we want to add more as the
opportunities in India are huge.
However, we can only grow as fast
as we can ensure our quality
standards.’
‘We are trying to build a multi­
disciplinary office, where every
single department focuses on
excellency. However, if I would have
to pick an area of expertise, I would
say that is our process,
Global chemical commodity
Methanol is a globally traded
commodity and is used as intermediary
chemical feedstock in the manufacture
of a wide range of other chemicals and
end products, from food ingredients to
fuel. It is exported from Oman to
destinations around the globe from the
nearby Port of Salalah.
instrumentation and mechanical
team. We can also do sizing and
detail design of mechanical
equipment like reactors and vessels
using PV Elite software.’
More info:
Mr. Ondrej Šterbák
Office Director Ahmedabad
[email protected]
+91 794 06 06 100
Global framework contract with Syngenta
TEBODIN RECENTLY SIGNED A GLOBAL FRAMEWORK AGREEMENT FOR EPCM (ENGINEERING,
PROCUREMENT AND CONSTRUCTION MANAGEMENT) AND CONSULTANCY SERVICES WITH
SYNGENTA CROP PROTECTION AG IN BASEL, SWITZERLAND. THE FRAMEWORK, EFFECTIVE FROM
AUGUST 1, 2014, IS VALID FOR THREE YEARS AND COVERS TEBODIN’S WHOLE NETWORK, IN THE
BUSINESS AREA OF SYNGENTA’S SEED PROCESSING AND CROP PROTECTION CHEMICALS.
Syngenta is one of the world’s
leading companies in plant breeding,
crop protection and seed care to
develop a fully integrated offer on a
global crop basis, combining
innovation in genetic and chemical
solutions. Syngenta, with a sales of
14.7 billion dollars a year, has more
than 28,000 employees and is active
in 90 countries worldwide.
Demand for increased quantity
and quality
Global population is expected to rise
from around seven billion today to
more than nine billion by 2050. In
parallel, a greater number of people
will experience increased wealth
and higher purchasing power, and as
a result will increase consumption of
processed food, meat, dairy and fish.
As demand for increased quantity
and quality of crops grows,
agriculture must evolve in order to
meet these demands in a sustainable
way. Changes in climate will further
stress the availability of water, land and
biodiversity necessary for productive
agriculture.
Until now demand has been met
primarily through yield improvement.
However, the improvement rate of
yields in the major grains has been
slowing down and will not be sufficient
to fulfil increasing demand.
Innovation required
Syngenta’s response to the evolving
needs of farmers across the globe is an
integrated strategy with those needs at
its very heart. The strategy recognizes
that solutions to complex farmer
challenges are no longer met by single
products, but instead require innovation
to weave together both existing and
new technologies in order to bring plant
potential to life.
Tebodin’s involvement
The last two years we have been
working for Syngenta in Russia,
Ukraine, Hungary, Vietnam and the
Netherlands in the area of site selection
services, master planning, plant
re-development, project management,
tender support and technical
supervision. We trust this framework
agreement forms the basis to a
further cooperation with Syngenta,
and that we can keep assisting them
with our process knowledge in their
future investments projects over the
world.
More info:
Mr. Remko Dur
Corporate Business Development
[email protected], +31 70 348 03 09
Combine harvester in barley
always close
OCTOBER 2014 / PAGE 5
Pharma plant
extension for Aspen
production in Oman
‘SMC’s aim when it floated the tender
was to find a reliable and qualified
engineering partner for the various
projects that ensure production goes on
without interruptions,’ says Tebodin’s
Project Manager Mr. John K. Sebastian.
The required engineering capabilities
included the whole range of
mechanical, piping, civil, steel
structural, electrical and
instrumentation control engineering.
Pipes, circuits and loops
The plant’s process route for methanol
consists of tubular steam reforming of
natural gas along with a saturation and
desaturation circuit and a methanol
synthesis loop, followed by a twocolumn distillation section that
produces the methanol product to the
required specification. The sweet
natural gas for the Salalah plant is
provided by the Oman Ministry of Oil
and Gas through Oman Gas Company.
Mr. Sebastian: ‘We are very pleased to
have been awarded this two-year
contract and look forward to working
closely with SMC and provide the level
of service that will hopefully extend
our business relationship beyond the
duration of the contract.’
FROM LATE 2012 TO EARLY 2014, ASPEN HAS BEEN ADDING A NEW FINAL
PURIFICATION SUITE TO THEIR PHARMACEUTICAL PRODUCTION PLANT
IN OSS, THE NETHERLANDS. TEBODIN PROVIDED EPCM SERVICES AND
GAVE SUPPORT TO THE COMMISSIONING & QUALIFICATION PHASE. THE
COOPERATION CONTINUES WITH AN EPCM FRAMEWORK AGREEMENT
FOR THE OSS AND BOXTEL SITES, SIGNED IN JULY. CURRENTLY, TEBODIN
IS WORKING ON AN EXTENSION OF BOXTEL FACILITY AND SEVERAL
SMALL CAPITAL PROJECTS.
Clean room for final purification
More info:
Mr. Salim Al Kindy
Managing Director Oman
[email protected]
+968 246 280 00
Long partnership
Tebodin has a long partnership with the
Oss production site. It has successfully
carried out over 60 projects under the
master agreement in the last years. In
2013, the Pharmaceutical Ingredients
(API) business of the Oss site was
acquired by Aspen Group. South
African-based Aspen is a supplier of
branded and generic pharmaceuticals in
over 150 countries, and of consumer and
nutritional products in selected
territories. Aspen products are renowned
for their quality, efficacy and affordability.
‘Hot’ plant reconstruction
MUNICIPAL ENERGY COMPANY TEPTO BRUNTAL’S COAL-FIRED HEATING PLANT IN THE CITY OF
BRUNTAL IS UNDERGOING MAJOR RECONSTRUCTION – WHILE REMAINING IN OPERATION. TEBODIN
IS SITE SUPERVISOR, BUT ITS INVOLVEMENT IN THE PROJECT STARTED FAR EARLIER.
The reconstruction project comprises
replacing the three existing boilers (K2,
K3 and K4) by new ones. Boiler K1 will
remain unchanged as a cold backup.
The new K2 and K3 will have about the
same power as the originals, while
boiler K4 will be replaced by one with
half the original power. This will allow a
more flexible response in supplying
heat during the summer months.
Transportation of boiler
pressure unit K4.1 to the
boiler room
Documentation
In 2011 Tebodin’s office in Ostrava
prepared the planning permit
documentation for this project. This
phase was followed by preparation of
the planning permit documentation for a
new silo for acidic sodium carbonate,
which is used as an additive. Earlier this
year, after tendering the contractor,
Uchytil, Tebodin prepared the next
stage of documentation, which was
building permit documentation,
including the obtaining of the building
permit.
Completion of the project is expected
in September 2015.
More info:
Mr. Jaromir Kriz
Area Director Central Europe
[email protected], +420 251 038 342
Tebodin and the contractors’
management held 64 official safety
inspection rounds. In the end, a total of
70,000 construction hours resulted in
zero harm. Contractors were also
coached to improve safety behavior,
says Tebodin Project Manager Mr. Mark
Courage: ‘We are all skilled and
educated employees, extensively
trained when it comes to safety. Our
interventions make the difference and
save lives’.
55 outsiders on site
High level of cooperation
The new API purification suite in Oss
called for adaptation of the existing
building, including demolition of existing
structures and creation of new process
floors. Also a clean room for final
purification, with all new process
equipment and associated utilities and
systems. At its peak, 55 contractors were
working in the small area, only 15 by 5
meters per floor, next to the plant in full
operation. For an efficient construction
workflow within the restricted area,
Tebodin applied craftsman resource
schedules per floor, shifted construction
hours, micro schedules and a phased
move-in of construction material in line
with the lean principle. All to ensure the
ambitious schedule could be met.
Combined safety success
Currently, a Tebodin team headed by
Mr. Martin Papez is performing site
supervision for Teplo Bruntál. This year,
the first phase of construction is taking
place, which involves the replacement
of boiler K4. In the second phase,
boilers K2 and K3 will be replaced.
Safety (EHS) plan, a blue print for
construction sites, based on Tebodin’s
EHS plan.
In the project, the forces were combined
of a third party engineering architect, the
procurement and construction
management knowledge of Tebodin, and
the capabilities of an external
commissioning & qualification contractor
to achieve the best results on safety. This
was the first project using the new site
standard Environmental Health and
Besides Tebodin, two other Bilfinger
sister companies performed on the
project. Bilfinger Industrietechnik
Salzburg worked on piping and
mechanical equipment installation, and
Bilfinger Industrial Services provided
scaffolding and insulation. The level of
cooperation between the Bilfinger
companies received high praise from
the client.
Smart from the start
Aspen Manager Engineering Mr. Guus
Bekkers said: ‘Tebodin is flexible, result
oriented with a hands-on mentality, and
has the required process and pharma
knowledge to get the job done.
Furthermore, Tebodin provides a
challenging view, ensuring useful
input,from all business representatives,
to improve the process from concept to
realization.’
More info:
Mr. John Horn
Office Director Eindhoven
[email protected], +31 40 265 21 74
OCTOBER 2014 / PAGE 6
‚
‘Teaming in dynamic pharmaceutical market
‘TEBODIN’S RESPONSE TO A DYNAMIC PHARMACEUTICAL MARKET IS TO MOBILIZE KNOWLEDGE
AND KNOW-HOW IN A GLOBAL ORGANIZATION,’ SAYS MR. NIEK DE KONING, DIRECTOR GLOBAL
PHARMACEUTICAL PROJECTS. HE HAS BEEN IN THIS POSITION FOR 18 MONTHS, FOLLOWING HIS FIVE-YEAR
POSITION AS DIRECTOR IN OFFICE MAASTRICHT, IN THE NETHERLANDS. THE CITY REMAINS HIS STARTING
POINT FOR TRIPS AROUND THE WORLD, TO IMPLEMENT A NEW WAY OF WORKING.
A wave of medicine
The pharmaceutical market is
experiencing accumulated growth
around the globe, says Mr. de Koning:
‘In Europe, pharmaceutical companies
are investing in innovation and
improving their production facilities.
Furthermore, as patents expire,
grassroots facilities sprout up in Asia.
The population is becoming wealthier
and older, and get for example more
diabetes, so a wave of medicines are
needed. In China, technology is
fast-growing and the knowledge level is
impressively increasing, so
professionals are available. India is the
world’s third biggest producer of
medicines. In Indonesia, the annual
growth of the pharmaceutical industry is
13 percent, twice their economic
growth. Many international companies
producing for Asia Pacific settle in
Singapore and also Vietnam.’
‘At Tebodin, we are providing
professional services in all four market
segments: pharmaceuticals with active
ingredients (API), bio-pharmaceuticals,
finished products and medical devices.
We have a wealth of professional staff.
In China, for example, we have about
60-70 employees working on
pharmaceutical projects.’
A new way of working
Mr. de Koning is travelling all over to
implement Tebodin’s market approach
with the Global Pharmaceutical
Program. It is an intensive program in
several stages over many months, to
create business, while also designed to
introduce key specialists from all
cultures to a new way of working, with
teaming.
Teaming is using fluid groups of experts,
from different backgrounds and places,
Investing in hygiene for profit
and peace of mind
CONSUMER CONFIDENCE IN THE FOOD INDUSTRY IS OF GREAT VALUE. INVESTING IN
HYGIENE CAN PREVENT MANY PROBLEMS AND SAVE THE COSTS OF PRODUCTION
LOSSES AND REPUTATIONAL DAMAGE. TEBODIN HELPS TO UNCOVER WEAK SPOTS
WITH THE HYGIENIC DESIGN SCAN.
The food sector increasingly finds itself
under a magnifying glass. Growing
regulatory pressure and waning
consumer confidence call for decisive
action, but many plant operators have a
hard time getting started. After all, if
you want to improve hygiene, you have
to know where to direct your efforts to
make a real difference.
Regaining confidence
‘The Hygienic Design Scan goes a long
way in regaining confidence’, says
Tebodin process engineer Mrs.
Margriet Bosma. ‘We scan the entire
process to establish whether it meets
all basic hygiene requirements in terms
of design and cleaning methods. When
all systems and processes are in proper
working order, many potential hygiene
risks can be avoided, and the chances
of batch rejections or recalls become
much smaller.’
Getting a grip on hygiene requires a
methodical approach. The
manufacturer first decides which parts
of the plant have to be scanned. The
scan covers numerous points, including
installations, valves, instrumentation,
piping, process and cleaning
procedures, as well as cabling and
automation. ‘If allowed, we prefer to
open up everything to have a good
look’, says Margriet Bosma with a
smile. ‘And we include architectural
elements, such as door and window
frames, walls and drains. Horizontal
Participants of the Global
Pharmaceutical Program in China
Eye-openers
real eye-openers, and our clients
mostly draw their own conclusions
without us making specific
recommendations.’
Plant and process adaptations,
outdated installations, new guidelines
and legislation are all risk factors. The
scan generates a practical report of
strong and weak points, with the risks
highlighted in pictures. ‘These are often
More info:
Mr. Lou Dostĕ
Office Director Deventer a.i.
[email protected], +31 50 520 95 66
cabling ducts can become racetracks
for mice, to name just one example.’
to deal with new issues and
opportunities as they come up
throughout a project. Teaming was
developed by Professor Amy
Edmondson and, for example,
successfully used to build the Water
Cube aquatics center for the Beijjing
Olympics. Now teaming is spreading.
Indonesia and India have started earlier
this year, and Singapore and Vietnam
recently. So we have sound professional
services to offer to our clients worldwide,
wherever they want to move. If they want
to establish a new factory, we can deliver
excellent services.’
Mr. de Koning: ‘Our offices in Central
Europe and all four offices in China have
already gone through all three phases of
the development program. Our offices in
More info:
Mr. Niek de Koning
Director Global Pharmaceutical Projects
[email protected], +31 43 329 47 03
Abu Dhabi
commits to
the H in
QOHSE
IN ABU DHABI, TEBODIN COMPLETED AN INTENSIVE 13-WEEK
PROGRAM TO MAKE PEOPLE AWARE OF A HEALTHY LIFESTYLE. ‘OUR
PEOPLE HAVE PARTICIPATED IN THE CAMPAIGN AND ENJOYED
EVERY ACTIVITY,’ SAYS MR. AMIR HASAN, DIRECTOR PROJECTS AND
CONSTRUCTION MANAGEMENT IN OFFICE ABU DHABI.
Health campaign
Mr. Hasan: ‘Over the past few years,
we have put a lot of emphasis on
QOHSE issues at different levels. The
results of these efforts for our
organization were impressive.
However, part of QOHSE is Health.
Many people take their own health for
granted. We decided to do something
about this with the ‘Commit To Be Fit’
health campaign.’
Commit to be fit
‘We thought to encourage our people
to make a New Year’s resolution for
2014, and commit to be fit in this year
and beyond. The 13-week program
provided employees with a health
checkup with the professional
assistance of a local health service
provider. For all staff, ten health
ambassadors went around the office with
morning exercises, informational flyers
and quizzes, healthy recipes and fruit
snacks.’
Seriously healthy
People enjoyed the program, but the
campaign also serves a sobering cause.
Mr. Hasan: ‘A few of our colleagues have
experienced health issues. We hope to
help avoid some of such cases, with a
healthier lifestyle.’
More info:
Mr. Amir Hasan
Director Projects and Construction
Management, Abu Dhabi
[email protected], +971 2 406 63 70
Industrial, Energy & Environment,
Infrastructure, Health & Nutrition,
Chemicals, Oil & Gas, Property
Pipelines
Value engineering gets APAG’s
high-tech plant on budget
AN INITIAL DESIGN FOR APAG ELEKTRONIK’S GREENFIELD PLANT IN THE CZECH REPUBLIC WENT SERIOUSLY
OVER BUDGET. VALUE ENGINEERING AND CLEVER PROCUREMENT REDUCED INVESTMENT COSTS BY 15%.
Quality demands are high for APAG’s
new facility in Pardubice, Czech
Republic. As a producer of electronic
parts for the automotive branch and
other sectors, they require a high level
of control over its work areas. Its main
products include various types of
electronic control units and printed
01_ Greenfield area
02_ Mr. Vlastimil Hrouda, Tebodin‘s
project manager
circuit boards, many with LED
components. The manufacture of these
has to take place in a non-static, clean
area that is permanently kept at the
right temperature and humidity levels.
Commitment to client’s interests
‘The initial design for our new facility
met those requirements,’ says
Mrs. Stanislava Cížková, project
manager on behalf of APAG, ‘but the
NAM, Sappermeer to Norg, the Netherlands
01
associated costs were much higher
than we found acceptable. At the
recommendation of a business partner
we contacted Tebodin. Their insights
during the re-design and also at the
procurement stage resulted in a design
that met the same quality demands but
at a much better overall price.’
Tebodin’s tasks on the project include
tender documentation, detail design,
procurement, construction
management and commissioning. ‘But
most importantly for our client,’ says Mr.
Vlastimil Hrouda, project manager at
Tebodin’s Pardubice office, ‘is the value
engineering and our commitment to
serving their interests.’
Perfect production environment
‘The existing rented facilities are no
longer up to APAG’s requirements’, says
Mr. Hrouda. ‘We are making sure that
by the end of the year they will have
their own facilities. Measuring 3,500 m²,
the place will be fitted with airlocks,
extensive climate control, and floors
that can neutralize electrostatic
discharges. The perfect environment for
their high-tech products.’
PDO, Oman
02
Tebodin is involved in this greenfield
project since February 2014 and the
construction is expected to be
completed on December 2014.
More info:
Mr. Jaromir Kriz
Area Director Central Europe
[email protected], +420 251 038 342
Transco, Abu Dhabi
Many pipelines for oil, gas, chemicals, and water distribution have been realized
through the integral and innovative approach of Tebodin. Both during the design
and construction of underground pipelines, important aspects such as
engineering, integration with urban planning, the permitting process and various
geotechnical issues are considered to ensure and safeguard the integrity of
pipelines.
In order to prepare a sound design, strength calculations are conducted to
correctly represent the interaction between soil and pipeline. Best
implementation methods have to be considered at crossings with other
infrastructure such as roads, railways, waterways, dikes and pipeline alleys,
especially in built- up areas and cities. Innovations such as 3D modelling,
environmental management in pipeline construction, focus on integrity and
corrosion engineering are some of the solutions that Tebodin offers in the
realization of underground pipelines.
Our clients benefit from the synergy between all disciplines that play a role in
pipeline projects. Our engineers make sure that the designs are reliable and in
line with the relevant safety standards.
The range of our pipeline expertise entails:
• 3 D modelling
• Hydraulic and hear loss calculations
• Feasibility studies
• Water hammer analysis
• Integrity research
• Pipelines integrity management
• Strength and permit calculations • Crossings
Grand opening of first Inter IKEA
Shopping Centre in Wuxi
LIVAT, the Inter IKEA Wuxi shopping
centre is the first Inter IKEA Centre
Group (IICG) shopping centre opened in
China. It is located in Wuxi and the total
floor area is 225,137m2, including one
main shopping centre building and one
110kV HV substation building.
Because of its complexity and size,
there were more than 30 construction
contractors involved in this project.
Besides the main building, the project
also includes one public road with a
length of around 510m. This road mainly
serves the visitors of the shopping
Through the network of Tebodin offices worldwide you benefit from short
communication lines combined with local as well as international expertise.
Additionally, the multi-disciplinary character of our organization ensures a flexible
structure providing services fully geared to your specific project needs.
More info:
Mr. Hans Kleiboer
Director Corporate Business Development
[email protected] | +31 70 348 04 89
centre. And a creek forms part of the
landscaping making it a nice scenery.
Tebodin’s scope of work includes project
management, design management,
procurement, construction management,
permitting and government coordination,
and tenant coordination support.
Tebodin started to work for this project
on November 2011 and the total service
duration is around 34 months.
Established in 2001, the Inter IKEA
Centre Group (IICG) is jointly owned by
the Inter IKEA Group and IKEA Group,
with headquarters in Kastrup, Denmark.
They have invested in three shopping
centre projects in China: Wuxi, Beijing,
and Wuhan.
More info:
Mr. Wei Wei
Managing Director China
[email protected], +86 21 2309 9966
Tebodin‘s project team
always close
OCTOBER 2014 / PAGE 7
OCTOBER 2014 / PAGE 8
APPOINTMENTS
Mr. Peter Downs
has been appointed
Area Director Asia
Pacific as of
August 18, 2014.
Together with
Mr. Petr Kurka, also
Area Director Asia
Pacific, he forms the
management team of
the Asia Pacific area.
Mr. Ondrej
Šterbák has
been appointed
Office Director
Ahmedabad,
India as of
August 1, 2014.
Mr. Parviz Abadi
has been appointed
Office Director
Qatar as of
August 22, 2014.
A smooth stress analysis for
Borouge in Ruwais
TEBODIN PROVIDED DETAIL DESIGN FOR A POLYETHYLENE PLANT OF ABU DHABI POLYMERS
COMPANY LTD IN RUWAIS, UNITED ARAB EMIRATES. TWO NEW ON-OFF VALVES WERE ADDED
TO EXISTING GAS FLUSHING LINES. THOUGH THE SYSTEMS AT THE FACILITY ARE COMPLEX, THE
STRESS ANALYSIS, TO ENSURE MECHANICAL INTEGRITY, WAS A FAIRLY STANDARD PROJECT.
Abu Dhabi Polymers Company Ltd is
the production entity of Borouge in
the Emirates. Borouge is a joint
venture between Abu Dhabi National
Oil Company (ADNOC) and Austria
based chemicals company Borealis.
The petrochemical production plant in
Ruwais, about 250 km west of Abu
Dhabi, is central to the company’s
operations.
and three production units provided
data on six different operational
cases - considering pressure,
temperature and wind conditions
- seeing that the stresses within the
system did not exceed set limits.
Borouge’s Project Manager Mr. Ali
Al-Shehhi was most helpful, ensuring
smooth progress of the project.
Commercially attractive
Operational flexibility
In the polyethylene facility, the new
valves were added to the gas flushing
lines connecting the outlet line of the
gas phase reactor to the batch outlet
vessel, to improve operational
flexibility. The challenge for Project
Manager Mr. Padmakumar Nair was
to find an accessible location for the
valves with minimum modifications to
the existing situation. Fortunately,
Tebodin has been involved in many
projects with Borouge in the past and
is well known with the plant and the
company’s requirements.
Mr. Nair: ‘We understand the client’s
requirement by frequently conducting
site visits and engaging in meetings on a
regular basis. Tebodin has performed a
number of complex stress analysis jobs
and is one of the leading consultants in
this area. Our proposal covered all
engineering aspects
clearly.
More info:
Mr. Srinivasan Mahalingam
Director Abu Dhabi, market unit
Chemicals, Oil & Gas
[email protected], +971 2 406 64 30
ASIA PACIFIC
China
Guangzhou Shanghai Nanjing
Tianjin India
Chennai Ahmedabad
Indonesia
Jakarta Vietnam
Ho Chi Minh City Hanoi Singapore
Malaysia
Kuala Lumpur
Thailand
Bangkok
Myanmar
Yangon
Tebodin‘s project team
THE CAR INDUSTRY HAS GONE TRULY GLOBAL. IN THE FAR EAST OF KAZAKHSTAN,
A NEW PRODUCTION PLANT IS BEING BUILT. FOR THE SEASONED DESIGN EXPERTS
AT TEBODIN IN CZECH REPUBLIC, THE VAST DISTANCE POSED NO PROBLEM AT ALL.
Made in Kazakhstan
Azia Avto started as an assembly plant
and quickly gained a reputation for
delivering quality. On May 2010, it
became a fully-fledged car factory,
producing cars from start to finish.
Numerous models of Lada, Skoda, KIA,
Chevrolet are now completely ‘made in
Kazakhstan’.
On a greenfield 180-hectare plot, the
company is building a new full-cycle
car production plant for the Lada Granta
and Lada Kalina. The plant is expected
to start producing in 2017 and will have
the flexibility to produce other brands
and models. ‘We worked the conceptual
design for three separate construction
phases, eventually resulting in a 300,000
m2 factory with 4,000 main production
employees’, says Tebodin Project
Manager Mr. Tomáš Perníček.
Car production specialists
01_ Mr. Tomas Pernicek from Tebodin
(left) and Mr. Dmitry Pavlov from
Azia Avto.
02_ 3D view of the future factory
01
AFRICA
Libya
Tripoli +31 70 348 09 11
+31 74 249 64 96
+31 50 520 95 55
+31 43 329 47 77
+31 40 265 22 22
+31 181 65 17 11
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+420 251 03 81 11
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02
WWW.TEBODIN.COM
Tebodin’s experience in the car industry,
which includes 65 years of cooperation
with Škoda Auto, is hard to match. The
Prague-based specialists in car
production technology were able to
complete the entire design, in
accordance with Kazakh standards, in
less than six months.
Mr. Pernícek: ‘In greenfield projects like
this, the process technology is usually
provided by the manufacturer. In this
case we started from scratch: plot,
infrastructure, utilities, building services
and process technology. The scope also
included the quality and production
control systems. We sent the
conceptual design to the client for
comments and approval within four
months. A great advantage in this
project is the fact that we are able to
work and communicate in Russian.
CENTRAL EUROPE
Poland
Warsaw Gdańsk Szczecin Poznań Cracow Czech Republic
Prague Pardubice Ostrava Hungary
Budapest Serbia
Belgrade Romania
Bucharest MIDDLE EAST
United Arab Emirates
Abu Dhabi Dubai Bahrain
Manama Qatar
Doha Oman
Muscat Sohar Saudi Arabia
Jeddah Serving the global car industry
Ust-Kamenogorsk, also known as
Öskemen, is the capital of East
Kazakhstan. Historically a mining and
metallurgical center, the city of 300,000
is home to the Azia Avto car factory.
The plant was state-founded in 2000
with the aim of creating a new industrial
cluster to serve the rising demand for
affordable cars in Central Asia.
NORTH WEST EUROPE
The Netherlands
The Hague Hengelo Groningen Maastricht Eindhoven Rotterdam Velsen Deventer Bergen op Zoom Belgium
Antwerp EASTERN EUROPE
Russia
Moscow Ekaterinburg Rostov-on-Don Ukraine
Kiev Lviv Stress analysis
Mr. Nair’s team provided detail
design, ensuring the mechanical
integrity of the system through stress
analysis. A model with twenty lines
CONTACT
no. 4 - October 2014
Colophon
Tebodin World - Tebodin‘s magazine is
published quarterly.
Editorial/design/production Public Relations
Department of Tebodin B.V., in cooperation
with The Freelance Connection, Jong Oranje
O-pen Coaching & Workshops, Back2Back,
Talig, Printing office De Eendracht and
Boulogne Jonkers Design.
Photography Tebodin employees
All the work was done in Czech
Republic, with call conferences as the
main means of communication.’
More info:
Mr. Jaromir Kriz
Area Director Central Europe
[email protected], +420 251 038 342
APP
Should you require more detailed information
concerning any of the subject matter in this
issue, please contact the PR Department via
[email protected]

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