PROZAP Sp. z o.o. - Company Presentationprozap.com.pl/wp-content/uploads/2019/03/PROZAP-Presentation.pdf · PKN ORLEN S.A., Płock, Poland Scope of work • Basic Design • Civil

50 years of experience in design and execution

of 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:

over 10 years

• Customer oriented, tailored engineering services

PROZAP Sp. z o.o.

al. Tysiaclecia P.P. 13

24-110 Puławy, Poland

[email protected]

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

of 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

of 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

of 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

of 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

of 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


• HAZOP Study


• Procurement

• Supervision + Training


• 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



• 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

of 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


• Process Manual

• Procurement management

• Concept of integration of the

new plant with existing units

on 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


• 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


• Tendering procedures for purchasing

• Detail Engineering and tank registration files



• Process Manual


• 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



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

obtain 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


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,


• 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


• 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


• 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,


• Tender and contracting procedures for both parts,


• As-built documentation of the storage area.


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


• Tendering procedures for purchasing including

technical attachments to contracts




Dry salt plant capacity increase

Soda Polska CIECH, Janikowo, 2016

Scope of work

Thank you

Documents

PROZAP Sp. z o.o. - Company Presentationprozap.com.pl/wp-content/uploads/2019/03/PROZAP-Presentation.pdf · PKN ORLEN S.A., Płock, Poland Scope of work • Basic Design • Civil