3D MODELLING FOR BEHN MEYER

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PHARMA PLANT EXTENSION FOR ASPEN

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‘TEAMING‘ IN DYNAMIC PHARMACEUTICAL MARKET

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OCTOBER 2014 / VOLUME 56 EDITION 4

WE MAKEIDEAS

WORK

DELTA focuses on energy efficiency

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.

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

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.

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

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

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.

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 b.erkens@tebodin.com, +31 181 65 17 07

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

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‘Joint Venture of the year’ award for 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 skindy@tebodin.co.om, +968 246 280 00

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).

OCTOBER 2014 / PAGE 2

Several major upgrades of power facilities for chemical clients for/with Ritter Starkstromtechnik in the NetherlandsScope: Detailed engineering and consultancy services

A SELECTION OF OUR VARIOUS

CURRENT PROJECTS

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

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.

Development of OSII platform including subsea pipeline and composite cable for Bunduq in Abu DhabiScope: Project Management Consultancy

Demolition cost analysis for Nuon

‚s power plants

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.

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.

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.

Stack of Nuon's Combined Cycle Gas Turbine (CCGT) in Purmerend, the Netherlands

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

Remarkable projects

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

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.

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 mstovpnik@tebodinme.ae, +971 456 72 700

‘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.

More than 30 years in Dubai

Tabreed’s current cooling plant

More info:Mr. Björn Erkens Director Netherlands West b.erkens@tebodin.com, +31 181 65 17 07

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OCTOBER 2014 / PAGE 3

3D modelling for Behn Meyer

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.’

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. .

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.

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

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 ronald.de.vries@tebodin.com, +65 929 79 27501_ Representatives of Behn Meyer and Tebodin at the groundbreaking ceremony

02_ 3D view of Behn Meyer‘s warehouse and office building

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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

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 WolterinkDirector Project Improvementjan.klein.wolterink@tebodin.com+31 70 348 18 17

Partnering on plant extension

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.

Stress analysis

Tebodin’s team, headed by Project Manager, Mr. Janusz Iwanowski, consists of nine engineers from many

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.

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 trouble-free 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 pressure-temperature profiles, will include 3D FEA (Finite Elements Analysis).

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 Hrabř Managing Director Poland j.hrabe@tebodin.pl, +48 22 334 43 11

Mr. Janusz Iwanowski

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.

Moving towards projects improvement

OCTOBER 2014 / PAGE 4

Global framework contract with Syngenta

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 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.

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

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.

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.

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).

Combine harvester in barley

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 DurCorporate Business Developmentr.dur@tebodin.com, +31 70 348 03 09

Supporting methanol production in OmanOffice Ahmedabad: Booming with quality

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,

‘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.’

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 ondrej.sterbak@tebodin.com +91 794 06 06 100

OCTOBER 2014 / PAGE 5

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‘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.

Supporting methanol production in Oman

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 two-column 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.’

More info:Mr. Salim Al Kindy Managing Director Oman skindy@tebodin.co.om +968 246 280 00

‘Hot’ plant reconstruction

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.

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.

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.

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.

Completion of the project is expected in September 2015.

More info:Mr. Jaromir Kriz Area Director Central Europe j.kriz@tebodin.cz, +420 251 038 342

Pharma plant extension for Aspen

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.

55 outsiders on site

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

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

Safety (EHS) plan, a blue print for construction sites, based on Tebodin’s EHS plan.

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’.

High level of cooperation

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 j.horn@tebodin.com, +31 40 265 21 74

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

Transportation of boiler pressure unit K4.1 to the boiler room

OCTOBER 2014 / PAGE 6

Investing in hygiene for profit and peace of mind

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

real eye-openers, and our clients mostly draw their own conclusions without us making specific recommendations.’

More info:Mr. Lou Dostř Office Director Deventer a.i. l.dost@tebodin.com, +31 50 520 95 66

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.

cabling ducts can become racetracks for mice, to name just one example.’

Eye-openers

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

Abu Dhabi commits to the H in QOHSE

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 HasanDirector Projects and Construction Management, Abu Dhabisyedamir@tebodinme.ae, +971 2 406 63 70

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.

‘Teaming‚ in dynamic pharmaceutical market

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

‘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.

cultures to a new way of working, with teaming. Teaming is using fluid groups of experts, from different backgrounds and places,

Participants of the Global Pharmaceutical Program in China

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.

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

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.’

More info:Mr. Niek de Koning Director Global Pharmaceutical Projectsn.dekoning@tebodin.com, +31 43 329 47 03

OCTOBER 2014 / PAGE 7

alw

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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• Feasibility studies• Integrity research• Strength and permit calculations

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 KleiboerDirector Corporate Business Developmenth.kleiboer@tebodin.com | +31 70 348 04 89

Industrial, Energy & Environment, Infrastructure, Health & Nutrition, Chemicals, Oil & Gas, Property

Pipelines

NAM, Sappermeer to Norg, the Netherlands

PDO, Oman

Transco, Abu Dhabi

• Hydraulic and hear loss calculations• Water hammer analysis• Pipelines integrity management• Crossings

Value engineering gets APAG’s high-tech plant on budget

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

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

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%.

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.’

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 j.kriz@tebodin.cz, +420 251 038 342

01_ Greenfield area 02_ Mr. Vlastimil Hrouda, Tebodin‘s

project manager

01

02

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

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 wei.wei@tebodin.com, +86 21 2309 9966

Tebodin‘s project team

APPOINTMENTS CONTACT

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ASIA PACIFICChina Guangzhou +86 20 8363 6020Shanghai +86 21 2309 9966Nanjing +86 25 5703 2522Tianjin +86 22 5830 8220India Chennai +91 44 434 03 200Ahmedabad +91 794 06 06 100Indonesia Jakarta +62 21 29 40 68 40Vietnam Ho Chi Minh City +84 8 39 90 69 93Hanoi +84 4 39 74 97 02Singapore +65 6316 2281Malaysia Kuala Lumpur +603 2161 4881Thailand Bangkok +662 634 4422MyanmarYangon +951 441 3410

AFRICALibya Tripoli +218 21 334 03 50

WWW.TEBODIN.COM

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

Should you require more detailed information concerning any of the subject matter in this issue, please contact the PR Department via info@tebodin.com.

APP

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.

OCTOBER 2014 / PAGE 8

A smooth stress analysis for Borouge in Ruwais

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.

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.

Stress analysis

Mr. Nair’s team provided detail design, ensuring the mechanical integrity of the system through stress analysis. A model with twenty lines

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.

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 msriniva@tebodinme.ae, +971 2 406 64 30

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.

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 Pernířek.

Car production specialists

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.

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.

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 j.kriz@tebodin.cz, +420 251 038 342

01_ Mr. Tomas Pernicek from Tebodin (left) and Mr. Dmitry Pavlov from Azia Avto.

02_ 3D view of the future factory

02

01

Tebodin‘s project team

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

Mr. Nair: ‘We understand the client’s requirement by frequently conducting