“output optimization by applying smart process & system

2 | PPA 12-02-2015 | © Egemin International NV | www.egemin-automation.com

PPA 12-02-2015

Raymond Kamp

COMMERCIAL MANAGER

“Output optimization by applying smart

process & system integration solutions”


What is your business driver?

How do we support you?


Case

Revamp vapour treatment

system for (un)loading tank farms


Project descriptionRotterdam

Capable of receiving Ultra & Very Large

Crude Carriers (ULCC&VLCC’s)

Handling & Storage of fuel, oil and middle

distillates (K1, K2, K3, incl. methanol, naphtha

and jet fuel).

Number of tanks: 28 pcs

Storage capacity: 1,100,000 m³ +

Number of Jetty’s: 14 pcs


Challenges & Goals

(Un)loading activities

VLCC’s & ULCC’s

Barges & Vessels

Trucks & Trains

NATO pipeline

Hydro carbon handling

Recovery HC not viable

Combustion

Main project targets

Reduction Natural Gas consumption VTP (used for burners)

Improve Carbon footprint

Optimize existing operation

Improve HSE conditions


Two (2) Vapour Combustion Unit (VCU)

Gas Skid

Stack

One (1) Vapour Blower Unit (VBU)

1x Knock Out Drum

2x Vapour Blowers

Vapour Collection System (VCS)

Interconnecting piping

Jetties, tanks & units

Control equipment

Vapour Treatment Plant


Situation analysis

Approach

Very close cooperation Egemin - Client

Subcontractor involvement

VCU supplier for efficiency & reliability

Integrated project team

Existing situation

Operational philosophy

Automation functionality

Legislation

Define expectations


Deliverables

Process optimization

Hazop, P&ID’s, datasheets, calculations, ..

Functional Safety engineering

Functional design, Operator manual, ..

Software development

Electrical & Instrumentation

Testing

FAT, SAT & start-up

Documentation

Project management


Recognized improvements

Efficiency VCU

Too early start-ups

No stop in between 2 loading actions

Unclear protocol VTP

Unnecessary activated VTP

Pressure control system VBU

Incorrect set points blowers -> to much

vapour transferred to VCU

Portfolio management

When VTP activated for what

Unawareness vapour flow

No false air detection

Confidence level

VTP a Black box with local control

panel, no interface DCS

Limited communication

Poor alarm control vs management

Lack of information

No general overview VCS/VCU in CCR

Hardware

Incorrect valve selection tank pit vapour

collection lines

Existing VTP > Redefined, Refurbished & Automated


Well prepared > no surprises

Client & contractor

Mutually agreed timings and protocols

Properly documented

Thoroughly tested

Prior to implementation

“Shadow” control room in Gorinchem office

Short implementation time

Only one (1) day

Implementation


Less natural gas consumption

Reduced carbon footprint

(5%+ reduction)

Increased plant efficiency

(System availability now 95%+)

Improved HSE conditions

Client benefits


Case

Output increase by relocating

and redesigning production plant


Project description

Nestlé Nunspeet

Baby food products & semi manufactured products

Portfolio of specialty products like:

Lactose free baby food

Extensive Hydrolyzed Products (EHP)

Baby food for infants with milk protein allergy

Food supplements for prematurely born infants


Situation analysis

ApproachVery close cooperation Egemin - Nestle


Tank & component suppliers

Civil contractors

Integrated project team

Multiple existing production locations

(Global) Logistics

(Global) Operational flexibility

Present & future recipe's

Cleaning philosophy


Define expectations


Challenges & Goals

Expectations

Centralized production capacity

Single & dedicated EHP plant

Increase capacity

Comply to the strict FDA regulations

Export to US & related markets

Restrictions

Very little time available

Only a few short stops foreseen

No room for errors

Brownfield conditions

Priorities

Increase output

Safeguarding quality

Safeguarding continuity

Safeguarding budget


DeliverablesEPCM+M

Process & Software engineering

P&ID, 3D, FDS, …

PLC, SCADA, Batch and linking to MES


RIO’s, MCC, Wiring

Mechanical Installation

Interconnecting piping, Platforms

Testing

I/O-tests, FAT, SAT & stand-by in test

runs

Documentation & FDA validation

Project management

Maintenance


Details


EHP production Nunspeet trippled

Overall capacity increase with 13%

Track- & Traceability

FDA approval

Global sales

Client benefits


Case

Aseptic vs sterile formulation plant


Project description

Top 3 pharmaceutical company

Production birth control medicines

Typical batch processing


Situation analysis

ApproachJoint engineering (integrated) team


Process & product know-how combined

Cleaning & Sterilization philosophy


Formulation

Cleanroom conditions

Toxic ingredients

Define expectations


DeliverablesEPCM

Basic & conceptual design

Detail engineering (2D & 3D)

Process

Mechanical

Automation


Software development

Installation & assembling

Startup & Commissioning

Qualification (IQ/OQ/PQ)

Project management


Challenges & Goals

Capacity increase

Cleaning & Sterilization

Sterile powder filling isolator

In-line dosing system

Sterile powder transfer

Zero Exposure to toxic powders

Time constraints

Maintenance accessibility

Typical tailor made solution

http://intra.egemin.be/libraries/marketingcommunications/Pics1/Pfizer (63).jpg



Improvements to implement

Improved CIP/SIP process

Speed cooling/heating

Multiple objects

Vacuum-pulses & accelerated de-

aeration

Automated mobile vessels

Accelerated API powder dosing

Prevent Breakdown of API clusters




Now 5 batches per week (before 3)

Overall capacity increase

Only 18 months from PO > FA

(where 24 months = std)

Improved HSE conditions

Track- & Traceability

Client benefits


WHO IS EGEMIN AND WHAT DO WE DO?


Four divisions

HANDLING

AUTOMATION

LIFE

SCIENCES

PROCESS

AUTOMATION

INFRA

AUTOMATION


RECEIVING PRODUCTION CONDITIONING STORAGE DISTRIBUTION

SUPPLY CHAIN INTEGRATION

AU

TO

MA

TIO

N IN

TE

GR

AT

ION

Total supply chain solutions

Level 0

Level 1

Level 2

Level 3

Level 4

MES

BCS / PLC / SCADA

ERP

Connectivity with 3rd party systems


Conceptual design & Basic engineering

Detail engineering

Process Engineering

Mechanical design


Safety Engineering

Automation & Software development

Project Management

Mechanical installation

Start up & Commissioning

Process Control and Safeguarding Systems (BPCS/SIS)

Manufacturing Execution Systems (MES)

Process Control Security

Qualification (IQ/OQ/PQ) & Validation

Energy Management & Sustainability

Competences & Know How

Multi disciplinary

A

E & I

Mechanical

Civils

Cross divisional expertise

Sole automation

Turn-key / EPCM

Green field / Brown field


Our approach

Collaboration &

“Ontzorgen”


Questions ?

Thanks for your attention !!

Raymond Kamp - Commercial Manager

“output optimization by applying smart process & system

Documents