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- 1. Tebodin World 3 5 7Over 50 years of cooperation with Skoda Supervising EPC contractors in Seoul Supporting Lafarge’s worldwide presence April 2011, Volume 51, Edition 1 State of the art production of KitKat ® chocolates Nestlé Middle East intends to make this facility a base to manufacture a top-line product portfolio for the Middle East consumers as per their quality standards, safety and environmental best practices. The facility spreads over 35,000 square meters in Dubai’s most modern industrial area, Techno Park in Jebel Ali Free Zone. The first phase of the facility (milk powder production unit) is fully operational. The second phase includes construction of offices, production and logistics facilities for KitKat® products and is operational since October 2010. Tebodin Dubai was asked to review the structural and HVAC design. Tebodin reviewed the structural design for both phases in view of the local regulations and recommended modifications to be integrated into the design. HVAC works for the project are very critical and have an important impact on the quality of the product, including shelf life. To ensure the HVAC design’s compliance with international standards, Tebodin carried out the design review. Tebodin also assisted Nestlé in selection of equipment such as the cooling towers. Nestlé Project Manager Mr. Pierre Capelani appreciated Tebodin’s performance. After the initial phase of design reviews and tender evaluations for phase two, Tebodin was involved in construction management and site supervision for the project. Tebodin’s Project Manager Mr. Andre Piaskowski explained that ‘we are all extremely proud to be a reliable associate for Nestlé and this manufacturing facility, which incorporates state of art technology.’ Besides in Dubai, Nestlé is a client in countries such as the Netherlands, Russia, Hungary, Czech Republic, Dubai, Ukraine, Romania, South Africa, Nigeria and Vietnam. More info: Mr. Marco van der Linden Office Director Tebodin Dubai +971 4 221 58 39 l mvdlinden@tebodinme.ae Nestlé of Switzerland, the company famous for its KitKat® chocolates, is setting up its Middle East manufacturing facility in Dubai. Tebodin Dubai is providing them with the local technical expertise they need. Modernizing Russia’s largest paper mill Partnering with Cabot in China The reconstruction of the Syktyvkar paper mill is the largest investment in the Russian paper industry for over thirty years. Mondi Group is upgrading the mill’s technologies, labor safety, environmental standards and product quality. Tebodin took a significant role for technical inspection and control for civil works in this project. Mondi Group is an integrated packaging and business paper producer, located in 31 countries worldwide. The company was founded in South Africa and started a long period of international expansion in the early 1990s. Wood is the essential raw material for the production of pulp, the basic ingredient of all paper and paper-based packaging. In 2009 Mondi produced around 3.5 million tons of pulp, largely for internal use. The company leases and manages 2.1 million hectares of mostly softwood forests in Russia alone. Expansion plans Mondi Group acquired the Syktyvkar timber processing complex in 2002. Today the mill is the largest Mondi operates anywhere. ‘The plant specializes Due to growing demand for their products, Cabot Corporation, a successful multinational corporation in global performance materials has decided to increase their production capacity. Tebodin China is proud to be chosen as a partner for Cabot’s expansion plans in Tianjin, China. Tebodin was chosen to assist Cabot with the FEED (front-end engineering design) package to investigate the possibility and help in designing the process to boost the current capacity of the facility to meet the growing demand for their innovative performance materials in China and the rest of the world. Since Cabot has already partnered with Tebodin for their Rotterdam facility in the Netherlands, partnering with Tebodin in China was the new step in deepening this successful relationship. Tebodin will continually support Cabot in the development and growth of their business. More info: Mr. Wei Wei Country Director Tebodin China +86 21 52 56 95 22 l w.wei@tebodin.cn in office and offset paper, with Snegurochka as our most popular and awarded product line’, says Mondi Group project director Mr. Wolfgang Schubert. ‘Newsprint paper and cardboard is also made here. The mill supplies the markets of Russia, Middle East and Far East. This modernization is central to the Group’s future expansion plans.’ Since the start of the project, Tebodin has elaborated the design documentation prepared by the Swedish company Sweco Bloco, adapting it to Russian standards. Tebodin office director Mr. Stanislav Shapovalov at the St. Petersburg office: ‘We also provided procurement assistance in the search for Russian contractors for the civil works. Finally, we were responsible for the construction management, including on-site construction supervision for the civil works.’ Production increase The new Syktyvkar paper mill has increased lumbering from 3.2 to 4 million m3 per year. Pulp production grew by 25 percent to 900,000 tons per year. The modernization of two papermaking machines enabled the company to add 20 percent to the production of cardboard and paper products, to over a million tons per year. Mr. Shapovalov: ‘The project was successfully finalized and we are proud to have taken part in this major reconstruction project.’ More info: Mr. Andrey Sosnovsky Managing Director Tebodin Russia +7 495 258 80 58 l a.sosnovsky@tebodin.ru Mr. Wolfgang Schubert of Mondi Group The Tebodin project team The KitKat® production facility in Dubai
- 2. 2 A selection of our various current projects Currentprojects LocaltemperatureatprojectlocationinApril Tebodin World, April 2011 Maastricht University combines hospitality and research: test subjects stay in comfortable ‘respiration rooms’ while participating in nutrition and physical activity tests. Tebodin Maastricht is helping to relocate and upgrade these highly innovative rooms. The goal of the university’s respiration rooms is to measure the effects of food and exercise on human metabolism. What is measured is the change in air Full-scale restoration of the central railway station of Gdynia, Poland, is underway. Management and project supervision are in the hands of Tebodin Poland. Poland’s main railway operator Polskie Koleje Pa´nstwowe SA (PKP SA) initiated the thorough restoration of the station in August 2010, with the intention to complete the project before the opening ceremony of UEFA EURO 2012. Registered building The existing station was built on the location of the original railway building that was destroyed during World War composition as test subjects eat, exercise and breathe in a strictly controlled environment. This means that the rooms need to be absolutely airtight and perfectly balanced in terms of temperature and humidity. At the same time, they need to ‘breathe’ a welcoming atmosphere. Complex challenge Mr. Paul Schoffelen, project manager for Maastricht University: ‘This project for our Human Biology department is a complex one, which requires the input II. Pre-war fragments were discovered during the preparatory stages, which will be incorporated into the new interiors. They will serve as a ‘memory wall’ in the registered historic building. Safe and luxurious Plans for the future building include a re-opening of the second floor as additional waiting areas and a modernization of the ancient colonnade, which will contain commercial pavilions. The new station will offer a modern traveling environment with visual information systems, escalators, press of a specialized engineering company. The project involves relocating and fully renewing our respiration rooms, adding new respiration rooms and designing a new research area, all within the space of an existing building. Right from the start, Tebodin has proved a valuable partner. They have helped us fulfill our scientific mission above expectations.’ Fulfilling high ambitions A multi-disciplinary team from various departments of Tebodin Maastricht has worked closely with the client’s team at the design stage. Tebodin’s Mr. Jimmy Siauw: ‘The challenge was to integrate civil technical solutions and the client’s scientific goals in the building, with the intention of creating something that would be beyond state-of- the-art. In addition to the design contract, Maastricht University has awarded us the follow-up contracts to oversee construction and coordinate the implementation of a new fire alarm system.’ The initial design phase of this project started in 2009, in response to lack of space in the face of high scientific aspirations. The business partnership continues and construction is now scheduled for completion in May 2011. More info: Mr. Niek de Koning Office Director Tebodin Maastricht +31 43 329 47 77 l n.dekoning@tebodin.com kiosks, cafes and restaurants. Monitoring systems inside and outside the building will ensure passenger safety. The project is co-funded by the EU Cohesion Fund and implemented in accordance with FIDIC. More info: Mr. Maciej Gwó´zd´z Office Director Tebodin Gda´nsk +48 58 785 36 90 l m.gwozdz@tebodin.pl Breathing comfort in advanced research rooms Modernization with respect for history Construction of two gas-and-steam generation units for KGHM Polska Mied´z S.A. in Poland, in cooperation with consortium partner Energopomiar Scope: Contract Engineer function including performance of the supervision inspector services New pipe section line at the Stone Wool Manufacturing Plant in Novi Marof, Croatia, for Knauf Insulation. Joint project by Tebodin Hungary as the consultant, Tebodin Serbia as the technical consultant and Architekti Budanko i Witt-Doerring Scope: obtaining the building permit Assembly of BMW cars’ motors in Shenyang, China Scope: Project Construction Management (PCM) services Autonomous safety systems and a measuring station for a gas storage project in Slovakia Scope: basic design New hydro electrical power plant in the Netherlands Scope: electrical and instrumentation engineering services Extension of automotive parts assembly plant in China Scope: Project Management Consultancy Extending Nestlé’s instant coffee production capacity in Vietnam Scope: engineering services in mechanical and piping disciplines Two new laboratory and office buildings for Evonik Goldschmidt, Germany Scope: conceptual and basic design, cost estimating; complex architectural design, civil, building services, electrical engineering and the basic + detail engineering of the laboratory equipments 7° 13° 14° 10° 7° 14° 23° 8° C° Maastricht University Artist impression of the respiration rooms Mr. Jimmy Siauw
- 3. 3Tebodin World, April 2011 new framework agreement for piping engineering services, which include basic and detail engineering jobs in various sizes. In a port infrastructure project, recently completed to BASF’s full satisfaction, we engineered two new jetties with loading arms, modifications to an existing jetty, new piperacks, fire protection equipment and a new compressor building.’ Netherlands As part of a new framework contract in the Netherlands, Tebodin started work on adjustments to the chemicals unloading facilities at the BASF location in De Meern. Tebodin project manager Mr. Bouke Lases: ‘There are new environmental regulations and BASF wants to optimize the unloading logistics. We started with defining the loss of containment scenarios and a fire fighting strategy, together with BASF and the local authorities. When the conceptual design was finished, we were also awarded the detail design and tender management. All activities are executed in close cooperation with the BASF team, to ensure that the strengths of both organizations are combined. The project will be realized in the second and third quarter of this year.’ Bahrain Tebodin is also working for BASF in Bahrain. More information to follow in the next issue of World magazine. More info: Mr. Hans Kleiboer Director Corporate Business Development +31 70 348 09 11 l j.kleiboer@tebodin.com Mr. Bouke Lases Mr. Peter Bijkerk The excellent working relationship between Czech car maker Skoda Auto and Tebodin already spans more than half a century. We asked Mr. Lubomir Vasicky, head of the Construction Department at Skoda Auto, to tell us more about what really counts in quality-oriented cooperation. Skoda Auto, a member of Volkswagen Group, is a global player in fiercely competitive markets. The company has three production plants in the Czech Republic and also makes cars in Ukraine, Russia, Kazakhstan, India and China. Mr. Vasicky has been responsible for every Skoda Auto construction project since 1999. Strong growth With increasingly attractive models and a relentless commitment to quality, Skoda Auto has experienced strong growth over the past two decades. Mr. Vasicky: ‘We are a Czech company with well over a hundred years of tradition in automobile production. In fact, Skoda is one of the world’s oldest car brands. The core of our business is the development, production and sales of cars, components, original parts and accessories. Since we became part of Volkswagen Group twenty years ago, production more than tripled, Skoda truly went global and has built up a large sales and service network in highly developed markets.’ New models ‘We are market leader in Czech Republic and want to extend our strong position in each of the other countries’, Mr. Vasicky continues. ‘In terms of investment projects, the next few years will be crucial in achieving our goals. All construction activities have to be coordinated with great accuracy in order to avoid any clashes with ongoing production or any delays for new models.’ Mr. Vasicky is proud of the ‘Building of the Year’ awards that Skoda earned since he has been leading the Construction Department. ‘We have been working together with Tebodin Czech Republic and its predecessor for more than fifty years now. This cooperation includes conceptual planning and design, preliminary studies and analyses, procurement and construction management.’ International experience ‘Our business relationship is based on mutual trust and top quality’, Mr. Vasicky concludes. ‘Nevertheless, all assignments are awarded on the basis of open tenders. As Tebodin has been working with us for such a long time, they know many of our buildings like their own shoes. They are able to react very quickly to our requests with regard to structural adaptations and extensions, partly due to their archives of original documentation. Moreover, their wide range of specialists is very beneficial to Skoda, not only with regard to our technical requirements, but also because of our tight schedules and Tebodin’s international experience. For example, we successfully cooperated on the expansion of our assembly capacity in Aurangabad, India.’ More info: Mr. Jaromir Kriz Managing Director Tebodin Czech Republic +420 251 03 81 11 l j.kriz@tebodin.cz Over 50 years of cooperation with Skoda Dubai BASF Construction Chemicals is the producer of a range of admixtures, which enable concrete manufacturers to improve concrete strength and durability. ‘Tebodin was asked to provide BASF and the authorities with comprehensive studies regarding the project’s environmental, social, and health and safety aspects’, says project manager Mrs. Flordeliz Guarin. ‘Besides the plant itself, the new design comprised an administrative and laboratory building, engineering workshop, warehousing and transformer, water and sewage facilities.’ The Environmental Impact Assessment covered soil and groundwater, ecology, air and noise levels. Mrs. Guarin: ‘For the Risk Assessment we performed a preliminary hazard analysis that covered all substances, activities and processes. We made several recommendations to mitigate and decrease the risks to staff and surroundings. We also proposed some additional guidelines and monitoring plans which will enable continuous improvement in minimizing risks to the environment and health and safety.’ Germany In Schwarzheide you will find one of BASF’s larger production sites. The 230-hectare site, boasting 12 kilometers of road and 20 kilometers of rail, has become an attractive location for chemicals and plastics producers. BASF welcomes and supports newcomers at Schwarzheide, where it operates over 20 separate plants and state-of-the-art R&D facilities. Tebodin has been working for BASF Schwarzheide since 1992. A dedicated team, led by Mr. Reinhard Stieg and Mr. Torsten Biela, works on operative requirements every day. ‘We support BASF’s in-house engineering department and are responsible for planning capacity extensions and redevelopment projects’, says Mr. Stieg. ‘The framework contract covers the process, mechanical, piping and civil engineering. Our dedicated technical team has built up valuable experience with the facilities and specific BASF regulations.’ Belgium In the Port of Antwerp in Belgium, BASF operates more than 50 separate plants on a 600-hectare site. The integrated chemical production center is one of BASF’s flagship Verbund-sites. ‘The cooperation between Tebodin and BASF started in 2007’, says project manager Mr. Peter Bijkerk. ‘At the close of 2010, we entered into a Supporting global client BASF Tebodin is a trusted international project partner for BASF. In Dubai, Tebodin recently prepared the relocation of a concrete admixture plant. In both Belgium and Germany, the framework contracts between BASF and Tebodin were extended. In the Netherlands a new framework contract was signed, with the design for a new chemicals unloading facility as the first job. Mr. Torsten Biela (left) and Mr. Reinhard Stieg Mrs. Flordeliz Guarin Mr. Lubomir Vasicky in front of the Skoda assembly hall in Mlada Boleslav city, Czech Republic The Skoda assembly plant in Aurangabad, India
- 4. 4 Tebodin World, April 2011 Group produces fresh and frozen bread, pizza’s and bakery products, as well as eggs, egg products and animal feed. Through the years, Novelli Group has steadily expanded its activities and target markets. Owner Mr. Enzo Novelli has lots of specific know-how and experience in the processing of flour, flakes and extruded products. ‘I first started the development of a new pet food plant in 2002. The complete design of a new building and production line, involving special equipment, was developed with the help of Tebodin CCE. They are renowned independent experts.’ Double capacity The Tebodin consultants enjoy an international reputation as the most experienced and knowledgeable consultants in the agricultural and food industries. ‘We assist clients with in-depth process and logistical knowledge’, says Mr. Harm Klein, Tebodin project manager for the Novelli plant. ‘Pet food production in Terni started in 2009. Now Novelli intends to double capacity, and at the same time realize a strict separation between the animal feed and pet food process.’ Based on the latest process concepts, the new plant will produce 15 tons an Agro Industry An important market that Tebodin supports is the Agro Industry. Feed mills, pet food plants, premix plants, grain terminals and processing plants for agricultural produce, they’re all part of our field of activity. Tebodin has also gained a wealth of experience when it comes to the realization of laboratories for this sector or even complete R&D facilities. We support many well-known multinational agro industrial companies in the development of their assets worldwide.Our range of services go all the way from consultancy for concept selection, master planning, site due diligence and selection and Environmental Impact Assessment and permitting through to design & engineering, procurement and construction and project management. A wealth of ideas from everyone involved was used in the preparation of nine initiatives that aim to reduce overall costs on Dutch LOP projects by five percent. The LOP contract is a long-term agreement between client NAM and a partnership of Cofely, A. Hak and Tebodin, which includes new builds and renovations to NAM’s onshore oil and gas installations in the Netherlands. Focus on results Mr. Peter Janssen of Tebodin Hengelo: ‘We are now at the implementation stage of what we call the ‘LOP efficiency’ (LEF) project, which started in September 2009. We analyzed the input from within the organizations of all LOP partners Tebodin Maastricht has recently been awarded a contract by Medwaste Control. The contract contains the civil, structural and architectural basic and detail design for the erection of a medical waste decontamination unit. The unit is housed in an existing building at the ENCI premises in Maastricht, which will partly be transferred into a business area. The decontamination facility plant comprises offices, a canteen, several PGS15 storages and a decontamination unit. Medwaste, founded in 2006, specializes in packaging, transportation, sterilization and recycling of Medical Waste. Decontamination is a relatively recent development to effectively kill infectious and contagious germs in medical waste. After treatment the decontaminated medical waste fraction is transported to a waste disposal unit and incinerated. The decontamination unit in Maastricht is unique in the Netherlands and should be operational in September 2011. hour of high-quality dog and cat food for the Italian and international market. Mr. Klein: ‘The lines are a combination of readily available equipment and purpose-made installations, developed and built in Novelli’s own workshop. The full separation of raw materials, production, storage and loading of animal feed and pet food will be completed this year.’ Flexibility A new building houses the storage silos and the process lines for dosing, flaking, grinding and mixing. Flakes can be produced and delivered as a single product, or be supplied as a mixture together with extruded products. Mr. Klein: ‘The lines are designed in such a way that the process can easily and decided to focus on a series of nine initiatives we expected to be feasible and lead to results. These initiatives are in the fields of reporting, conducting meetings, project teams, procurement, scope control, agreements, using NAM standards and knowledge management. Examples are: combining consultation structures from separate contracts, reducing the amount of space taken up by site offices, combining project reports and critically considering who needs to attend a meeting.’ Workable plans After the partners identified the focus of their joint efforts, they worked out their plans in more detail. To ensure optimal practical feasibility, project leaders from current LOP projects were included in the ‘spotlight teams’. One of these was be applied to different final products. Production can take place just-in-time because of this flexibility and the large silo volumes. Smooth materials for floors, walls and roof ensure a working area clear of dirt and residues. This modern plant is able to produce the highest possible quality pet food.’ More info: Mr. Bert Frowijn Office Director Tebodin Deventer +31 570 63 89 00 l b.frowijn@tebodin.com Tebodin’s Mr. Rein Sieswerda: ‘The work required a good many hours on top of already busy schedules, and several very intensive phones off sessions away from the office. Over time, we have seen the rough ideas bloom into workable plans of action.’ Early success The first cost reductions have already been reported. Delegated ‘initiative owners’ are watching over the realization in actual LOP projects. Awareness of the initiatives is further supported by PR materials such as posters and regular news updates in the form of newsletters and the publication of cost saving results per project. More info: Mr. Rob Beeks Office Director Tebodin Hengelo +31 74 249 64 96 l r.beeks@tebodin.com Top quality pet food Down with costs for LOP partners Unique decontamination unit Mr. Harm Klein Mr. Peter Janssen The Novelli Group of Italy is building a new production line for pet food. The specific expertise of Tebodin CCE was called upon again to realize a process that meets all client demands. The Tebodin project team Mr. Enzo Novelli and Mr. Luigi Di Renzi of Novelli Group With a full range of services and an extensive knowledge network Tebodin assists clients in various market sectors: Industrial, Health & Nutrition, Utilities & Environment, Oil & Gas, Chemicals, Infrastructure, Property
- 5. 5Tebodin World, April 2011 Based in Waiblingen, Germany, Andreas Stihl sells its products through a network of 35,000 dealer- servicers. Besides an extensive range of chainsaws for both professionals and homeowners, Stihl also markets protective wear, garden equipment and hiking gear. ‘Our strong customer focus is reflected in the emphasis on service’, says Mr. Axel Overath at the Industrial Planning department in Waiblingen. ‘In many countries we have a training center, providing dealer and customer instruction on safe operation, maintenance and repair.’ Simultaneous extension and renovation The facilities in Sady, a village just outside Pozna´n, are becoming too cramped for the expanding business. The project scope covers a simultaneous extension and renovation of the Stihl premises. Tebodin project manager Mr. Kamil Kaniewski at the Pozna´n office: ‘The warehouse will be enlarged with almost 4,000 m2 of floor space, while the office and training space is gaining almost 550 m2. The project also includes a fire tank with pumping station, a special sprinkler system and the associated site infrastructure.’ Consistent high quality As predicted by Mr. Hans Peter Stihl from the Stihl Board of Directors after the festive Ukraine opening in 2010, Tebodin was made responsible for the project management. ‘The Tebodin knowledge network provides consistent high quality anywhere’, says Mr. Kaniewski. ‘We are also responsible for the investor’s supervision and cost control. The first phase, culminating in the selection of the general contractor, has been completed at the end of March. Then we continue with the challenging part, the extension and renovation without any real interruption of daily operations. The only free days are during the weekends. We also have special insurance-related requirements to deal with. This project is to be finished by the end of January 2012.’ More info: Mr. Robert Wojciechowski Office Director Tebodin Pozna´n +48 61 668 76 00 l r.wojciechowski@tebodin.pl Next to the more generic engineering capabilities we employ experts on core know-how to the business such as bulk handling, dosing, weighing, sieving, mixing, grinding, drying, pelleting and packaging. Furthermore, we know the guidelines and directives relevant to this sector like the back of our hand. In this way we help our clients to feed an ever growing world population. More info: Mr. Hans Kleiboer Director Corporate Business Development +31 70 348 09 11 l j.kleiboer@tebodin.com Expanding Polish warehouse and training center Andreas Stihl invented the mobile motorized chainsaw, as we know it today. He patented the first gasoline-powered and portable chainsaw, called the ‘tree-felling machine’, in 1929. Today Stihl manufactures a variety of handheld outdoor power equipment, with the chainsaw still being the centerpiece. The company continuously works on product innovation, holds over 1,000 patents and exports to more than 160 countries. In the United Arab Emirates, the growing economy and population are boosting demand for gasoline, diesel, and jet fuel. Abu Dhabi Refinery Company TAKREER is building a third refinery and upgrading the infrastructure to distribute and store the refined products. A new pipeline network of almost a thousand kilometers in length is to connect the refineries in Ruwais and Sas Al Nakhl with various storage terminals. Contract requirements Two South Korean companies, Daewoo and GS Engineering & Construction are awarded the EPC contracts for this 1 billon US$ project and the detail design is done in their Seoul headquarters. As explained by projects director Mr. Frits Boonen, Tebodin Middle East has provided project management services to TAKREER in a similar project. ‘Due to its successful execution, Tebodin Middle East was shortlisted to bid for this project. We have been made responsible for managing and supervising the FEED contractor and the EPC contractors. We need to ensure that their performance meets all contract requirements.’ Innovative fire fighting The project includes 37 new storage tanks and environmental protection measures, such as fire fighting and leak detection systems. Mr. Boonen: ‘Tebodin introduced a new concept called the Big Flow Foam System for fighting full tank top fires. Until now it was customary to pump out product as much as possible and then let the tank burn out, which leads to considerable damage and fires that often burn longer than two full days. New technology and modern foam agents can now extinguish a full tank top fire in four hours. TAKREER has decided to install Big Flow Foam Systems in all of their tank farms.’ Enjoying Korea The EPC phase started in May 2010 and project completion is expected in December 2013. ‘We currently have two project management teams stationed in Seoul, one at Daewoo and one at GS’, says Mr. Boonen, who enjoyed making his acquaintance with the South Korean capital. The Tebodin team, currently made up of 29 professionals, is definitely enjoying the work on this prestigious project.’ More info: Mr. Taco Boerstra Office Director Tebodin Abu Dhabi +971 2 406 60 00 l tboerstra@tebodinme.ae Supervising EPC contractors in Seoul Mr. Kamil Kaniewski Artist impression of the warehouse and training facilities From left: Mr. James Early, HSE Manager – Mr. Frits Boonen, Project Director – Mr. Erik Swanson, Construction Manager – Mr. Ashraf Gharbia, QA/QC Manager – Mr. Jamal Qasem, Civil Construction Superintendent PMC team for the main package of the Inter Refinery Pipelines project Two Korean companies are the EPC contractors for a large pipelines and oil terminals project in Abu Dhabi. Tebodin Middle East sent two teams to Seoul to manage and supervise the design process. Power tool manufacturer Andreas Stihl wants to expand and renovate its warehouse and training facilities in Poland. The project management went to Tebodin because of the excellent results in a similar project in Ukraine. PMC team for Mussafah terminal expansion package
- 6. 6 Tebodin World, April 2011 Rarely has a project been acquired in a more direct way than the SIKO project: ‘One of our employees, while travelling from a construction site, made a stop at a SIKO shop. A manager spotted the Tebodin logo on his car, hard-hat and safety vest and asked him for the contact,’ tells Tebodin project manager Mr. Ivo Kejnovský. Building partner SIKO was planning a brand new bathroom equipment and accessories store in Bratislava, Slovakia. SIKO also needed a storage hall to supply all Slovak SIKO stores in the future, and a partner like Tebodin, experienced in project management of the construction of commercial buildings. Tebodin Czech Republic entered the property market sector two years ago and is strengthening its position. SIKO was sufficiently The chance of accidents is lowered by risk-assessment, taking measures, and sticking to rules, regulations and permits. However, despite all precautions, calamities may occur, dropping the company into unknown territory that they had better prepare for. Out of your hands Mr. Jef Royen, Senior Consultant Safety and Risk Management at Tebodin Maastricht, helps companies face reality: ‘Calamities can not be prevented with absolute certainty and after a calamity, the situation is out of your hands. We saw this again recently after a major fire at a chemical storage complex in Moerdijk, the Netherlands. Immediately, operational management is taken over by outsiders. Production gets halted and other parties, on behalf of the government, will research the causes, question of blame, and direct and hidden damages.’ Assessment, measures and records Mr. Royen, with his experience, stresses the importance of correct record keeping: ‘During the research, high-quality records showing proper risk-assessment, application and maintenance of risk-reducing measures, and conscious adherence to regulations and permits are important - and actually required when European ordinances apply. In short, attention to risks, measures and correct records strengthen the position of the company significantly in case of a calamity. Tebodin can assist your company with a broad range of services, from any office in our worldwide network.’ More info: Mr. Niek de Koning Office Director Tebodin Maastricht +31 43 329 47 77 l n.dekoning@tebodin.com impressed to expand the initial ‘in-store’ contact into a full-blown partnership. Biggest chain SIKO Koupelny is currently the biggest Czech specialized chain, with 40 stores, 500 employees, 35,000 m² indoor warehousing and CZK 2.5 billion (100 million EUR) in annual revenues. For the new store and storage hall, Tebodin project manager Mr. Ivo Kejnovský and three colleagues took on project management, construction management, cost survey and change management. The project ran from February 2010 to February 2011. SIKO offers prospects for expanding the business partnership, with further activities planned in Czech Republic and Slovakia. More info: Mr. Jaromir Kriz Managing Director Tebodin Czech Republic +420 251 03 81 11 l j.kriz@tebodin.cz Energy company GDF Suez keeps enlarging its capacity for generating renewable energy. Tebodin is assisting GDF Suez Energy Poland in two projects. They involve the world’s largest biomass-only power plant and a 30 MW wind farm. Safety The energy provider, employing over 200,000 people worldwide, is increasingly active in renewable energy. GDF Suez already is the European leader in power generation from biomass and wants to become Poland’s biggest producer of renewable energy. Green Unit The French company is building the ‘Green Unit’ next to its 1,800 MW co-fired power plant in Połaniec. With a capacity of 190 MW, the Green Unit will burn wood and agricultural waste with a Circulating Fluidized Bed (CFB) boiler, the first of its kind in the world capable of burning biomass fuels only. This will bring a reduction in CO2 emissions by 1.2 million tons per year. Bringing the Green Unit into full operation by December 2012 requires several adaptations to other installations. The Warsaw and Kraków offices of Tebodin Poland were awarded a multi-year contract for the supervision of the electrical works, consultancy services and detailed design of biomass storage and transport. Wind power Apart from biomass incinerators, GDF Suez is also developing wind power. The company’s first 20 MW wind farm is under operation in Jarogniew- Moltowo and several other projects are in the pipeline. Most Polish wind farms can be found in the northwest of the country, along the Baltic coast. ‘We are building a new complex of fifteen wind turbines with a combined capacity of 30 MW’, says GDF Suez project manager Mr. Wojtek Wieclaweck Sierota. ‘It is currently our biggest wind energy project in Eastern Europe. Due to their experience with wind power and tight project management, we have asked Tebodin Poland to perform the Owner’s Engineer services.’ Owner’s Engineer ‘We are proud of this assignment’ says Tebodin project manager Mr. Andrzej Matyja at the Szczecin office. ‘As the Owner’s Engineer under international FIDIC standards, we are responsible for the selection of contractors, verifying the detailed design, cost management and procurement for the turbine delivery and installation. We also do the overall project management, technical supervision and the commissioning phase. The project is to be completed by the end of 2011, after which we will manage the guarantee period. We hope to be involved in future GDF Suez wind energy projects.’ More info: Mrs. Ewa Porada-Spieszny Office Director Tebodin Szczecin +48 91 454 21 36 l e.porada@tebodin.pl Chance meeting leads to construction project Prepare to get through calamities Investing in green energy From left: Mr. Ondrˇej Buriánek (Tebodin), Mr. Tomáš Stanovský (SIKO), Mr. Ivo Kejnovský (Tebodin) The SIKO construction site in Bratislava, Slovakia Mr. Jef Royen
- 7. 7Tebodin World, April 2011 World leader in building materials Lafarge is world leader in cement, number 2 in aggregates and number 3 in concrete and gypsum. From its headquarters in Paris, France, Lafarge has been operating in Russia for almost 15 years. The company has a cooperation agreement with the European Bank for Reconstruction and Development (EBRD) which supports Lafarge’s growth in Russia. Lafarge Cement Russia currently BREEAM (the British Research Establishment Environmental Assessment Method) provides a practical and measurable framework for sustainable design, construction, operation and maintenance all kinds of new buildings and renovations. Tebodin is applying its expertise to its first BREEAM project in the Netherlands. The three-day Industrial Biotech World 2011 conference was recently held in Amsterdam, the Netherlands. The event focused on the next steps in applying biotechnology on an industrial scale. Developing and upscaling the biorefinery industry is vital to make the move towards a bio- based economy. Biotechnology offers enormous opportunities, not just for the economy, but equally to our environment and to our society. Chemical and biotechnological companies are exploring nature’s treasure chest in owns and operates two plants in Russia, Voskresensk 120 km southeast of Moscow and Korkino, 40 km south of Chelyabinsk in the Urals, the industrial heartland of Russia. A significant challenge The first new project of Lafarge in Russia, in cooperation with EBRD, will be a modern dry line cement plant at Ferzikovo in Kaluga region, with a ‘Excellent’ renovation in the Netherlands Mrs. Kitty Eegerdingk of Tebodin Netherlands relates: ‘Monarch’ is the name of an office building in the city of The Hague that is to be one-hundred percent renovated. BAM Techniek obtained the design and built contract for ‘Monarch’ for all building installations. They called in the support of our expertise for the deliverance of evidence for the BREEAM certificate ‘Excellent’ at the end of December 2011.’ ‘One specific task, among others, is the appointment of a Commissioning Authority. Tebodin Eindhoven has the expert with the appropriate education and skills to perform this role, in the person of Mr. Marco Vink. According a commissioning plan he will lead a commissioning team and makes sure all stated requirements will be guarded during the design, realization and users phase.’ Other offices within the Tebodin network have experience with LEED and BREEAM projects as well, such as Poland and Serbia. Don’t hesitate to contact any office for more information. search of methods to replace petroleum- based synthetics. In what is known as ‘white biotechnology’ for example, enzymes and living cells are used to synthesize products that are degradable, and sometimes require less energy and create less waste during production. Event sponsor There are still many big challenges in this field, and plenty of topics for lively discussions. As one of the event’s sponsors, Tebodin was also involved as a ‘content provider’. According to project engineer Remko Dur, Tebodin participated in presentations, networking sessions and panel discussions. ‘It was an international gathering of key players in production capacity of two million tons a year. This greenfield project represents a breakthrough in Russia in terms of energy efficiency, safety performance and minimized environmental impact. Lafarge also plans to make use of renewable energy sources at this plant. The construction process has started recently and the plant is expected to be operational in 2014. Tebodin and Lafarge: a proven partnership Tebodin became General Designer of Lafarge’s Ferzikovo greenfield project; responsible for complete engineering, including basic design, detail design validation and development, procurement services, author and technical supervision, safety supervision, start-up and commissioning. The new cement production line will have a capacity of 5,000 tons of clinker per day. The scope of the project is huge, and the schedule and specifics are challenging. For example, the plant will have a long belt conveyor across the river Oka, spanning 240 meters between its supports. For this project, Tebodin Russia has formed a consortium with Tebodin Ukraine and the scope is split between the two countries. With its extensive global network, Tebodin can truly always be close to such global clients and their projects. Besides Russia, Lafarge is a client in countries such as Ukraine, Romania, Russia and Poland. More info: Mr. Andrey Sosnovsky Managing Director Tebodin Russia +7 495 258 80 58 l a.sosnovsky@tebodin.ru biotechnology, including developers, scientists and chemical companies such as DSM, Akzo, Dow and Dupont, as well as government representatives.’ New processes and partnerships With an expected global turnover of $375 billion in 2013, compared to $175 billion in 2010, the business potential of industrial biotech is clear. Remko: ‘An important topic was the shift and future focus on the pharmaceutical, food & feed, bioplastics and fine chemicals sectors, before moving on to bulk chemicals and biofuels, for we currently only see a focus on biofuels and biomass to energy. We also discussed second-generation biotechnical production processes with new enzymes, acids and up- downstream processes, biofuels, feedstock locations and its logistics. Significant industrial developments can now be expected as large companies are working on new processes, often in partnerships with small pioneering developers. We look back on a successful event for Tebodin, both in terms of knowledge exchange and from a marketing and PR perspective.’ More info: Mr. Rob Kwakkelstein Office Director Tebodin The Hague +31 70 348 09 11 l r.kwakkelstein@tebodin.com Supporting Lafarge’s worldwide presence First BREEAM project in the Netherlands Industrial Biotech World 2011 Mr. Marco Vink (Tebodin, left), and Mr. Nick Blijlevens (BAM Techniek region West). Mr. Remko Dur Mr. Reinout Holland (Tebodin) during the panel discussion Lafarge plants are about as big as they get – they have to be, for the world leader in building materials. This huge company experiences the full advantages of Tebodin’s global network. More info: Mr. John Horn l Office Director Tebodin Eindhoven l +31 40 265 22 22 l j.horn@tebodin.com Clockwise, starting from left: Mr. Pierre Ozimina (Lafarge), Mr. Roman Golubev, (Lafarge), Ms. Alexandra Volegova, (Tebodin Russia), Mr. Oleg Bas (Tebodin Ukraine)
- 8. 8 C O L O P H O N Tebodin World, April 2011 Western Europe The Netherlands The Hague +31 70 348 09 11 Hengelo +31 74 249 64 96 Groningen +31 50 520 95 55 Maastricht +31 43 329 47 77 Eindhoven +31 40 265 22 22 Rotterdam +31 181 65 17 11 Velsen +31 251 26 24 64 Deventer +31 570 63 89 00 Bergen op Zoom +31 164 21 60 00 Belgium Antwerp +32 3 250 28 01 Germany Gelsenkirchen +49 209 170 90 0 Schwarzheide +49 35752 94 80 0 Central Europe Poland Warsaw +48 22 33 44 111 Gdan´sk +48 58 785 36 90 Szczecin +48 91 454 21 36 Poznan´ +48 61 668 76 00 Katowice +48 32 782 59 99 Cracow +48 12 295 24 50 Czech Republic Prague +420 251 03 81 11 Pardubice +420 466 05 36 11 Ostrava +420 591 001 591 Slovak Republic Bratislava +421 232 66 02 00 Kosˇice +421 55 685 40 87 Hungary Budapest +36 1 205 96 01 Szeged +36 62 429 738 South Eastern Europe Serbia Belgrade +381 11 313 24 65 Romania Bucharest +40 21 311 71 86 Eastern Europe Russia Moscow +7 495 258 80 58 St. Petersburg +7 812 718 37 80 Ekaterinburg +7 343 344 37 70 Rostov +7 863 240 14 70 Ukraine Kiev +380 44 481 21 21 Lviv +380 32 242 14 31 Kharkiv +380 57 728 12 88 Middle East United Arab Emirates Abu Dhabi +971 2 406 60 00 Dubai +971 4 221 58 39 Bahrain Manama +973 17 70 05 44 Qatar Doha +974 44 67 56 54 Oman Muscat +968 24 62 80 00 Sohar +968 99 65 14 49 Saudi Arabia Jeddah +966 2 669 55 95 Asia China Guangzhou +86 20 83 63 60 20 Shanghai +86 21 52 56 95 22 India Chennai +91 44 434 03 200 Vietnam Ho Chi Minh City +84 8 38 21 76 55 Africa Libya Tripoli +218 21 334 03 50 See our website for the latest information on offices and addresses. WWW.TEBODIN.COM no. 1 - April 2011 Tebodin World - Tebodin Consultants & Engineers house journal is published quarterly. Editorial/design/production Public Relations Department of Tebodin B.V., in cooperation with The Freelance Connection, O-pen Coaching & Workshops, Talig, Printing office De Eendracht and The Attic - Graphics Studio. Photography Tebodin employees. Should you require more detailed information concerning any of the subject matter in this issue, please contact the nearest Tebodin office or the PR Department via info@tebodin.com. Appointments New at Tebodin! As per 1 April 2011 Mr. Dennis Brand has joined Tebodin as Office Director for Velsen, the Netherlands. Mr. André van Drunen has been appointed Managing Director of Tebodin Middle East & India as of 1 April 2011, next to Mr. Jack Overkamp. Mr. Rob Beeks has been appointed Office Director Hengelo, the Netherlands, as of 1 March 2011. As of 15 February Mr. Mariusz Szmyd has been appointed Director Cluster South-West Poland. As per 1 February 2011 Mr. Robert Wojciechowski has started as Office Director Poznan, Poland. As of 1 January 2011 Mr. Jeroen Schouten has been appointed Office Director Gelsenkirchen, Germany. As of 1 February 2011 Mr. Auke de Leeuw, has been appointed Office Director Groningen, the Netherlands. Mr. Andrey Sosnovsky has been appointed Area Director of Tebodin Eastern Europe, presently consisting of our operations in Russia and Ukraine, as of 1 February 2011. As per 1 February 2011 Mr. Valery Levko has been appointed Country Director of Tebodin Ukraine next to his position as Office Director Tebodin Kiev. As of 1 January 2011 Mr. Károly Ecker has been appointed Office Director Tebodin Serbia, next to his position of Office Director Tebodin Hungary Kft. Mr. John Horn has been appointed Office Director Eindhoven, the Netherlands, as of 1 January 2011. As of 9 February 2011 Messrs. Niels van Rhenen (left) and Mark Vossen (below left) have been appointed Managing Directors of Tebodin Germany, next to their positions as Managing Directors of the Netherlands and Belgium. Between early Summer and Christmas of 2010, Tebodin assisted Zeolyst in modifying their chemical installation at Delfzijlto be able to test a new product. In that short time span, Tebodin also managed to implement a new control and safeguarding philosophy. Significant modifications Zeolyst CV produces a wide variety of zeolites-based catalysts at facilities in Kansas, the United States, and Delfzijl, the Netherlands. One of Zeolyst’s catalytic products enables diesel fueled trucks to meet EURO-6 emission requirements per 2013 as dictated by European legislation. To meet market demand for this product, they aimed to raise production capacity in Delfzijl, requiring significant modification of the installations. Intense cooperation Zeolyst chose Tebodin because of its known expertise in concept selection, judging environmental impact and permitting requirements, and its ability to quickly screen the market for suitable vendors. Because of a tight project schedule the exhaust gas treatment installation was ordered before the complete process design was frozen. Tebodin, with project manager Mr. Erik Eppinga, was responsible for overall project management, permits application, and civil, mechanical and process design for both basic and detailed design. Furthermore, a major change in the reactor required a new control and safeguarding philosophy. To ensure a safe design Tebodin conducted a Tebodin newsletter Besides this paper version of our magazine, we are offering you a bi-monthly newsletter as well. It will contain news items about our markets, our services, our projects, market developments and other business related topics. Did you recently receive our first version? If not, visit www.tebodin.com and sign up. We hope you will enjoy this initiative. HAZOP study and a fire and explosion risk assessment, also indicating safeguarding measures. New production line All work was executed in intense cooperation with Zeolyst, which provided part of the engineering capabilities themselves. Plant manager Mr. Jos Leuveld monitored the multidisciplinary Zeolyst-Tebodin project team: ‘With this project, Zeolyst CV entered a new area, handling combustible materials in our calciner. To assure the development of a safe and efficient process, we needed support of consultants with expertise in this area. Tebodin supplied this.’ After a successful test period Zeolyst intends to build a new production line in Delfzijl. More info: Mr. Auke de Leeuw Office Director Tebodin Groningen +31 50 520 95 55 l a.deleeuw@tebodin.com A catalyst for change at Zeolyst Mr. Henk Jan Veenhuis (left) and Mr. Marco Snelten New exhaust treatment system: a regenerative thermal oxidizer. This apparatus burns volatile organic compounds (VOC’s) with a high energy efficiency.