Output optimization by applying smart process & system integration solutions

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2 Output optimization by applying smart process & system integration solutions PPA Raymond Kamp COMMERCIAL MANAGER 2 PPA Egemin International NV

3 What is your business driver? How do we support you? 3 PPA Egemin International NV

4 Case Revamp vapour treatment system for (un)loading tank farms 4 PPA Egemin International NV

5 Project description Rotterdam 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 5 PPA Egemin International NV

6 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 6 PPA Egemin International NV

7 Vapour Treatment Plant 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 7 PPA Egemin International NV

8 Approach Very close cooperation Egemin - Client Subcontractor involvement VCU supplier for efficiency & reliability Integrated project team Situation analysis Existing situation Operational philosophy Automation functionality Legislation Define expectations 8 PPA Egemin International NV

9 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 9 PPA Egemin International NV

10 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 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 No false air detection Existing VTP > Redefined, Refurbished & Automated 10 PPA Egemin International NV

11 Implementation 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 11 PPA Egemin International NV

12 Client benefits Less natural gas consumption Reduced carbon footprint (5%+ reduction) Increased plant efficiency (System availability now 95%+) Improved HSE conditions 12 PPA Egemin International NV

13 Case Output increase by relocating and redesigning production plant 13 PPA Egemin International NV

14 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 14 PPA Egemin International NV

15 Situation analysis Multiple existing production locations (Global) Logistics (Global) Operational flexibility Present & future recipe's Cleaning philosophy Automation functionality Define expectations Approach Very close cooperation Egemin - Nestle Subcontractor involvement Tank & component suppliers Civil contractors Integrated project team 15 PPA Egemin International NV

16 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 16 PPA Egemin International NV

17 Deliverables EPCM+M Process & Software engineering P&ID, 3D, FDS, PLC, SCADA, Batch and linking to MES Electrical & Instrumentation 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 17 PPA Egemin International NV

18 Details 18 PPA Egemin International NV

19 Client benefits EHP production Nunspeet trippled Overall capacity increase with 13% Track- & Traceability FDA approval Global sales 19 PPA Egemin International NV

20 Case Aseptic vs sterile formulation plant 20 PPA Egemin International NV

21 Project description Top 3 pharmaceutical company Production birth control medicines Typical batch processing 21 PPA Egemin International NV

22 Situation analysis Cleaning & Sterilization philosophy Automation functionality Formulation Cleanroom conditions Toxic ingredients Define expectations Approach Joint engineering (integrated) team Subcontractor involvement Process & product know-how combined 22 PPA Egemin International NV

23 Deliverables EPCM Basic & conceptual design Detail engineering (2D & 3D) Process Mechanical Automation Electrical & Instrumentation Software development Installation & assembling Startup & Commissioning Qualification (IQ/OQ/PQ) Project management 23 PPA Egemin International NV

24 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 24 PPA Egemin International NV

25 Improvements to implement Improved CIP/SIP process Speed cooling/heating Multiple objects Vacuum-pulses & accelerated deaeration Automated mobile vessels Accelerated API powder dosing Prevent Breakdown of API clusters 25 PPA Egemin International NV

26 Client benefits 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 26 PPA Egemin International NV

27 WHO IS EGEMIN AND WHAT DO WE DO? 27 PPA Egemin International NV

28 Four divisions HANDLING LIFE PROCESS INFRA AUTOMATION SCIENCES AUTOMATION AUTOMATION 28 PPA Egemin International NV

29 Total supply chain solutions Connectivity with 3 rd party systems ERP MES BCS / PLC / SCADA AUTOMATION INTEGRATION Level 4 Level 3 Level 2 Level 1 RECEIVING PRODUCTION CONDITIONING STORAGE DISTRIBUTION SUPPLY CHAIN INTEGRATION Level 0 29 PPA Egemin International NV

30 Competences & Know How Conceptual design & Basic engineering Detail engineering Process Engineering Mechanical design Electrical & Instrumentation 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 Multi disciplinary A E & I Mechanical Civils Cross divisional expertise Sole automation Turn-key / EPCM Green field / Brown field 30 PPA Egemin International NV

31 Our approach Collaboration & Ontzorgen 31 PPA Egemin International NV

32 32 PPA Egemin International NV Questions? Thanks for your attention!! Raymond Kamp - Commercial Manager