Founded 1991 - SODACONSULTsodaconsult.com/wp-content/uploads/2016/03/Cooperation-Proposal.pdf · Founded 1991 BIURO: ul. F. Konecznego 8/8u, 31 - 216 Kraków, Polska, tel. ... Bentley

Founded 1991

BIURO: ul. F. Konecznego 8/8u, 31 - 216 Kraków, Polska, tel.(+48 12) 416 55 05, fax:420 62 61; NIP 677-004-75-55

e-mail: [email protected] ; http: www.sodaconsult.com 1/25 str. 1/1

SCOPE OF

ACTIVITIES:

CHEMISTRY

INORGANIC

TECHNOLOGY

PRE-DESIGN STUDIES • Location study

• Feasibility study

• Environmental study

PROCESS DESIGNS

EQUIPMENT BIDDING

BASIC ENGINEERING PACKAGES

DETAIL ENGINEERING DESIGNS

• Plant Design & Piping

• Instrumentation & Control

• Checking local engineering

• Assistance at equipment

procurement

FABRICATED EQUIPMENT MECHANICAL DRAWINGS

STAFF TRAINING PROGRAMS

INSTRUCTIONS & MANUALS

• Start-up

• Operation

• Maintenance

SUPERVISION SERVICES • Erection

• Putting into operation

• Conducting guarantee tests

ASSISTANCE AT INDUSTRIAL RUN

PROCESS CONSULTING

TECHNICAL AUDITS

– Confidential –

GENERAL COOPERATION PROPOSAL

on Soda Ash Project preparation & implementation

Contents

1. SODACONSULT IN BRIEF

2. FIELDS OF COOPERATION 2.1 Soda Ash & by-Products production processes 2.1.1 Soda Ash production process 2.1.2 Technology of Soda Ash & by-Products 2.1.3 Scope of Soda Ash Project in B.L. – example

2.2 Unit processes & operations 2.2.1 LSA production 2.2.2 DSA production (monohydrated) 2.2.3 DSA production (compacted) 2.2.4 BIC production 2.2.5 Environmental protection aspects

2.3 Unit operations 2.3.1 Material conveying systems 2.3.2 Dedusting systems 2.3.3 Drying systems 2.3.4 Crushing & screening 2.3.5 Storing & packaging 2.3.6 Silos and shipment

2.4 Mechanical designs of fabricated equipment 2.4.1 Key column apparatuses 2.4.2 Big rotary equipment 2.4.3 Bins & storage silos for bulk materials 2.4.4 Tanks for process solutions 2.4.5 Pressure vessels

3. OFFERED DESIGN ENGINEERING & SERVICES 3.1 Stages of documentation preparation 3.2 Equipment bidding & contracting procedure 3.3 Used software tools 3.4 Scope of documentation & services 3.4.1 PRE-DESIGN STUDIES (P-DS) 3.4.2 BASIC ENGINEERING PACKAGE (BEP) 3.4.3 DETAIL ENGINEERING & DESIGN (DED) 3.4.4 SUPERVISION SERVICES 3.4.5 OPERATIONAL ASSISTANCE

mailto:[email protected]

http://www.sodaconsult.com/

General Cooperation Proposal AS-572.100 2/25

Consulting & Engineering Office

4. COOPERATION WITH LOCAL ENGINEERING COMPANIES 4.1 General assumptions 4.1.1 Introduction 4.1.2 Pre-design Studies 4.1.3 Basic Engineering Package 4.1.4 Detail Engineering 4.1.5 Exemplary list of the Project Units / Sections

4.2 Idea of optional cooperation at detail engineering 4.3 OPTION I 4.4 OPTION II 4.5 OPTION III

5. COOPERATION WITH OWNERS OF INNOVATIVE DESIGNS 5.1 Specific process solutions 5.2 Specific design of critical equipment

5.3 Control systems, visualization and others

6. ADDITIONAL CONSULTANCY SERVICES 6.1 PRE-DESIGN STUDIES (P-DS) 6.2 BASIC ENGINEERING PACKAGE (BEP) 6.3 DETAILED ENGINEERING & DESIGN (DED)

7. ENCLOSURES 7.1 SODACONSULT MAIN REFERENCES 7.2 Historical Folder 1991 – Soda Industry In Poland 7.3 Historical Folder 1996 – Your Partner In Project Development



1. SODACONSULT IN BRIEF 1.1 Origins & roots SODACONSULT has its roots in BIPROKWAS KRAKÓW, managed by A. Bukowski, where the basic

staff of the present SODACONSULT office was employed. In 1991, to face new challenges of transforming Polish economy, two project managers – Andrzej

Auriga (Janikosoda) and Stanisław Smyk (Soda Mątwy) – founded SODACONSULT – a private company for Consulting & Engineering Services.

In 1994 the owners of SODACONSULT and POLIMEX-CEKOP Ltd. founded a new company POLIMEX-SODACONSULT Ltd. – dedicated mainly to execution of the contract for Lime Burning Plant at M.C.I. Alexandria in Egypt.

1.2 Owners & basic staff Now, the owners of the Office are: Andrzej AURIGA, Stanisław SMYK & Bartosz SMYK

Bartosz Smyk after graduation as civil engineer, has been starting his design coordination activities and engineering management at SODACONSULT.

Chief Engineer of the Office is Mariusz Zastawny. As chemical engineer has been starting his design carrier at SODACONSULT.

Within the range of technological & mechanical aspects the independent advisers are Leszek TARCZYŃSKI (long-term Technical Manager of the Polish Soda Plants and co-author of “Soda Technology”) and Zdzisław TRZECIAK (Experienced Chief Design Engineer of the Soda Installations and mechanical designer of critical apparatuses and machinery).

SODACONSULT staff consists of: – experienced engineers, highly qualified, previously working at BIPROKWAS and CHEMADEX Kraków

– young engineers and economists graduated from the AGH University of Science and Technology, the Cracow University of Technology and the Cracow University of Economics, all located in Kraków.

The above group represents the following specializations: • process technology • utilities • mechanical & piping • instrumental & control • electrical • civil & structural • cost estimation provided for SODA PROCESS KNOW-HOW and MULTIDISCIPLINED ENGINEERING covering offered fields of cooperation.

1.3 Special teams A dynamic team for special tasks can be immediately assembled from the cooperating specialists living in Kraków. For larger projects, SODACONSULT can organize and manage special teams in cooperation with well-known Engineering Companies from Kraków and Warszawa.



1.4 General offer scope – from concept to implementation



2. FIELDS OF COOPERATION

2.1 Soda Ash & by-Products production processes

2.1.1 Soda Ash production process



2.1.2 Technology of Soda Ash & by-Products



2.1.3 Scope of Soda Ash Project in B.L. – example



2.2 Unit process & operations

2.2.1 LSA production

a) Lime and CO2 production

b) CO2 compression

c) Brine purification

d) Absorption & distillation

e) Carbonation & filtration

f) Calcination

2.2.2 DSA production (monohydrated)

a) Crystallization

b) Drying

c) Crushing & screening

2.2.3 DSA production (compacted)

2.2.4 BIC production (compacted)

a) Soda solution preparation

b) Solution filtration

c) Solution carbonation

d) Drying

e) Crushing & screening

f) Storing & shipment

2.2.5 Environmental protection aspects

a) Washing of slurry

b) Decantation & clarification

c) Filtration

d) Fertilizer chalk production



2.3 Unit operation

2.3.1 Material conveying systems

a) dusts

b) liquids

c) pulps

d) solids

2.3.2 Dedusting systems

2.3.3 Drying systems

2.3.4 Crushing & screening

2.3.5 Storing & packing

2.3.6 Silos and shipment

2.4 Mechanical designs of fabricated equipment

2.4.1 Column type apparatuses

a) Carbonating towers

b) Distillation towers

c) Washers

2.4.2 Big rotary equipment

a) Lime slakers

b) Calciners

2.4.3 Bins & storage silos for bulk materials

2.4.4 Tanks and mixers for process solutions

2.4.5 Pressure vessels



3. OFFERED DESIGN ENGINEERING & SERVICES

3.1 Stages of documentation preparation



3.2 Equipment bidding & contracting procedure



3.3. Used software tools

For execution of offered design engineering we are using below updated software systems.

No Documentation Designing Software Notes

1 2 3 4

1. Plant Design & Piping

1. Bentley AutoPLANT V8i 2. ISOGEN 3. Autodesk INVENTOR 2013 4. AutoCAD 2013

Model 3D Pipelines isometric dwgs 3D models of equipment etc.

2. Instrumentation & Control

1. CADprofi Electrical

2. Schneider Electric Library AutoCAD

3. AutoCAD 2013

3. Electrical Installation

1. CADprofi Electrical

2. Schneider Electric Library AutoCAD

3. AutoCAD 2013

4. Civil & Structural

1. Autodesk ROBOT Structural System 2012 2. ZwCAD+ 2014

Calculation + model 3D

5. Architecture 1. Autodesk Revid Structure 2. Autodesk INVENTOR 2013 3. AutoCAD 2013

6 Others 1. Microprotol V32.8.8.2 – EuReserch (www.microprotol.com) 2. MathCAD 14.0 3. MS Excel 2013 4. MS Word 2013 5. MS Project 2003

UDT (TÜV) calculation Technological calculation

NOTE:

1. Application of above designing tools depends on stage of design engineering to be worked out.

2. Technical documentation will be e-mailed and in papers copies.

http://www.microprotol.com/



3.4 Scope of documentation & services 3.4.1 PRE-DESIGN STUDIES (P-DS)

Conceptual design studies Site selections/evaluations Technology evaluation Technical and economic feasibility studies Optimization studies Environmental impact assessments

3.4.2 BASIC ENGINEERING PACKAGE (BEP)

Process design - general

- material and heat balances

- process and utilities flow diagrams

- control & visualization philosophy

- main equipment selection

- executive summary

Basic engineering - basic design data

- P + ID’s for process and utilities (preliminary)

- equipment arrangements

- general plot plan

- instrumentation philosophy, data sheets and schemes

- electrical general specifications, single line diagrams and load/power user summary

- civil and structural general specification, architectural concept and general arrangement drawings

- data/guide lines for local engineering and activities

Manuals and instructions For the whole Plant/Unit

- start-up instruction

- operating and maintenance manual

- chemist’s manual

- safety manual

For mechanical, electrical equipment and instrumentation

- vendor’s manuals

BEP executive summary

3.4.3 DETAIL ENGINEERING & DESIGN (DED)

Civil and structural - concrete/foundation drawings

- structural detail drawings

- steelwork pipe supports

- building drawings

- road lay-outs

- paving and drainage drawings

- U/G coordinated drawings

- material requisitions



Plant design & piping - overall site plans

- unit plot plans

- P + ID’s for process and utilities (final)

- design area matchlines

- piping arrangement drawings

- isometrics


Instrumentation/Control & visualization systems - instrument installation schedules

- instrument lay-out drawings

- logic diagrams

- instrumentation/material requisitions

Electrical - tray/racking lay-outs

- cable routing drawings

- communications

- lighting lay-outs

- U/G cable trench drawings

- cable schedules

- interconnecting diagrams

- substation lay-outs


Detail mechanical drawings For fabricated critical equipment

- technical specifications

- assembly drawings

- drawings of subassemblies

- drawings of main details

- operating and maintenance manuals

3.4.4 SUPERVISION SERVICES

Local detailed engineering - assistance / supervision and checking the multidiscipline detailed engineering - assistance/supervision and checking detailed mechanical drawings of fabricated eq-nt - assistance in obtaining approvals from local authorities

Technical procurement - imported critical equipment and machinery - local equipment and materials - spare parts for proprietary equipment and others

Inspection of equipment fabrication - supervising during fabrication - inspection before shipment - assistance at packing and storing



Civil works & structural - supervising in compliance with Plant Design & Piping requirements

Equipment assembly/erection - supervision of field – assembled big equipment, locally fabricated or imported - erection supervising of the equipment and installation - supervision of mechanical completion operations - supervision of pre-commissioning operations

Commissioning & start-up - supervision of start-up activities - management of performance tests and commissioning

3.4.5 OPERATIONAL ASSISTANCE

Technical management - assistance at plant operation

Training & technology transfer - training program - theoretical and practical training conducting

Revamp & debottlenecking services - yield improvement studies - expertizes on bottlenecks and trouble shooting

“As-built” documentation - machinery and equipment lay-outs - P+ID’s and piping isometrics - instrument details and lay-outs - electrical lay-out and cable details - complete list of plants and equipment



4. COOPERATION WITH LOCAL ENGINEERING COMPANIES 4.1 General assumptions 4.1.1 Introduction

SODA WORKS to be designed by SDC including optional participation of INV OFF-SITE INSTALLATIONS to be designed by INV including coordination,

guidelines, consultations & checking of SDC 4.1.2 Pre-design Studies

BASIC REPORT / Feasibility Study to be elaborated by SDC PRELIMINARY BUSINESS PLAN to be elaborated by INV including participation of SDC

4.1.3 Basic Engineering Package

SODA WORK as a whole to be elaborated by SDC OFF-SITE INSTALLATIONS – all necessary guidelines & consultation to be rendered by SDC

4.1.4 Detail Engineering

See Optional Cooperation Proposal it. 4.3, 4.4, & 4.5 4.1.5 Exemplary list of the Project Units / Sections

100 – DENSE SODA ASH PLANT (DSA) 200 to 400 – SODA BY-PRODUCTS (Reserved for future) 500 – UTILITY FACILITIES 600 – MATERIALS & UTILITIES STORAGES 700 – GENERAL & MAINTENANCE SERVICES 800 – WASTE SLURRY TREATMENT 900 – TRANSPORT INFRASTRUCTURE 1000 – OFF – SITE INSTALLATIONS



4.2 Idea of optional cooperation at detail engineering



4.3 OPTION I

OPTION I

SODA PROJECT UNITS

100 – DENSE SODA ASH PLANT (DSA)

200 to 400 – SODA BY-PRODUCTS (Reserved for the future)

500 – UTILITY FACILITIES

600 – MATERIALS & UTILITIES STORAGES

700 – GENERAL & MAINTENANCE SERVICES

800 – WASTE SLURRY TREATMENT

900 –TRANSPORT INFRASTRUCTURE

1000 – OFF- SITE INSTALLATIONS to be agreed later on

SODACONSULT / Polish Engineering: o Complete Documentation for the whole SODA PROJECT covering the following

Units: 100, 200, 500, 600, 700, 800, 900 (Column 3 as below)

INVESTOR / Local engineering: o Adaptation to the local standards selected

parts /disciplines (Column 6) of INVESTOR documentation, as below:

electricals

civil & structural

interconnections

roads & railways

general lay-out

No Multidiscipline Detail Engineering

Polish En-ng Local En-ng

EXECUTION Guidelines consulting checking

EXECUTION Adaptation

to local standards

1 2 3 4 5 6

1. PLANT DESIGN & PIPING X – – –

2. INSTRUMENTATION & CONTROL X – – –

3. ELECTRICAL INSTALLATIONS X – – X

4. CIVIL & STRUCTURAL X – – X

5. INTERCONNECTIONS X – – X

6. ROADS & RAILWAYS X – – X

7. GENERAL LAY-OUT X – – X



4.4 OPTION II

OPTION II

SODA PROJECT UNITS








1000 – OFF- SITE INSTALLATIONS to be agreed later on

SODACONSULT / Polish Engineering: o Documentation for the whole SODA PROJECT covering the following Units: 100, 200, 500,

600, 700, 800 & 900 (Column 3) excluding the below parts/ disciplines (Column 5):

electricals

civil & structural

interconnections

roads & railways

general lay-out o Guidelines, consulting & checking of INVESTOR

below documentation

INVESTOR / Local Engineering: o Documentation for the whole SODA

PROJECT as above, covering selected parts/ disciplines as below (Column 5):

electricals

civil & structural

interconnections

roads & railways

general lay-out



EXECUTION Guidelines consulting checking

EXECUTION Adaptation

to local standards

1 2 3 4 5 6

1. PLANT DESIGN & PIPING X – – –

2. INSTRUMENTATION & CONTROL

X – – –

3. ELECTRICAL INSTALLATIONS – X X –

4. CIVIL & STRUCTURAL – X X –

5. INTERCONNECTIONS – X X –

6. ROADS & RAILWAYS – X X –

7. GENERAL LAY-OUT – X X –



4.5 OPTION III

OPTION III

SODA PROJECT UNITS








1000 – OFF – SITE INSTALLATIONS to be agreed later on

SODACONSULT / Local Engineering: o Complete Documentation for production

& storing of the SODA PROJECT covering the following Units: 100, 200, 600 & 800 (Column 3)

o Guidelines, consulting & checking of INVESTOR below documentation (Column 4)

INVESTOR / Local Engineering: o Complete Documentation for utilities, general

& maintenance services, roads & railways covering the following Units: 500, 700 & 900 (Column 5)

o Adaptation of SODACONSULT documentation to the local standards (Column 6)



EXECUTION

100+200+ 600 +800

Guidelines consulting checking

500+700+ 900

EXECUTION

500+700+ 900

Adaptation to local

standards

100+200+ 600+800

1 2 3 4 5 6

1. PLANT DESIGN & PIPING X X X –

2. INSTRUMENTATION & CONTROL X – X –

3. ELECTRICAL INSTALLATIONS X – X X

4. CIVIL & STRUCTURAL X – X X

5. INTERCONNECTIONS X X X X

6. ROADS & RAILWAYS X X X X

7. GENERAL LAY-OUT X X X X



5. COOPERATION WITH OWNERS OF INNOVATIVE DESIGNS 5.1 Specific process solutions 5.2 Specific design in critical equipment 5.3 Control systems, visualization and others



6. ADDITIONAL CONSULTANCY SERVICES AT DESIGN DEVELOPMENT

6.1 PRE-DESIGN STUDIES (P-DS)

ENGINEERING STAGES LOCAL SUPPLIER

INVESTOR ORDERING

SODACONSULT CONSULTING SERVICES

Conceptual design studies

Site selections/evaluations

Technology evaluation

Technical and economic feasibility studies

Optimization studies

Environmental impact assessments

Equipment bidding

P-DS BIDDING & SUPPLIER SELECTION

< Draft of Invitation to bid (ITB)

< Offers/quotations collecting & comparison

< Recommendations for contracting

P-DS CONTRACTING < Participation in negotiation (option)

< Advising at contract signing

MONITORING P-DS PROGRESS & DESIGN MEETINGS

< Checking Telecon Records

< Checking Design Reports

< Participation in key design meetings

< Documents transmission way proposal

< E-mail communication system proposal

< Elaboration Design Progress Reports

P-DS APPROVAL

< Checking recommendations fulfilment by the Supplier

< Draft of Final Approval Report

< Participation in the Final Approval meeting (option)



6.2 BASIC ENGINEERING PACKAGE (BEP)


INVESTOR ORDERING


Process design - general

- material and heat balances

- process and utilities flow diagrams

- control & visualization philosophy

- main equipment selection

- executive summary

Basic engineering - basic design data

- P + ID’s for process and utilities

- equipment arrangements

- general plot plan

- instrumentation philosophy, data sheets and schemes

- electrical general specifications, single line diagrams and load/power user summary

- civil and structural general specification, architectural concept and general arrangement drawings

- data/guide lines for local engineering and activities

Manuals and instructions For the whole Plant/Unit

- start-up instruction

- operating and maintenance manual

- chemist’s manual

- safety manual

For mechanical, electrical equipment and instrumentation

- vendor’s manuals

BEP executive summary

BEP BIDDING & SUPPLIER SELECTION



< Recommendations for contracting of BEP Supplier

BEP SUPPLIER CONTRACTING

< Participation in negotiation (option)

< Advising at contract signing (option)

DETAILED TIME SCHEDULE OF THE BEP DEVELOPMENT

< Comment to Supplier execution time schedule

< Comment to detailed list of documentation (contents)

< Participation in discussion & agreements

SITE VISITING APPROVAL

< Draft of visiting program

< Participation in the site visit (option)

< Draft of visiting Report

KEY EQUIPMENT BIDDING & DESIGN DATA TRANSMISSION

< Checking Supplier enquiries & recommendations

< Copies of offers/quotation collecting & comparison

< Recommendation for selection of 3. potential deliverers

< Checking design data to be transmitted to BEP Supplier

MONITORING BEP PROGRESS & DESIGN MEETINGS



< Participation in key design meetings (option)




BEP PRELIMINARY APPROVAL – working version

< Checking key items of BEP & recommendations

< Draft of Preliminary Approval Report

< Participation in the Approval meeting (option)

BEP FINAL APPROVAL – final version

< Recommendations fulfilment by the Supplier





6.3 DETAIL ENGINEERING & DESIGN (DED)


INVESTOR ORDERING


Civil and structural - concrete/foundation drawings

- structural detail drawings

- steelwork pipe supports

- building drawings

- road lay-outs

- paving and drainage drawings

- U/G coordinated drawings


Plant design & piping - overall site plans

- unit plot plans

- design area match-lines

- piping arrangement drawings

- isometrics


Instrumentation/Control & visualization systems

- instrument installation schedules

- instrument lay-out drawings

- logic diagrams

- instrumentation/material requisitions

Electrical - tray/racking lay-outs

- cable routing drawings

- communications

- lighting lay-outs

- U/G cable trench drawings

- cable schedules

- interconnecting diagrams

- substation lay-outs


Detail mechanical drawings For fabricated critical equipment

- technical specifications

- assembly drawings

- drawings of subassemblies

- drawings of main details

- operating and maintenance manuals

DED BIDDING & SUPPLIER SELECTION (Option)



< Recommendations for contracting

DED SUPPLIER CONTRACTING (Option)

< Comment to the draft of DED Supplier contract

< Participation in negotiation

< Advising at contract signing

DETAILED TIME SCHEDULE & LIST OF DOCUMENTATION

< Comment to Supplier schedule of documentation execution

< Comment to detailed list of documentation

< Comment to schedule of telecons & design meetings

< Participation in discussion & agreements

SITE VISITING APPROVAL

< Draft of visiting program

< Participation in the site visit (options)

< Draft of visiting Report

KEY EQUIPMENT CONTRACTING & CONTRACTUAL DATA TRANSMISSION TO DED SUPPLIER

< Checking Supplier contractual specifications & recommendations

< Participation in the contract negotiation

< Advising at guarantee test procedure

< Checking the time schedule of contractual data transmission

MONITORING DED PROGRESS & DESIGN MEETINGS



< Participation in key design meetings




DED PRELIMINARY APPROVAL – working version

< Checking key items of DED & recommendations

< Draft of Preliminary Approval Report

< Participation in the Approval meeting

DED FINAL APPROVAL

– final version

< Recommendations fulfilment by the Supplier





7. ENCLOSURES

7.1 SODACONSULT MAIN REFERENCES

7.2 Historical Folder 1991 – Soda Industry in Poland

7.3 Historical Folder 1996 – Your Partner in Project Development