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ENGINEERING.THE UNIVERSALLANGUAGE

T R I P L A N E N G I N E E R I N G M A D E I N G E R M A N Y

02 B U S I N E S S S E C T O R S

04 – 15 Engineering Services06 Life Science08 Refinery14 Chemicals

16 – 18 Technology Services

27 S U C C E S S S T O R I E S & S P E C I A L K N O W - H O W

42 C O M P A N Y H I S T O R Y

19 T R I P L A N I N I N D I A

20 Engineering hub for India, Southeast Asia and the Middle East

22 Dynamic growth – TRIPLAN’s business in India

24 Creating value in India

26 India’s hot spot for German investors

Contents

Our customers’ business is international. The combination of the TRIPLAN Group’s decentralised structures and our international network is the right fit. We offer engineering services, technology services and consulting regardless of location. We’re always where the customer needs us: on site, around the world. Our tried-and-true regional customer relationships and a market-based international focus connect in particular at our locations, with special focus on the life sciences, refinery and chemicals indus-tries in Germany and Switzerland.

Our experts have access to the entire group, with branches and specialised subsidiaries of TRIPLAN AG in the areas of engineering, technology, IT and consulting. Forty engineers from our subsidiary TRIPLAN India Pvt. Ltd and a global partner network support the TRIPLAN Group and customers in their international projects, with engineer-ing expertise and excellent market and cultural experience in Southeast Asia and other regions. This is the heart of our “follow the customer” strategy.

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T R I P L A N L O C A T I O N S

1 Gelsenkirchen

2 Krefeld

3 Leverkusen

4 Bad Soden

5 Merseburg

6 Karlsruhe

7 Burghausen

8 Lörrach

9 Reinach, Switzerland

10 Pune, India

Reinach, Switzerland

Pune, India

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CLOSE TO OUR CUSTOMERS:ON SITE AND AROUND THE WORLD

E N G I N E E R I NG

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DE I N G E R M A N Y

TRIPLAN

FIVE DECADES OF EXPERIENCE IN PLANT ENGINEERING

Thanks to our many years of engineering expertise, technologically leading software applications and comprehensive consulting services, we develop solutions that meet the highest technical and economical standards for the long term. Moreover, they conserve resources and are environmentally friendly.

Few German engineering companies have more experience in plant engineering. Since 1967, TRIPLAN has been developing and optimising complex production plants as a discipline and general engineering contractor. This division’s focus lies on project engineering, onsite engineering and consulting. Always the best team for the best individual solution.

TRIPLAN has permanent teams of specialists at leading locations of the key indus-tries: refinery, chemicals and life sciences. These industry centres have access to all resources and regional locations of the TRIPLAN Group and oversee the projects from the initial inquiry to successful implementation – always using the best team for the best solution.

This allows us to provide the perfect combination of proven regional structures and in-depth knowledge of customer processes with industry expertise and our global network. We develop solutions with a focus on optimal, individual plant concepts, which always take into account our customer’s local requirements.

Thanks to this combination, we support our customers regionally, nationally and internationally and continuously expand our position as a trusted and preferred partner.

ENGINEERING SERVICES

A R E A S O F E X P E R I E N C E

› Refinery

› Petrochemicals

› Chemicals

› Monomer and Polymer Production

› Crop Protection

› Polysilicon and Monosilane Production

› Fine & Specialty Chemicals

› Semiconductor Production

› Biotechnology

› Active Ingredients Production

› Pharmaceutical Production

› Medical Devices

› Clean Media

› Cleanrooms

› Food

› Infrastructure

› Tank Farm

› Utilities

› Logistics

› Solids Handling

› HVAC & Building Services

› Laboratories

Business SectorsEngineering and IT competence lined up

02 B U S I N E S S S E C T O R S

TRIPLAN is the first engineering company that is able to support its engineering services using proprietary software applications. Practical experience and IT skills are in perfect harmony.

Engineering and IT competence lined upThe quality and performance of design and simulation technology are the key to successful projects. TRIPLAN has driven these developments over time: from 3D plastic model construction as a volume model 40 years ago to database-supported CAD/CAE design tools, which are now the industry standard in the core segments of digital factory design.

Our Technology Services division combines these IT activities for development, application, implementation and consulting for the market of suppliers and OEMs for factory and plant construction and building services. The products for factory and plant design and lifecycle document management stand out for their practical relevance and top functionality. “For engineers by engineers” is our pledge.

TECHNOLOGY SERVICES

P R O D U C T S & S E R V I C E S

› TRICAD MS®

› Digital Factory Design

› Plant Design

› Building Services

› Traffic Design

› vSP Navigator

› Bentley Applications

› Document Management

› System Integration

› IT Consulting

› Training and Support

B U S I N E S S S E C T O R S03

04 E N G I N E E R I N G S E R V I C E S

Through our clear focus on three sectors of the process industry, we continuously further develop our know-how in these sectors.

L I F E S C I E N C E R E F I N E RY C H E M I C A L S

The Life Science division consolidates TRIPLAN’s competence in development and engineering of facilities for R&D as well as production and finishing plants for the active ingredients, bio technology, pharma, specialty chemicals and food industries.

In the Refinery division, the focus is on optimisation, modernisation and engineering of plants and infrastructure to process feedstock into primary and secondary products.

Process plants and ancillaries in almost all areas of organic and inorganic chemistry are designed by TRIPLAN and supported throughout their lifecycle.

S E R V I C E P O R T F O L I O

Project engineering On-site engineering Consulting

Feasibility study Concept Basic engineering Detailed engineering Procurement Construction management Commissioning

Plant documentation Technical operations office Process optimisation Small projects Modernisation projects Cost estimates Supplier management Support for plant engineers

Site selection Authorityengineering Safety analyses Shutdown planning Creation of factory standards Maintenance management Compliance and qualification

E N G I N E E R I N G D I S C I P L I N E S

Process engineering Mechanical and vessels Layout and Piping CSA – civil, structural, architectural Electrical & instrumentation Solids handling

Project management and control Procurement Construction management Safety/environmental protection Qualification

All services from a single source!

Engineering Services

E N G I N E E R I N G S E R V I C E S05

Life Science Engineering consolidates expertise in the engineering and modernisation of production and finishing plants, including specific laboratories for the food, pharmaceuticals production, speciality and fine chemicals and biotech industries. It covers the entire production chain, from delivery through all manufacturing steps to the packaged and inspected end product.

For pharmaceuticals production, we design the building concept with cleanrooms and the handling of highly active substances in containment up to packaged goods. The technologies for conventional production processes for solid, semisolid and liquid dosage forms, parenteral and disposable goods, along with the use of isolation technologies, are standard procedure.

Our bioprocess expertise includes antibiotics, vitamins, enzymes, amino acids and other biochemicals. We design fermentation with microorganisms, animal and plant cells and handle the entire upstream and downstream processing chain.

Our specialists account for all relevant guidelines – the national and international GMP rules, along with the various FDA guidelines.

We design R&D labs that integrate HVAC technology and cleanroom technology using stateoftheart design methods and tools.

Our comprehensive engineering services for the life sciences industry include concept design, upscaling, basic and detailed engineering, construction management including commissioning, along with a complete cGMP and FDAcompliant qualification and validation package.

Full engineering compliance (project management in accordance with customer and official regulations in a GMP environment) is a matter of course.

L I F E S C I E N C E


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Customers from the Refinery & Petrochemicals division derive a direct benefit from our refinery expertise, knowledge of international and national guidelines and the individual factory standards. TRIPLAN stands for compliance with environmental and safety standards, quality and timely fulfilment along with training, documentation and technical services in running plants.

One example of TRIPLAN’s innovation process is the development of its patented Closed Coke Slurry System (CCSS). This technology is currently the most environmentally friendly system for handling petroleum coke.

The engineers from our Refinery & Petrochemicals division have outstanding international expertise thanks to their many years of close cooperation with the industry’s market leaders. TRIPLAN offers complete engineering services primarily for plants that process feedstock into primary and secondary products, and for plants that produce the required components. This includes greenfield as well as brownfield projects, modernisation and process optimisation. Our project management ranges from feasibility studies to concept design, basic and detailed engineering, procurement and construction management to commissioning.

R E F I N E RY


01 OVERVIEWOFVACUUMTOWER (MiRO Karlsruhe)

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TRIPLAN developed an innovative system technology for the economic and environmentally friendly handling of petroleum coke: the Closed Coke Slurry System for Delayed Coker units.

TRIPLAN AND THE CLOSED COKE SLURRY SYSTEM ENABLE A BREAKTHROUGH IN CLEAN AND SAFE TREATMENT OF PETROLEUM COKE

The Hydrocarbon Processing Industry (HPI) has to cope with an increasing amount of heavier crude slate, so the proportion of heavy residues is also going up. For example, according to US studies, the proportion of heavy crude on the market for crude oil will grow by 50% during the current decade. Many experts are of the opin-ion that the sudden production increase for light oil obtained by fracking in the US will not change this long-term outlook. At the same time, the market for high- sulphur and high-metal residues is shrinking because of stringent environmental limitations, restricting it’s use as fuel for conventional power plants or as marine fuel.

Closed Coke Slurry System eliminates emissionsOne way out is to have conversion units available to crack these residues into valuable light products and petroleum coke, as it happens with the Delayed Coking process. In this process, the gas and liquid products remain in the usual refinery for further processing, while the produced petroleum coke is hydraulically removed from the coke drums during regular process cycles and treated outside the refinery in the open atmosphere.

One characteristic of a Delayed Coker – which is unique in the HPI landscape – is that production takes place in batches, for example one batch at a time. The coke drums (at least two or up to eight drums but always an even number – consist of a process unit) are filled in alternation and then the solid coke is removed. Unlike a conventional refinery there is a large portion of mechanical equipment and compo-nents involved to treat, handle, move and store the petroleum coke.

The coke in the drum, which is still hot, is removed with high-pressure water and falls onto a large concrete area in front of the unit, forming a typical steam plume visible from far away. Once the water has drained off from the coke pile, manned gantry cranes or front loaders pick the coke to empty the concrete sur-face. The material is then dispatched to customers using trucks, rail cars or ships. Another intermediate open storage pile is not uncommon, causing another source of dust and smell.

» Of all the high-tech conversion processes used in the HPI, delayed coking is the most attractive from the point of view of investment and operating costs for many operators. There are over 160 Delayed Coker units throughout the world; additional units are planned or existing, brownfield units will be expanded.«

Ralf Gast Head of the TRIPLAN Competence Centre for Refining in Karlsruhe


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01 COKEDRUMWITHCRUSHER Produces the petroleum coke in the coke drum and the crusher grinds the coke into a product meeting specifications

02 DEWATERINGBINSeparates petroleum coke from free water until the defined remaining moisture level is reached

03 WATERTANKSContains circulating water for the process

A D VA N TA G E S

› Best Available Technology (BAT)

› High availability of the CCSS

› Low cost for maintenance

› High degree of automation

› Low operating costs


For a long time, these historically determined work steps have been problematic for a number of reasons:

Coke dust and hydrocarbon components are released into the atmosphere with the steam

The separation of fine coke particles and the runoff water is unsatisfactory

This water is reused as a highpressure medium to remove coke from the coke drum. Fine particles are extremely abrasive and an inferior water quality results in increased wear and tear in the system

When compared with other continuous refinery operations, the availability of the unit is significantly lower because of the frequent repairs of the solidshandling components in a harsh service

Quantum leap in environmental protection and occupational health and safetyOperators of Delayed Cokers must therefore factor in high maintenance budgets and costs for maintenance personnel over the long term. This is where the Closed Coke Slurry System developed by TRIPLAN comes into the picture: using the water, which is available anyway, the coke is pumped and the mechanical steps of transporting solids become obsolete. In a further step, the water-coke mixture is pumped into dewatering bins for water removal.

These bins are equipped with special screens that separate the water quickly and effectively from the coke. Most of the coke fines are caught and retained in the bed. A small slipstream is removed finally in an adjacent tank before the water is reused as high-pressure water with quality that had previously been impossible to maintain. The petroleum coke, which is dry to customary standard, can be loaded directly.

01 Visualisation of a CCSS plant

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The primary incentive for the Closed Coke Slurry System is for environmental reasons, as well as for the protection of the health of fellow employees and the re-finery neighbourhood, but it also offers economic effects:

No emissions of volatile organic matters (VOM) and no steam plume

Effective water savings and optimal onsite treatment of coke slurry with better water quality

Fewer personnel in ongoing operations and maintenance

Significantly reduced need to keep spare parts on hand

Effective drying of petroleum coke allows shorter cycle time for batches

High availability and long lifetime using special metallurgy for the components with the Closed Coke Slurry System

In addition, the Coker operator attains additional attractive economic incentives and side effects on a case-by-case basis depending on the situation and the location. Because of the innovative approach to solving the problem in conjunction with special configuration and selection of materials for process-critical facility parts, TRIPLAN obtained a patent for the Closed Coke Slurry System.

Feasibility studies for a number of interested parties have shown that invest-ment costs for the Closed Coke Slurry System are the same as for a conventional concrete coke pit. In the context of a new greenfield Delayed Coker project, even more savings can be achieved with a substantial reduction in Coker structure elevation. An additional advantage of the Closed Coke Slurry System is its compact structure. The CCSS also offers high flexibility as the location of the dewatering bins and water tanks can be adjusted to local spacing constraints or client needs. The Slurry (coke-water mixture) could also be pumped over long distances to customers performing the dewatering on their own sites in line with their require-ments, sparing additional handling steps and investment.

Studies for interested coker operators in India, China and the US have shown that an existing Delayed Coker unit will only then be converted into a Closed Coke Slurry System when more and stricter environmental regulations are in effect. However, increased environmental requirements are currently not expected in these countries. At present, TRIPLAN is in extensive negotiations to provide a Closed Coke Slurry System for a new Delayed Coker project for a European oil company.

TRIPLAN’s service scope consists of engineering package preparation and the fabrication and supply of selected proprietary components as TRIPLAN’s own development. Field supervision, commissioning and start-up support upon request.

Check out our website for more information:

http://ccss. TRIPLAN.com


Right from the design phase, we assist our customers in determining the key parameters for plant engineering at an early stage, identifying the potential for optimisation and making initial cost estimates. Our independence allows us to suggest the best solution at any time not only for new plants but also for optimisation, revamping or expansion of existing plants.

We have access to stateoftheart engineering tools such as process simulation programs to calculate and design processes and process steps. For all areas, our proprietary CAD system TRICAD MS® is used to create process flow and P+I diagrams, along with floor plans; alternatively, plans based on MicroStation or Autocad can be drawn up. All data can be centrally managed with our own data management system.

We use innovative PM tools for project planning and management along with document management.

The Chemicals division is handled by teams of specialists who have extensive knowledge of classic engineering and plant construction. Our customers benefit from this even during the development phase, through basic and detailed engineering and construction management to commissioning. This applies to general engineering for complex plants, the integration of new plants into existing buildings, capacity expansions and modifications, utility networks, environmental facilities, shutdown and maintenance planning.

C H E M I C A L S


01 SIMPLIFIEDVISUALISATIONOFSILICONEGRINDINGUNIT (GE Bayer Silicone Leverkusen)

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Products from VenturisIT turn the digital factory into reality. Advantages are a productivity gain and faster project execution. Software solutions for central data

storage and an innovative document management solution allow for safe handling and storage of technical documents throughout the lifecycle of a plant.

Our Technology Services segment combines IT activities with our proprietary software TRICAD MS® for the digital design of factories and process plants. Our software is "developed by engineers for engineers". A Central database, a seamless workfloworiented modular structure and easy to use are the key features.

Technology Services

16 T E C H N O L O G Y S E R V I C E S16

The commercial use of the computer in engineering was still an unheard innovation in the 1980s. But the available software suffered from the problem that programmers really understood little of the world of industry and engineers.

TRICAD MS®

OUR DESIGN TOOL IS IN DEMAND AROUND THE WORLD

01 Visualisation and virtual test run after completion of detailed engineering and before start of construction

At TRIPLAN, this led to the decision to develop our own software for plant design: TRICAD was born. The advantages of a design tool developed by engineers for engineers that has been maintained that way to this day by VenturisIT, a sub-sidiary of TRIPLAN, are recognised by many customers, with over 3,000 installa-tions in 27 countries around the world.

More productive, faster, lower costThe idea that every engineer – whether in the automotive industry, building servic-es or process technology – achieves productivity gains by using the CAD/CAE tool called TRICAD MS®, thereby completing projects faster, is not a theory; it is a prac-tice in everyday use. TRIPLAN engineers use the current Bentley MicroStation- based TRICAD MS® on over 70 stations (if the customer prefers another tool, the engineers will of course use the tool desired). This way, software developers have constant feedback.

Every new version, every new release has been sufficiently tested in advance in practice. TRICAD MS® demonstrably increases the productivity of the engineer; even complex projects can be quickly implemented. This is really a facility design tool by and for engineers.

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17 T E C H N O L O G Y S E R V I C E S

Established standard in the VDASo it is no wonder that TRICAD MS® has established itself in the German automo-tive industry as a standard solution, but engineers and operators in chemical and life sciences, building services engineering and transportation use the productivity advantages of TRICAD MS® as well.

Our key customers throughout the world have increased the global demand, and VenturisIT consultants are travelling around the world to offer training in German, English, Spanish, French and Hungarian; additional training in China, Russia, Mexico and India is planned.

Software that is always one step ahead We work very closely with our customers in the development and respond quickly and flexibly to their individual needs. For example, a facility layout module was de-veloped with over 5,000 components. This covers a substantially broader spectrum in factory design, going well beyond the individual disciplines, like classic building services engineering.

Using Bentley’s MicroStation platform as a basis, we rely on an internationally available and well-known system and are now the biggest Bentley partner in Europe distributing Bentley software.

T R I C A D M S ®

D I G I TA L FAC T O RYD E S I G N

BUILDINGSERVICESE N G I N E E R I N G

P L A N T D E S I G N

› Conveyor systems › Steel platform/steel › Painting & coating

systems › Tractory curves › Crane systems › Swarf conveyors › Layout module

› Schematic › Building module › Heating/cooling › Ventilation › Sanitary › Sprinkler/fire

protection layout › Electric › Infrastructure

› P&ID › Piping 3D › Pipe classes › Isometrics (Iso X) › Steel structure

Database (vDB)Quality check

Report managerInterference check

Construction moduleViewer

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01 TRICAD MS® is an integrated CAD/CAE industry application with special modules for all engineering disciplines

18 T E C H N O L O G Y S E R V I C E S

TRIPLAN in India

TRIPLAN has entered the Indian market. The establishment of TRIPLAN India Pvt. Ltd is a key step on the path to internationali sation. The engineering centre opened in Pune, home to millions of residents. More than 300 German companies have already established themselves in the area.

The location’s strength lies in its proximity to customers and target industries. Another advantage lies in its access to a wealth of well educated engineers. Each year, about 15,000 of them graduate from the University of Pune, which is India’s largest university.

Pune


By establishing its own subsidiary in India, TRIPLAN AG has reached a milestone in its internationalisation strategy. TRIPLAN India Pvt. Ltd is building an engineer-ing centre in Pune, which will initially employ 40–50 engineers. The services are provided to clients from the chemical industry, refineries and life science companies (pharmaceuticals, food and beverage). The first projects are already in execution.

TRIPLAN India consults local companies for their investment plans in India and assists European TRIPLAN customers with their projects on site. It also helps its customers to enhance their own competitive edge and successfully launch strategic innovations. Additionally, the location will assist in TRIPLAN’s international pro-jects in the Middle East and Southeast Asia.

Thanks to TRIPLAN India Pvt. Ltd, TRIPLAN is particularly supporting the activities as a technology provider: the patented “Closed Coke Slurry System” (CCSS) technology is now also being made available to Indian refineries.

TRIPLAN has years of experience on the Indian market following a prior part-nership with an Indian company. The establishment of TRIPLAN India is a logical step in the internationalisation strategy and an investment in the future. India’s economic growth makes it one of the most rapidly expanding economies, and the country is becoming one of the top economic drivers around the globe.

TRIPLAN has established a new subsidiary in Pune, home to millions of residents.

ENGINEERING HUB FOR INDIA, SOUTHEAST ASIA AND THE MIDDLE EAST

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» Apart from serving European customers in India, TRIPLAN India intends to serve the local market, which was in need of a mid-sized engineering company with strong process engineering expertise from Europe.«

Sunil KulkarniManaging Director of TRIPLAN India Pvt. Ltd, Pune

» The establishment of TRIPLAN India is a major milestone in our internationalisation and growth strategy.«

Peter Stromberger CEO of TRIPLAN AG, Bad Soden


01 Indian rituals for the new office opening

02 TRIPLAN’s office in Pune

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DYNAMIC GROWTH – TRIPLAN’S BUSINESS IN INDIA

» Investing in our Indian engineers means sharing our values and goals.«

Peter Stromberger

What was the motivation for establishing the subsidiary TRIPLAN India Pvt. Ltd?

It was the growth opportunities that drove our decision. The process industry mar-kets in India and Southeast Asia are very dynamic. India’s chemicals industry has recently posted high growth rates in spite of the ailing global economy. Annual growth in chemicals production is forecasted at 4.5% annually until 2030. These figures are expected to be even higher for the pharmaceuticals and life sciences segments. However, we also see additional potential in the infrastructure, energy and water segments. Our concept is well suited to the “Make in India” initiative of the new Indian government, which aims to attract more international investors to the country.

“Follow the customer” and local business

Our motto is “Follow the customer”. Accordingly, we assist our customers with their international expansion. We have been working closely and cooperatively with many of these customers for decades. We know their requirements and standards. Using our model to support foreign investments, we meet the expectations of European customers. We also handle the coordination between the customers’ German and national companies and now with our local Indian subsidiary. However, the Indian market also offers great potential and the combination of “German engineering” plus “local engineering” is well received by Indian customers.

TRIPLAN’s decision to launch a subsidiary in India was a logical step in its continued internationalisation strategy. Now the company is closer to the markets with high growth potential and closer to the customers as well.

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TRIPLAN India is expanding into a support hub for national and international projects, including projects in Southeast Asia and the Middle East. Of course, the fact that English is practically a second native language to Indian engineers is also important.


TRIPLAN also markets its own technologies and products in India

Our patented CCSS – Closed Coke Slurry System – is the most environmentally friendly method for safely and economically handling petroleum coke in refineries. The CCSS technology completely eliminates the pollutants emitted by conventional petroleum coke handling. This is most likely the number one advantage. Now this technology is also available in India.

However, we will also assist with the rollout in India and provide on-site assistance to our global customers from the automotive industry, who use our TRICAD MS® product for digital factory design.

Especially in Pune, many companies want to make good use of the potential offered by well-educated engineers

Our long company history and excellent reputation help us with recruiting. The special training courses and possibility to work in Europe make us a very appeal-ing employer for Indian professionals. In Germany and India alike, what we need most of all are experienced engineers who not only have the required expertise, but also can serve as project managers and mentors.

In this regard, there is little difference between the attitudes and skills in Ger-many and in India. Our Indian employees are part of the TRIPLAN family and enjoy special status in our company. They are not merely assistants: we are one TRIPLAN team but have not abandoned the regional traditions.

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01 Managers of TRIPLAN India Pvt. Ltd (Sunil Kulkarni and Peter Stromberger)

02 One team: the core team during outdoor team building


CREATING VALUE IN INDIA

Leading German companies from the chemicals and petrochemicals industries have been customers of TRIPLAN for many years. Most of these companies are globally active and are rapidly establishing their branches outside Europe. The main focus is on Asia. This is why Sunil Kulkarni, Managing Director of TRIPLAN India, feels the opportunities are great for the company’s Indian business. Together with his employees in Pune, he wants to help utilise these opportunities.

Double-digit growth in chemicals and petrochemicalsThe chemicals industry already has a market volume of EUR 110 billion in India. “And it will keep growing”, says Kulkarni with confidence. Double-digit annual growth is considered a reliable forecast. The drivers of this growth, in turn, are globally focused companies and thus the customers of TRIPLAN.

India’s government has decided to accelerate this development. With its eco-nomic initiative “Make in India”, it is hoping to recruit leading companies looking for new business locations. Great efforts are being made to strategically expand the infrastructure for chemicals and petrochemicals. Some of the chemical and petrochemical locations thus have the potential to become leading centres of these industries, joining the ranks of Antwerp, Rotterdam, Singapore and Shanghai.

Last but not least, India is also a very dynamic market for the life sciences in-dustry. Here, too, TRIPLAN has outstanding expertise that has grown along with its customers for four decades.

India’s economic initiative “Make in India” will help TRIPLAN make full use of its opportunities in India.

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01 The chemical industry, one of the pillars of India’s economy

02 Manufacturing at Tata’s plant in Pune

03 Scene on a road in Pune

Wide range of suppliers for capital goods in plant construction An enormous number of small and medium-sized companies means a wide range of suppliers for all industries. “In particular, it is the skill-intensive industries that form the industrial pillars of the region”, says Kulkarni. By origin, these companies are subsidiaries of European suppliers, JVs and original Indian suppliers.

TRIPLAN’s site in Pune is near these industries. This proximity to the manufac-turers of equipment and systems components also opens the possibility to arrange for local procurement of capital goods for customers in and from Germany.

» In particular, it is the skill-intensive industries that form the industrial pillars of the region.«

Sunil Kulkarni

Thanks to its experience from previous projects and its familiarity with local structures, TRIPLAN is thoroughly familiar with the Indian market. With its em-phasis on quality and compliance with standards, TRIPLAN links up discerning customers in Europe with Indian suppliers.

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01 University of Pune, founded in 1948, is one of the leading universities of India

Pune, home to millions of residents, has long been an integral part of India’s major cities. Its nicknames “The Oxford of the East” or “The Detroit of India” refer to two of the city’s selling points. Pune is India’s capital of higher education. The University of Pune is among the country’s best, with 500,000 students. Moreover, this boom-ing city in the state of Maharashtra is among the world’s largest centres for the auto-motive industry. The climate in Pune is mild. Today, German companies in particular are contributing to the dynamic growth of the city. They represent the largest for-eign investor group.

More than 300 German companies in PuneSome 300 German companies and JVs have settled here. Among the international carmakers are VW, Mercedes-Benz, General Motors, Fiat and of course the national giants like Tata and Bajaj. Suppliers such as Bosch, Knorr Bremse and Saint Gobain also have sites here. The industrial belt is home to the top names in mechanical and systems engineering: Siemens, Demag, Sandvik, Alfa Laval and Atlas Copco. TRIPLAN has been represented there since 2014.

It is estimated that more than 15,000 well-educated engineers graduate from the local colleges and universities every year. The vast potential of valuable profes-sionals is magnetic: software companies, biotech, chemicals and pharmaceuticals companies are also very interested in them. Long gone are the days when inves-tors merely operated production sites. More and more R&D centres are being built.

Pune, “The Hidden German City”Germans visiting Pune will feel right at home. The city boasts India’s largest German community and has the largest number of German-speaking Indians in the country. It is easy to become part of this network. The University of Göttingen and the Free University of Berlin are partner universities to local colleges. The Goethe Institute opened its doors in Pune in 1959. Foreign chambers of commerce and economic development organisations offer a great deal of help to German compa-nies. Little wonder, then, that more and more, you hear Pune’s third nickname: “The Hidden German City”.

Pune’s hallmarks: proximity to customers and a wealth of engineers.

INDIA’S HOT SPOT FOR GERMAN INVESTORS

P U N EFAC T S & F I G U R E S

› India’s ninth largest city with about 5 million residents

› Second largest city in the state of Maharashtra

› The country’s largest university with about 500,000 students

› Business location for more than 300 German companies

› Strongest industries: automotive, IT, engineering, biotech and pharmaceuticals

› Closest metropolis: Mumbai (about 12 million residents), about 150 km away

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Success Stories & Special Know-how

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P R O J E C T SI N E U R O P E

Hellenic Petroleum, Athens, Greece

Currenta, Krefeld

Asse II, Wolfenbüttel

InfraLeuna GmbH, Leuna

Bayer CropScience, Muttenz, Switzerland

EPC Project, Terneuzen, Netherlands

AgfaGevaert, Wiesbaden

Trinseo GmbH, Schkopau

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P R O J E C T SW O R L D W I D E

SE Tylose GmbH & Co. KG, Plaquemine, Louisiana, US

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Every day, our engineers work to find the ideal solutions for our customers – for companies in all industries

and sizes and for a wide range of markets. Everything we do is with the same passion for developing a

stateoftheart and affordable solution that meets local standards and official requirements. Here is a

sampling of the projects we have implemented and our special expertise.

R E F E R E N C E P R O J E C T S

27 S U C C E S S S T O R I E S & S P E C I A L K N O W H O W

Customercompliance

HSEcompliance

GMP compliance

01

The taskWhen new pharmaceutical plants are engineered, assembled and set up, customer-specific require-ments along with compliance with domestic and international rules must be observed.

The solutionAnyone who builds a new pharmaceutical plant or expands an existing one must interpret and apply domestic and international regulations – and that requires experience. But even in big companies, there aren’t new plants to be engineered or mod-ernised every day. However, outside engineers like TRIPLAN are continually tied in to all sorts of proj-ects – every client profits from the lessons learned from the service provider’s experience with other companies.

This particularly applies to engineering compli-ance: in planning, assembly and start-up of new plants, both customer-specific requirements and domestic and international conformity with rules must be observed. For example, specific documents are needed even in the design phase; duties and responsibilities must be assigned, and risk plans and timetables must be established. Lack of knowl-edge or failure to comply with GMP guidelines is a clear business risk.

To maintain compliance over a project period of multiple years is not a trivial matter in times of heavy deadline and cost pressure. Given this pres-sure, the temptation to simply follow the path of least resistance is very strong for those involved. However, the quality of the planning can suffer from that, and with it the quality of the plant and finally the quality of the product.

As an external compliance service provider, TRIPLAN relieves the customer’s internal project management staff by coordinating planning, start-up and qualification activities with the goal of completing projects to meet time, budget and quality requirements.

Here, TRIPLAN pays particular attention to the following project phases:

Start phase: the user requirement specifications must be produced – what are the requirements for the plant? What exactly does the order say? Setting up a joint communications culture (language) is of great significance in this project phase – experience shows that compliance can only be reached as a team. To do that, a training session for all engineers involved must be conducted; the dos and don’ts need to be established early.

Planning phase: ensuring that the engineering documents produced cover all the requirements. That particularly includes all management of changes, deviations and open issues.

Start-up phase: ensuring that all the requirements considered in the design have been built and have been tested for proper function while complying with management of changes, deviations and open issues.

For TRIPLAN, engineering compliance means staying within the customer’s requirements, the GMP rules and, to a growing extent, the work safety (HSE) rules.

TRIPLAN engineers with practical experience acting as compliance service providers ensure that a project is executed in a GMP environment in compliance with customer and authority requirements.

ENGINEERING COMPLIANCE IN PHARMACEUTICAL PLANT ENGINEERING

01 The central engineering compliance components for regulated companies: GMP, work safety (HSE) and customer requirements

28 S P E C I A L K N O W H O W

TRIPLAN handles all the disciplines needed for laboratory design using its own resources. By closely tying laboratory design to the design for the building systems, we offer these services from a single source.

The taskHardly any one laboratory is like any other. That is primarily due to the concept of special purposes. A material testing laboratory poses requirements that differ from those of a research laboratory in the pharmaceutical industry, particularly in regard to infrastructure (water, sewage, vacuum, com-pressed air and purified water). In addition, the laboratory designer must consider the employees’ desires for an efficient workplace. And not least, legal framework conditions require expertise of their own as concerns occupational health and safety and environmental protection.

Here, TRIPLAN manages to add particular value when its experts in laboratory design and technical building services engineers work together. The rel-evant disciplines (laboratory equipment, cleanroom design, technical infrastructure such as media, en-ergy, ventilation, cooling, sanitary and heating) and ensuring energy efficiency are all done from a sin-gle source.

TRIPLAN has a fully developed planning tool in its TRICAD MS® CAD/CAE software, covering all the relevant disciplines. The self-developed labo-ratory database makes it possible to do supplier- independent laboratory design, creating a virtual 3D model from the very beginning. This makes it easier to get a good orientation through 3D visual-isation.

Laboratory planning at the Consumer Protection Office

A particular challenge for TRIPLAN’s engineers was designing the new administration and laboratory office for the Consumer Protection Office in Stein-hausen for the Canton of Zug.

Based on the requirements from the competi-tive call for tenders previously put out, the archi-tect and TRIPLAN defined the laboratory area. That was the basis for discussion with users. In multiple workshops with the various users and vis-its to the existing laboratory, the new laboratory was continually developed further. Each workshop was followed by an adjustment of the layout. The intensive cooperation ended in an optimal labora-tory solution and in a quickly obtained permit.

LABORATORY DESIGN: ALL THE RELEVANT DISCIPLINES FROM A SINGLE SOURCE

02 State-of-the-art laboratories, designed by TRIPLAN

02

29 S P E C I A L K N O W H O W

The taskDeveloping a concept for district heating for the city of Aspropyrgos utilising the waste heat from a local refinery.

The solutionIn its renewable energy act entitled “Power Pro-duction from Renewable Energy”, Greece is seek-ing solutions to further develop alternative energy production methods/innovative energy use. A TRIPLAN showcase project is a blueprint for the corresponding plans of the city of Aspropyrgos near Athens: drawing off the waste heat from the MiRO refinery to be used as district heating for the city of Karlsruhe.

Based on an initiative by the Federal State of Baden-Württemberg, contact was made between the public utility company of Karlsruhe, the Greek city council and its advisers. During an initial visit to Karlsruhe, the framework conditions and the possible positive effects of such an ambitious pro-ject were discussed. The waste heat is to come from a nearby refinery, similarly to the situation in Karlsruhe, and be made available to the citizens of the city as district heating, but use as cooling in summer would also be an option.

The refinery operated by Hellenic Petroleum is one of the most modern in Europe. The decisive part of the project will be doing the modifications within the refinery in close cooperation with the operating personnel. Therefore, in addition to re-presentatives of the city works in Karlsruhe, repre-sentatives of TRIPLAN were asked to support the

project development in Greece. TRIPLAN engineers from the Karlsruhe branch have acquired experi-ence through multiple projects in cooperation with the public utility company in Karlsruhe and Ingol-stadt that is decisive for successfully implementing the project in Greece.

All of those involved assume that the project can be started soon and will be profitable for all parties. TRIPLAN’s expertise and years of experi-ence in energy optimisation of process plants are also sought abroad.

The City Council for the City of Aspropyrgos – a suburb of Athens and a significant refinery site – is planning a district heating connection with Hellenic Petroleum.

DISTRICT HEATING FOR ATHENS

01 This refinery in Aspropyrgos near Athens could make its waste heat available to the public utility company as remote heating

01

30 S U C C E S S S T O R I E S

The taskNo refinery or chemical company can operate without storage or transfer facilities (tank farms). TRIPLAN engineers are familiar with the technical standards, the specific local safety requirements and the official framework conditions.

The solutionA distinction needs to be made between production- related tank farms and general tank farms. Produc-tion-related tank farms are permanently assigned to a specific production unit in a plant. The pur-pose of the tanks has been set for the long term; usually there are only changes if there are changes in the production flow. Feedstocks are liquids, gas-es or sometimes solids that can be transferred to/from storage or transported using pumps or other conveying equipment. From the engineer’s point of view, doing the engineering for a production- related tank farm is less time-critical than for gen-eral tank farms; the farm is planned well in advance as part of the production unit.

General tank farms are run by providers of bulk- handling plants or trade services companies and usually consist of the tank area and ancillary facili-ties needed to operate the tank area. The interests of the operator of a general tank farm lie in opti-mally and profitably renting/occupying the tank area it has available – this requires a high degree of flexibility, both from an organisational and a technical point of view. For the engineering con-tractor, that means that general tank farms nor-

mally have to be planned and built faster. Because of the flexibility required, broad practical expertise is necessary in regard to the types of material to be stored, the feasibility of specific technology features and the various safety concepts. In par-ticular, the engineering contractor must be very familiar with the environmental requirements, sometimes using them fully until they reach their limits.

Through its structure, TRIPLAN covers all the industries that require tank farms. Our engineers know the current regulations and provide com-plete design for greenfield units or modernisation of existing tank farms and transfer facilities. With-in the TRIPLAN Group, it is possible to transfer the appropriate specialised expertise from one branch to another and supplement it with the specific op-erator and product requirements.

Analysis of the situation, studies, basic and detailed engineering, logistics planning, local authority engineering liaison, safety analyses, construction management.

PLANNING AND MODERNISING TANK FARMS

02 Bitumen storage, engineered by TRIPLAN

02


01

The taskFeasibility study and detailed design to set up a new rotary kiln; development of a 3D plant model to include the existing building areas, plant compo-nents and new design in neighbouring plant areas. Various process and structural calculations.

The solutionCurrenta’s RVA2 waste incineration facility in Krefeld-Uerdingen – a rotary kiln with afterburner chambers – was put into operation in 1985. The facility is designed to process 25,000 tons/year. Liquid and solid hazardous waste is incinerated at temperatures up to 1,200°C (heat output: 13.8 MW).

The facility, which had been renovated in 1996, was up for modernisation in 2013. In this regard, the TRIPLAN branch in Krefeld received extensive engineering contracts for survey, machinery engi-neering, steel construction design and structural analysis, monitoring the manufacturing process for suppliers and supporting dismantling and in-stallation. In order to determine the status, laser scanning was done in addition to conventional measurements and integrated into our 3D model. Additional steps in the function of RVA2 were planned and integrated into the facility model. Then all the model components were consolidated into an overall facility model for the incineration facility. The model was the basis for various struc-tural analysis computations and for the definition of individual reconstruction stages for dismantling and installation sequences for the main equipment and peripheral systems. That was the basis for detailed scheduling, coordinating assembly and an animation of the overall sequence.

Currenta had all the project stages for delivery, dismantling and installation of the new rotary kiln documented chronologically by a professional film team. A 3D planning model produced using TRICAD MS®, our proprietary planning tool, was used to work out an animated film.

General planning of modifications in existing facilities – one of TRIPLAN’s strengths!

Currenta – a joint venture between Bayer and Lanxess – specialises in waste disposal and ecological cleanup of all types. The services provided: disposing of hazardous waste, collecting and recycling waste, treating sewage, cleaning large tanks and tank cars, making appropriate use of environmental technologies as required and legal advising.

CURRENTA USES A 1,200˚C FLAME FOR WASTE DISPOSAL

01 Visualisation of waste incineration unit

© Currenta


ASSE II: MANAGING THE INCOMING WATER

The taskDesign to build up solution management in the underground storage area of the Asse II pit area on behalf of BeMo Tunneling GmbH.

The solutionThe shut-down pit facility Asse II was purchased by the Federal Government in 1965 and used to store radioactive waste. From 1967 to 1978, drums and containers with low-level to mid-level radio-active waste were brought in. The Federal Radia-tion Protection Office announced in 2010 that it plans to remove the waste.

Until then, it is necessary to manage the in-coming water. Background: every day, about 12 m³ of ground water saturated with salt (incoming water) gets into the mine through fissures in the surrounding mountains over the south flank of Asse at a depth of 500 to 600 metres. In addition to the main collecting area at a depth of 658 me-tres, there are a number of other locations in the mine where salt slurry collects. This is not always water coming in from outside; it also includes salt slurry that was encased when rock salt was formed or comes from the operation of the mine.

TRIPLAN got the design task of handling this incoming water in a technically suitable and safe form. Specifically, the job was to collect all the incoming water, collect it in one place, trans-port it, provide interim storage for it and quickly dispose of it inside or outside the mine. The tech-nology needed to do that consists of equipment to collect incoming slurry on the various levels, high-pressure pumps to transport the slurry to the storage/emergency storage tanks at different depths and equipment to manage and oversee the transport routes.

The TRIPLAN engineers came up with a rins-ing and cleaning concept and produced P&I flow charts, pipe layouts (including 10,000 metres of DN 80 pipes), arrangement plans and steel con-struction overviews. The job also included sizing and specifications for fittings and installed instru-mentation and control equipment. Hydraulic calcu-lations and structural analysis for pipes as well as structural analysis for foundations and steel supports were part of the job. In addition, the client was provided with a functional and process description.

A team with years of engineering experience and very good technical understanding provided an optimal solution for this task, which for an en-gineering company is certainly unusual and prob-ably a one-off task.

Engineering technical measures for water holdup in storage of nuclear waste.


The taskComplete engineering for piping, steel construc-tion, instrumentation and control equipment and electrical equipment for heat tracing of pipes. Calculation of temperature and pressure losses as well as pipe stress analysis.

The solutionOn 8 October 2014, InfraLeuna GmbH put a new medium-pressure steam supply system for the chemical site in Leuna into operation. The back-ground for this investment: energy costs increas-ingly determine the costs of production for chemi-cals. To fight that, InfraLeuna GmbH started in 2013 the energy concept called “ProEnergie 2014+”.

The first step was the signing of a cooperation agreement between InfraLeuna GmbH and MVV Umwelt GmbH in Mannheim to hook up additional, cost-efficient sources of steam for the Leuna chem-ical site. MVV Umwelt GmbH also provides ener-gy from its waste-to-energy facility to InfraLeuna GmbH. It took a construction period of about 10 months to set up the 3 km long steam pipe and to carry out the necessary technical modifications at TREA Leuna. The investment: about EUR 8 mil-lion. “Done on schedule and on budget, construc-tion of the new steam supply system was a success-ful project for all involved”, according to Dr Christof Günther, Managing Director of InfraLeuna GmbH.

Under the Pressure Equipment Directive 97/23/EC, the medium-pressure steam pipes are Catego-ry III. That means that all the technical documen-tation (design and calculation documents) were turned over to TÜV Nord for preliminary assess-ment and approval – which was a challenge given the tight schedule.

Concerning the necessary coordination (engi-neering consultant, TÜV and the construction company), a competent and flexible local engineer-ing partner was engaged as well for the construc-tion phase; the Merseburg branch of TRIPLAN AG demonstrated to be successful here as well.

InfraLeuna GmbH operates the infrastructure for the Leuna site. The services include, but are not limited to, provision of power and water and waste disposal through the central sewage processing facility, as well as logistics and laboratory services.

NEW MEDIUM-PRESSURE STEAM SUPPLY FOR LEUNA

01 The new medium- pressure steam pipe – engineered by TRIPLAN specialists

01

© InfraLeuna GmbH


The taskProcess and equipment engineering, 3D detailed design, construction support/construction manage-ment for the new crop protection production facility in Muttenz.

The solutionOn 22 September 2014, Bayer CropScience opened a crop protection products facility in Muttenz, which is one of its most modern and most efficient production facilities worldwide. The investment was about EUR 100 million.

TRIPLAN’s engineers supported Bayer Crop Science in process and equipment engineer-ing, in the 3D detailed engineering and in con-struction. The majority of the work was done by employees at TRIPLAN’s Lörrach office due to its

vicinity to the project location, but the Leverkus-en branch was also involved. The engineers who work there have years of experience with the cus-tomer and know its processes and its requirements well. Triplan Ingenieur AG with its registered head-quarters in Reinach naturally knows the local standards in Switzerland, so it supported the pro-cess and equipment engineering and construction management.

It took a little more than a year from the start of basic and detailed engineering until mechanical completion. While detailed engineering was still going on, changes in the process had to be imple-mented. The design and installation priorities also had to be adjusted to meet the delivery capabilities for certain equipment.

In addition, TRIPLAN did the study, the basic and detailed engineering and the construction super vision for the necessary expansion of the site infrastructure and power system for the site opera-tor (Infrapark Baselland). This was required to meet the demand of future investments.

“Our strength is not only in engineering production facilities; it is also in designing the as-sociated infrastructure, including all the supply and waste disposal systems. We know the overall requirements; we implement both modernisation and expansion proj ects (brownfield) and new con-struction (greenfield). In order to achieve the best solution for the customer, we use the expertise of the entire group”, says Peter Stromberger of TRIPLAN AG.

Bayer CropScience, a Bayer AG company, is one of the world’s leading crop science companies in seeds, crop protection and pest control, with sales of EUR 8.8 billion in 2013.

BAYER CROPSCIENCE HIRES TRIPLAN TO EXPAND ITS SWISS SITE

02 The new Bayer CropScience production facility for crop protection products in Muttenz

02

© Bayer CropScience AG


Within the KRESTA industries Group, there are neither limitations nor boundaries when it comes to the cooperation of the associated companies. Instead, its competencies and expertise expand into a seamless performance and value-creation chain in plant construction. Using these synergies, KRESTA industries offers added value as a single- source and general contractor for clients from dif-ferent industries.

The first project realised with TRIPLAN takes us to the Netherlands. The customer planned a new chemical plant on a plot that had previously not been used. KRESTA industries was awarded a contract as general contractor. This extensive job included technology, piping, equipment and machinery, electrical, instrumentation and control systems along with steel construction.

TRIPLAN’s key role: engineeringTRIPLAN’s job in this project included detailed engineering for steel structures and planning of pipes. For KRESTA industries, the system partner-ship with TRIPLAN means expansion of its portfo-lio of services offered by adding project study, project planning and engineering services. Because TRIPLAN is often already involved in the early engineering phase for new facilities, KRESTA industries is now in a position to offer customers complete projects – from engineering to on-site start-up – as a one-stop shop in even more fields than previously.

For the project to be successful in the Nether-lands, it was imperative to keep the schedule. That led to a challenge in coordinating all those in-volved and the process management in regard to interfaces. There are frequently delays if not all the companies involved have the same goals and interests. It is hard to keep to deadlines if not all the stakeholders are cooperating. Because the KRESTA industries Group as a general contractor shows itself to be responsible for all services as a single- source supplier, efficient process manage-ment is ensured at all times. A one-stop shopping solution for the customer.

The KRESTA industries Group is building a chemical plant in the Netherlands as a general contractor. It performs all services for project execution based on the “engineering, procurement and construction” (EPC) standard.

FIRST EPC PROJECT WITH TRIPLAN

01 Visualisation of the new plant

01

© KRESTA industries


The taskRedo/optimise the existing flow diagrams, layouts for equipment arrangement and piping design us-ing an integrated 3D model.

The solutionThe Wiesbaden plant houses the worldwide com-petency centre for Agfa Graphics for digital offset printing plates; analogue plates as well are still produced there. When it was necessary to do a partial modernisation of a conveying line, TRIPLAN got the job to first create a 3D model of it. The 3D model was needed because the middle part of the conveying line was supposed to be dismantled and expanded. The goal of the retrofit was to make the system more efficient, saving resources and optimising product quality. Without a 3D model, the planned expansion would not have been possi-ble in the extremely limited space.

The job was executed in the project office in Wiesbaden, right next to the construction site and in close cooperation with the Agfa project manager.

The fact that the available building space left no expansion area available, even though two rinsing stages and larger tubs were supposed to

be placed there, was the first major challenge in the project. The second one followed: it was ex-tremely difficult to get an overview of the installa-tions in the basement under the system because of various unused pipes and ducts. In the past, only the connections were removed during dismantling, so there were many pipes and ducts for which the purpose was no longer recognisable. Due to the installation density of the pipes and ducts, a com-plete as-built survey would have been too costly. Therefore, the survey was done only for affected lines by preparing routing isometrics that were then taken over into the 3D model.

The combination of a virtual 3D model for vi-sualisation and to optimise the new installation and existing obstacles, combined with the necessary manual on-site survey, resulted in an economical planning solution.

The AgfaGevaert Group is one of the world’s leading companies in imaging solutions and information technologies. Agfa Graphics offers integrated prepress solutions for the print and media industry.

EXPANSION/MODERNISATION OF AN AGFA PRODUCTION LINE

02 Visualisation of the production line

02

© Agfa-Gevaert


SE Tylose GmbH & Co. KG is a wholly owned subsidiary of Shin Etsu Chemical Co. Ltd, one of the biggest Japanese chemical companies. SE Tylose is a globally significant manufacturer of cellulose ethers.

TRIPLAN AS A PARTNER FOR A US PROJECT

The taskBasic and detailed engineering of a production facility, including infrastructure in the US, to manu-facture hydroxyethylcellulose (HEC) – in an inte-grated international team.

The solutionThere is a long tradition of TRIPLAN and SE Tylose working together; two challenging large projects have already been engineered by the two compa-nies together at the Wiesbaden site. This project posed additional challenges in execution for both partners. First, this was the customer’s first facility being set up outside Germany – in the US. The proven integrated team made up of the client and TRIPLAN was expanded by an engineering team from the parent company, Shin Etsu Chemical, which was also later responsible for execution at the construction site.

In addition, the scope expanded greatly for TRIPLAN; in addition to the proven collaboration in process design, equipment specification and layout and piping design, we also took over the entire civil, structural and architectural engineer-ing and preparation of piping specifications. Of course the design had to meet applicable local US standards and regulations. In addition to the local project team, the TRIPLAN Group also brought in experts from the branches in Leverku sen, Karls-ruhe, Gelsenkirchen, Bad Soden and Merseburg and, for civil, structural and architectural design, colleagues from India and the US; at its peak, over 45 TRIPLAN employees were involved. There were also up to 15 client employees involved. The proven execution concept of an integrated team with the customer was also used here – in this case, it was particularly necessary to overcome the substantial time differences between the teams in Germany, the US, Japan and India.

This project is a good example as to how one can build on an established business relationship – based on an established partnership approach – to master new challenges together as well. We were able to successfully implement our “follow the customer” model here too.

“With TRIPLAN, we can also strike a new path, both in operations support engineering and in pro-jects; this has again been proven”, says Cornell Schulz, the head of projects at SE Tylose.

01

01 The heart of a new plant under construction

© Shin Etsu Chemical Co. Ltd


Trinseo Deutschland GmbH took over multiple plants from Dow Olefinverbund GmbH. At the Schkopau site, there are multiple plants that manufacture synthetic rubber and polystyrene.

The taskWork out a detailed specification/call for tenders coordinated with the client for the new dryer, plan-ning the arrangement of the equipment, various electrical designs and the design of the utilities.

The rubber produced by Trinseo Deutschland GmbH (formerly Styron) in Schkopau is sold under the Buna brand name, among other labels. Trinseo’s cold emulsion polymerised SBR varieties are used as multi-purpose rubber in nearly all parts of the rubber industry, mostly in manufacturing tyres and industrial rubber items, such as conveyor belts, vibration attenuators for the automotive industry and industrial hoses.

The TRIPLAN branch in Merseburg was hired to plan a new conveyor-belt dryer so that the plant could be expanded further. About one month was the time slot from the beginning of the dismantl-

ing of the old three-story conveyor-belt dryer until the start-up of the newly installed one-belt dryer.

How can such a complex project be done in such a short time frame? TRIPLAN Merseburg’s answer: 1.) Compliance with all the safety require-ments and development of a technical solution with no variants. 2.) A schedule consistently im-plemented by all those involved. Maximising early work preparation to implement the new dryer while the old plant was continuing to oper-ate was important for keeping to the schedule. On 15 October 2014, the new E-SBR Straße Süd drying facility was put into operation.

The customer was extremely satisfied because of the very good results of the new plant. “The quality of the drying at maximum capacity accom-panied by optimal energy use has fulfilled our expectations.” One challenge was to integrate the drying equipment with a reduced active drying surface and the newly added exhaust system, crumb transport and new electrical supply into the limited space provided. In the end, the TRIPLAN engineers were also able to flexibly support Trinseo’s construction management in all phases of implementation and start-up.

An additional project in which the decades of experience of TRIPLAN in brownfield projects (projects involving existing facilities) is valued. “Dear people from TRIPLAN, thank you very much for the good job!” was what came from Trinseo – as a service provider, can you ask for anything more?

NEW DRYER FOR TRINSEO: FROM 3 FLOORS TO 1 BELT

02

02 Chemical park Schkopau

© Trinseo Deutschland GmbH


Our service: consultation on permits for planned investments, preparation and update of documents, coordination of the overall process and coordination with all parties involved, engineering liaison with authorities.

The taskSeamless execution of filing applications for per-mit proceedings under the Federal Emissions Act (BImSchG), the Water Management Act (WHG), regulations for protection against explosions and building law as the basis for rapid and economic project completion.

Permit proceduresWe do documentation coordination for our custom-ers and compilation of documents for procedures requiring permits under the Federal Emissions Act (BImSchG), the Water Management Act (WHG) and building law, as well as coordinating professional expert opinions and support in discussions with au-thorities, both for new permits and for changes.

That includes:

Consulting and clarification of ability to obtain permits

Compiling the documents relevant to permits

Preparing the application documents

Preparing for discussions and coordinating with the authorities issuing permits

Preparing or coordinating professional expert opinions

Providing support at public hearings on permits

Checking the permit requirements and providing support in implementation

Safety conceptWe work out plant safety concepts with the client and provide support in their implementation.

Protection against explosionsWe support the client in defining explosive zones and in preparation/optimisation/updates of the ex-plosion protection documents and testing concepts.

The TRIPLAN team consists of specialists with years of experience and extensive knowledge of the laws, regulations and rules. This provides the customer with safety and gives it an element of freedom for its core business.

Protection against explosions in fluxDecentralised energy generation, heat transfer and off-gas treatment – those were the central topics in the Quo Vadis? symposium of Dürr Clean Technology Systems in Bietigheim-Bissingen. Achim Gulde, a TRIPLAN specialist on explosion protection and occupational safety as well as an expert in protection against explosions under Section 29a BImSchG, gave a presentation there about protection against explosions being in flux. He explained the new version of the Operational Safety Regulation (BetrSichV) and the change to the Hazardous Materials Regulation (GefStoffV).

For industrial production facilities as well as in the pharmaceuticals and food industries, Gulde is sought after as an expert in explosion protection. His references pertain to preparation of docu-ments on explosion protection for tank farms, pro-duction facilities, sewage treatment facilities and on optimising concepts of explosion protection and explosion protection zones. The list of projects he has been involved in range from calculation of source ventilation within production facilities as a basis for configuring ventilation equipment for blending areas to computational checks of existing pressure-relief devices for a spray drying unit to optimising the inerting procedure for chemical re-actors. Gulde is known as a lecturer at seminars for TÜV SÜD Akademie GmbH.

SAFETY AND ENVIRONMENTAL PROTECTION AND PROTECTION AGAINST EXPLOSIONS

40 S P E C I A L K N O W - H O W

The jobThe Federal Employment Agency analysis from June 2014 shows that there is a clear shortage both at the engineer level and at the non-academic specialist level. In building services engineering and disposal engineering technology, heating and cooling technology, sanitary and plumbing, there is also a clear lack of applicants. It takes an aver-age of 109 days before a position can be filled.

TRIPLAN’s Executive Board is not just stand-ing by and watching this development. In February 2013, it followed the recommendation of the man-agement of the Burghausen branch: we’ll offer ap-prenticeships! The training as a “Technical Sys-tems Planner for Building Service Engineering and Equipment Technology” was defined as a profes-sional goal.

In November 2013, Georg Hopper and Peter Rippel successfully passed their trainer test at the Chamber of Commerce and Industry (IHK) for this programme. In this way, TRIPLAN ensures that employees with professional experience, who have been trained in both legal and pedagogical respects, conduct the training.

Two young men took this opportunity to train with TRIPLAN in Burghausen in 2014: Stefan Weimer and Lukas Pittner. Why did they decide to get trained at TRIPLAN as “technical systems design-ers”? First of all, they said it was a chance to make their first forays into the working world in a large engineering company with many locations. They both see the demanding and high-quality training as an opportunity to become sought-after specialists.

They are quite correct in this assessment: after completing a three-and-a-half-year training course that is regulated on a Germany-wide basis, technical systems planners in building services engineering and equipment technology make technical draw-ings and 3D models for the fabrication and instal-lation of technical building systems. They mostly work in design and planning offices of building and equipment technology companies. In addition, they work in engineering and architectural firms, as well as public administration.

It is obvious why TRIPLAN is doing its own training: the goal is to make flexible use of well-trained young employees after they have passed their tests in TGA (building services engineering) and VT (process technology), thus actively com-batting the lack of specialists that can already be felt today. In this way, the company gains competi-tive advantages and can serve customer require-ments on a long-term basis. According to Albert Krawutschke, “Not least, it is also important to build up knowledge and skills with young employ-ees and keep them at TRIPLAN!”

A technical systems designer for building services engineering.

COMBATTING THE LACK OF SPECIALISTS: TRIPLAN OFFERS APPRENTICESHIP POSITIONS

01 Trainees, trainer and management of the Burghausen branch

01

41 S P E C I A L K N O W - H O W

1985Market launch of TRICAD software

Technology leadership with CAD/CAE industry

applications

2007Foundation of TRIPLAN

Consulting GmbHThe company is founded to

support the expansion of the product life-cycle management

(PLM) business

2008Acquisition of

Planungsbüro Burkart AG and Planungsbüro

Burkart GmbHThe expert in classical plant engineering is focused on

the chemicals, biotech, phar-maceuticals and vitamin

industries and energy technology

2005Acquisition of IMA

IngenieurgesellschaftAsset deal to expand the

engineering business with a focus on chemicals

2009Partnership with

Neilsoft, IndiaInternationalisation

with engineering for the Asia region

2011First patent for the Closed

Coke Slurry System (CCSS)Beneficial to occupational safety and environmental

protection. TRIPLAN establishes itself as a technology provider

2012 TRIPLAN acquires the

German business of the former company TEBODIN

Gelsenkirchen The asset deal means a

reinforcement for TRIPLAN’s national and international

project business

2013KRESTA becomes majority

shareholder of TRIPLAN AG TRIPLAN, an independent

company, becomes a system partner and part of the

KRESTA industries Group

2014Foundation and opening

of subsidiary TRIPLAN India Pvt. Ltd

An engineering hub for South-east Asia and the Middle East is

founded in the city of Pune

GROWTH AND INNOVATION MILESTONES: 48 YEARS OF TRIPLAN


The foundation philosophy is devoted to decentralised

structures


Switzerland The focus is on life science engineering and chemicals

1983Start of CAD software

developmentThe computer assists with development and design

through 3D imaging


1991Foundation of

TRIPLAN AustriaNew site at the

Chemiepark Linz

1995Foundation of TRIPLAN Prague Building services engineering

solution on MicroStation (technology leader)

Cost advantages with new branch; all TRICAD modules are integrated

into the MicroStation industry standard

1997Life-cycle database

development Higher productivity thanks

to direct access to all project data

1999Foundation of TRIPLAN AG

Plans begin for the later IPO

2000Acquisition of CADISON

and A&HThe IT profile of TRIPLAN is

further honed by the acquisitions

2001IPO of TRIPLAN AG and acquisition of

Venturis GmbH Long cooperation with

Venturis results in acquisition

2003Foundation of

VenturisIT GmbH The TRIPLAN Group's

IT activities are consolidated into VenturisIT GmbH and

spun off as an independent IT GmbH

1989Software development

TRICAD building services engineering

Leading industry solution for building services engineering, digital factory design and plant

design

The reputation of TRIPLAN as a reliable and, at the same time, innovative development and engineering partner is based on almost 50 years of experience in plant engineering.

Endowed with comprehensive consulting, engineering and service competencies, we offer the complete range of instruments required for quality-, time- and cost-oriented solutions for all project phases.


EditorTRIPLAN AGAuf der Krautweide 3265812 Bad Soden a. Ts. Germany

Phone + 49 61 96/60 92-0Fax + 49 61 96/60 92-203

[email protected]

Concept, layout and realisationmpm Corporate Communication Solutions, Mainzwww.digitalagentur-mpm.de

PhotographyGetty Images (pages 4/5, 16), Helena Schaetzle/laif (page 19),Tom Parker/REPORT DIGITAL-REA/laif (page 15 top),Fotolia (page 45)All other images: TRIPLAN respective reference projects

PrintingPh. Reinheimer, Darmstadt

Issue: J une 2017

44 I M P R I N T

TRIPLAN AGAuf der Krautweide 3265812 Bad Soden a. Ts. Germany

Phone + 49 61 96/60 92-0Fax + 49 61 96/60 92-203

[email protected]

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