the Netherlands Pharma partnership with MSD - Tebodin

Mr. Waldemar Pernak
Large renewable
energy source
Renewable energy company Ozen Plus asked Tebodin Poland to
co-manage the final stage of construction of a green power and
charcoal plant that will be one of the largest of its kind.
Final phase
Ozen Plus produces charcoal/charcoal
briquette and electricity using biomass:
mainly round/scrap hardwood timber
and straw. The new plant is located in
Wałcz (town in the north-west part
of Poland), in the area of Słupsk Special
Economic Zone. Tebodin Poland,
with project manager Mr. Waldemar
Pernak, was asked to co-manage a final
phase of the project: obtaining permits
and coordination and supervision of
faultless execution of the design by
August 2011.
New wastewater
storage
Top green and charcoal plant
The plant will cover almost 9 hectare
and produce about 52,500 MWh of
green electricity and 20,000 tons of
charcoal and charcoal briquette annually.
The power plant is one of the largest
using renewable energy sources in
Poland outside the professional power
industry and the largest and most
modern factory of charcoal at least
in Europe.
More info: Mr. Robert Wojciechowski
Office Director Poznań
+48 61 668 76 00 l r.wojciechowski@tebodin.pl
OCI Nitrogen, a division of Orascom
Construction Industries (OCI) of Egypt, holds a major share in a
melamine production joint venture in Bontang, Indonesia. In an
EPCm project, Tebodin is realizing extra wastewater storage capacity.
Melamine is an organic compound often combined with formaldehyde and urea to
produce a specific resin. This resin is often used in combination with wood to produce
for instance particle boards and laminate floorings. Due to the high stability, as well as
fire-resistant properties, tropical hard wood applications can be replaced by melamine
resin treated soft wood to spare precious natural resources.
Mega PDO project puts Tebodin
in Oman’s big league
The OCI Kaltim Melamine plant
produces 60,000 tons of melamine per
year. Its commercial end product is sold
to many countries in the Asia Pacific
and South America region and can be
used in a wide range of applications.
‘We need additional wastewater storage
to deal with surplus process wastewater
produced during normal operation and
shutdown periods’, says OCI program
Tebodin World
October 2011, Volume 51, Edition 3
3 5 7
Moving from wet to dry
cement production
CRH is an international leader in the
cement industry and employs about
80,000 people at over 3,700 locations
in 35 countries. Situated just outside
the ancient city of Kamyanets-Podilsky
in rural western Ukraine, the cement
plant was built in the 1970’s.
The traditional wet production process
involved mixing lots of water with
crushed lime, clay and iron additives.
The water then had to be evaporated
before feeding the slurry into the rotary
kiln, a massive oven for baking
the ‘clinker’.
Raw meal
‘The wet process took enormous
amounts of energy’, says CRH project
Pharma partnership with MSD Construction management
for Lafarge
Irish building materials group CRH modernized the Podilsky cement
factory, one of the largest in Ukraine. Moving from wet to dry cement
production brings significant reductions in energy use and emissions.
Tebodin’s experience in cement technology was important in every
stage of this complex project.
The Podilsky cement factory in Ukraine
manager Mr. Marek Skwarski.
‘With dry cement production technology,
the mixture contains little moisture and
is called ‘raw meal’ rather than slurry.
The new plant meets EU standards
and has reduced our production costs.
We expect to lower the energy need by
more than 50 percent, while improving
productivity by 40 percent. The project
was carried out within a Kyoto Protocol
framework and is major contribution
to achieving emission reductions.’
Design and author supervision
Tebodin began the reconstruction work
with detail design documentation in
October 2007. ‘A team of 80 engineers
from four different offices has since
manager Mr. Werner Ploumen. ‘The
new equipment will also reduce the
wastewater flow to the treatment plant’.
The project entails the installation of a
600m3 tank, including the pump and
associated utilities.’
Full integration
Especially when the normal process
is interrupted or when a shutdown is
unavoidable, the current system has
insufficient storage volume to empty all
process equipment. ‘The new tank will
be fully integrated to enable OCI’s Clean
Production Concept’, says Mr. Richard
Oude Reimerink of Tebodin Indonesia.
worked on the design, permitting,
technical consulting, cost control and
supplier communications’, says project
manager Mr. Oleg Moskalenko.
‘The project consists of 75 different
objects. Tebodin was also responsible
for the author supervision, technological
analysis and adaptations, as well as
construction support.’
Impressive
The new dry process line was
commissioned in September of this year.
Everything seems to be outsized on this
project: the pre-heater tower with a
height of 120 meters, the dome-shaped
limestone storage with a diameter of
106 meters, and the conveyor bridge
with a length of almost half a kilometer.
Mr. Moskalenko: ‘Both the scale and
the technology are impressive. The
production process is tightly controlled
and highly automated. The new line also
benefits the local environment through
significantly lower dust emissions.’
More info: Mr. Valeriy Levko
Managing Director Tebodin Ukraine
+380 44 426 49 40 l v.levko@tebodin.ua
The tank will be built and connected
during normal operation, with tie-ins
to be performed during the planned
shutdown for cook-out. In close
cooperation with the OCI specialists,
Tebodin is responsible for the
engineering, procurement, construction,
installation and commissioning of the
new equipment. ‘The project will take
a full year from the basic design to
commissioning and start-up, which is
expected in October 2012.’
More info: Mr. Richard Oude Reimerink
Director Tebodin Indonesia
+62 21 25 26 777 l r.oudereimerink@tebodin.cn

Current projects
A selection of our various current projects
8°
5°
10°
8°
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26°
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13°
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15°
2 Tebodin World, October 2011
Construction of shopping and entertainment
center Magellan near Kharkiv in Ukraine
Scope: Construction management, technical
support during commissioning
Reconstruction of the existing production in
the Leningrad region (Russia) for Heinz
Scope: Technical support, engineering surveys and
elaboration of project documentation
Framework agreement for plant changes in
Belgium for BASF
Scope: engineering services
Expansion and renovation warehouse and
training facilities for Andreas Stihl in Poland
Scope: project management
Completion design package of 57,5
Megawatt wind farm in South-West Poland
for Eolfi
Scope: conceptual and detail design
New project for Hettich to build plant to
manufacture furniture / kitchen fitting
in India
Scope: master planning and concept plan, HVAC
design, green concept, concept and basic design,
cost estimate, detailed design and tendering and
construction management
New spray bottle packaging line in current
factory of Procter & Gamble in Vietnam
(Dong An- Binh Duong)
Scope: site clearance, AHU system, fire protection
system, fire alarm system, lighting system, power
supply system and pipe rack
Repair of 3 cement silos for the cement
production plant of Holcim in Popovac,
Serbia
Scope: design and consultancy services
Modifications of the existing logistic hall for
PointPark Properties in the Logistic Park in
Lozorno, Slovakia
Scope: Technical supervision
Development of Poti Sea Port for APM
Terminals in Georgia
Scope: environmental site assessment (phase 2, soil
and ground water analysis)
Local temperature at project location in Oktober
State-of-the-art plant for BASF
Tebodin is a trusted international partner for BASF. The April 2011 issue of World magazine gave an update
on projects with BASF in Dubai, Germany, Belgium and the Netherlands. Now Tebodin has won the
bidding for a cutting-edge BASF project in Bahrain.
State-of-the-art plant
BASF will build a state-of-the-art plastic
additives blending plant in Bahrain
Industrial Investment Park in Salman
Industrial City to produce antioxidant
blends for the Middle East market.
BASF was positive about Tebodin’s
successful completion of the basic
engineering phase of the project.
BASF’s project manager for the plant
Dr. Wulfrich-Friedemann Beer said:
‘We appreciate the pragmatic approach
of Tebodin Bahrain’s in understanding
and bringing together local and BASF
requirements during the basic
engineering phase.’
The EPCm contract was signed by the
seated gentlemen Dr. Gordian Schilling
(left, BASF) and Mr. Mehdi Honar (Tebodin)
And so BASF invited Tebodin Bahrain
to participate in competitive bidding
for Engineering, Procurement services
and Construction management (EPCm)
for the plant.
Winning offer
Mr. Mehdi Honar, Director of the
Tebodin Bahrain office, recalls:
‘We provided a competitive, flexible
offer with a multidisciplinary engineering
team in Bahrain office as an added value
in order to succeed. With the help
of our network, we submitted a
winning proposal.’
Mr. Luc Swinkels (right, Nunhems) and Mr. Jim Ross (Tebodin) Mr. Wim Bosma (Tebodin), construction supervisor
As a global specialist in vegetable
genetics and services, Nunhems serves
the professional horticultural production
industry and supply chain. The company
has developed an extensive range of
over 2,500 varieties of 28 fruit and
vegetable species, from leek to tomato
and from lettuce to watermelon. Hybrid
varieties have traits and characteristics
suited to different climates and growing
conditions.
Nunhems operates 26 R&D stations in
14 countries, as well as seed processing
centers in the Netherlands, United
States, Chile, China and India. ‘The
relationship between Nunhems and
Tebodin has been long and fruitful’,
say Nunhems project manager Mr.
Luc Swinkels and Tebodin project
manager Mr. Jim Ross. CCE engineered
the laboratory that is now being
reconstructed before they became part
of the Tebodin organization.’
Nunhems R&D center
Tebodin is responsible for the
design, tender procedures, contract
management, and construction
supervision. The extension of laboratory
and offices is taking place in several
stages. Tebodin made the basic
engineering package in 2009 and
prepared the contracting packages and
procurement services for the building,
laboratories, mechanical/HVAC and
electrical/instrumentation installations in
the first half of 2010.
Mr. Swinkels and Mr. Ross continue:
‘The new lab and offices were completed
and ready for occupation in June
2011. The R&D personnel were then
re-housed to the new premises, so
the demolition works could start.
Certain climate chambers must remain
operational during the rebuilding so we
have provided them temporary power
and water supplies. As a team we are
confident the completely rebuilt older
facilities will be ready for occupation at
Successful partnership
The engineering started in July 2011 and
the plant is expected to start production
by December 2012. Dr. Gordian
Schilling, BASF Production Manager
Middle East, expressed his confidence in
the partnership: ‘We are convinced that
we will together - continuing our open
and fair cooperation - deliver a successful
project.’
More info: Mr. Mehdi Honar
Office Director Bahrain
Fruitful cooperation in expanding
R&D laboratory
+973 17 70 05 44 l mhonar@tebodinme.com
BASF polyetherol plant in Germany
Nunhems, a business unit of Bayer CropScience, is among the world’s leading vegetable seed suppliers.
In the small village of Nunhem in the south of the Netherlands, the company is refurbishing and extending
its R&D laboratory with the help of Tebodin.
the end of November 2011 as planned
and within the project budget.’
India spin-off
As a spin-off Tebodin CCE is now involved
in the development of a new multi-crop
breeding station for Bayer CropScience
in Chandipa, India. Experts from the
Deventer office worked on the conceptual
design for this prestigious R&D center that
will focus on rice, millet, corn and cotton.
Tebodin India is preparing the basic
design for the facilities, including offices,
utilities and all associated infrastructure.
Climate chambers with plants being cultivated
More info: Mr. Bert Frowijn
Office Director Deventer
+31 570 63 89 00 l b.frowijn@tebodin.com

Mega PDO project puts Tebodin in Oman’s big league
The STS-Tebodin joint venture has been entrusted by Petroleum Development Oman (PDO) with the
prestigious Engineering & Maintenance Contract for the Northern Oman area.
Redevelopment Project
The first mega project awarded to
STS-Tebodin under this EMC is the
Ghaba North Redevelopment Project.
Ghaba North is a producing field in
northern Oman since 1975 under PDO
concession area of Qarn Alam. The
production has declined steadily over the
years. To fully exploit the reserves, PDO
decided to revive the existing field by
drilling 22 new wells and installing new
production facilities.
Its tomato ketchup is world famous
and in Great Britain alone, 1,5 million
cans of Heinz beans are sold every
single day. Heinz has various factories
in Europe, which accounts for a third of
total turnover. The company owns many
‘local’ heritage brands and continuously
develops new products. Heinz project
manager Mr. Robert Stuart: ‘Developing
this new European research center is
the biggest investment in innovation the
company ever made.’
The city of Nijmegen is in the heart
of Food and Health Valley, the Dutch
knowledge center for agriculture
and food production that proves
increasingly attractive to companies and
professionals. Mr. Stuart: ‘The Heinz
The extension of Knauf Gypsum’s Cikampek plant
The concept study has been done by
PDO and the Front End Engineering
Design has been entrusted to Tebodin
under the EMC. The total estimate
project cost of surface facilities is
282 million USD and the total man
hours required for FEED are an
estimated 75,000. This job was awarded
to Tebodin in May and it is to be
completed in a tight schedule of
eleven months.
Innovation Center will incorporate
the current research department in
Nijmegen and be responsible for the
technical development of new products
for European markets. More than 100
top researchers and product developers
will start work here in the first quarter of
2013, when the center is completed.’
Sustainability
The new R&D facilities will include
product development kitchens,
laboratories, a pilot plant, offices, and
a visitor center, according to Tebodin
project manager Mr. Wouter Perry.
‘We worked together very well in the
concept phase and were awarded the
design contract at the start of this year.
We do a common thing uncommonly
Dedicated Task Force
The facilities being designed for high
sour and high CO2 requires up to
50 specialists, engineers and designers.
A dedicated Task Force has been set
up with the best engineers available
in Oman. Mr. Adesh Malhotra, Project
Manager of the Task Force, says: ‘It
is a challenge worth accepting and
demonstrating. It will prove that
Tebodin has joined the big league in
Oman in oil and gas.’
Heinz builds European innovation center
H.J. Heinz Company, one of the largest food companies worldwide, is going to concentrate its European
R&D operations into a single purpose-built innovation center in Nijmegen, the Netherlands. Tebodin is
responsible for the design of the new facilities.
well. In August our team of 25 engineers
completed the conceptual, basic and
detailed design for all building related
disciplines, including architectural,
structural, HVAC and electrical. We
are proud of the façade of the building
and the energy-efficient installations.
Sustainability was an important design
theme. After the final tender stage,
construction began in September.
We also provide site supervision and
construction management assistance.’
More info: Mr. Rob Kwakkelstein
Office Director The Hague
+31 70 348 09 11 l r.kwakkelstein@tebodin.com
Further expansion of long-term relation
with Knauf
From March to September, Tebodin assisted Knauf Gypsum with the extension of a plant in Cikampek,
Indonesia. Knauf is a major international building products group and a long-time Tebodin client.
Experience, innovation, flexibility
Knauf values experience and innovation,
emphasizing specialist expertise, an
understanding of customer needs and
pioneering achievement. Tebodin has
worked with Knauf Gypsum in Russia,
Ukraine, Australia and Indonesia, and
with Knauf Insulation in Belgium,
Croatia, Czech Republic, France,
Germany, Russia, Serbia, Slovakia,
Ukraine, and the UK.
For this project in Indonesia, Knauf
chose Tebodin for its flexibility, being
able to adapt quickly to the situation
Tebodin will be using PDMS for
modeling the facilities for the first time
and for this an experienced PDMS
colleague from the Netherlands supports
the team.
Exceeding targets
All required technical safety and HSE
deliverables are included in Tebodin’s
scope. ‘Tebodin work on this project has
so far exceeded the PDO targets,’ says
PDO Engineering Team Leader
Mr. Robert Stuart
Artist impression of the Heinz Innovation Center
as the project was already on the way.
Knauf project manager Mr. Wayne
Studdon: ‘Tebodin has high standards in
engineering, safety and quality. We also
needed the local, cultural approach.’
International teamwork
Tebodin supplied engineering,
procurement support and site
supervision for the addition of silos,
conveyors and mixers powder packing
machines to the production facility. The
team was selected from the international
network, with site supervisor Mr. Deddy
Suhenra from Tebodin Indonesia and
the project manager and four specific
engineering experts from the Vietnam
office.
Project manager Mr. Doan Ngoc Son
says the team was alert to the client’s
needs on the project and beyond:
‘The team has to be proactive, not just
thinking about the contract but with
Mr. Aruna Kumar. It is a crucial project,
both for Tebodin and PDO, and when
delivered in time and up to the
PDO/Shell quality standard, it will herald
many more awards to Tebodin, both in
FEED and detailed engineering work
under the EMC.
More info: Mr. Wout Voorthuis
Director STS-Tebodin
+968 2461 2401 l wout.voorthuis@ststeb.com
Mr. Wouter Perry
an eye for the next project.’ Knauf
appreciates good communication and
attention to the project, and has already
shared plans for further expansion of the
plant with Tebodin.
More info: Mr. Richard Oude Reimerink
Director Tebodin Indonesia
+62 21 25 26 777 l r.oudereimerink@tebodin.cn
Tebodin World, October 2011
3

Improving process safety with liquid hammer studies
Liquid hammer is best known as ‘water hammer’ or fluid hammer and the noise in the pipes when you quickly close the kitchen or bathroom tap. In chemical installations,
the same phenomenon can be very dangerous and damaging. These risks can be excluded with assessments in the design phase.
Liquid hammer is also known as
hydraulic shock. A high-speed
pressure wave is caused by a
momentum change in the fluid that
results from the forced stop when
a pump is operated or a valve is
closed. In general, the greater the
lengths of straight pipe, the bigger
the risk of liquid hammer.
The surge and shock waves can
cause severe vibrations and even
lead to pipe collapse, says Tebodin
process engineer Mr. Steffen
Walgien at the Rotterdam office.
‘Liquid hammer risks should always
be studied during the design
phase of a piping system, before
the choices on pipe dimensions and
materials are made.’
Mitigating measures
Any extensions or increased flow rates in
piping systems also warrant an analysis.
Tebodin helps companies to keep their
installations safe with liquid hammer
studies and the engineering of mitigating
measures. ‘These measures limit peak
pressures and may include installation of
pressure relief valves, expansion tanks or
slowly-closing valves.’
Tebodin usually employs a two-step
approach. The first step is a quick-scan.
Mr. Walgien: ‘We assess the risks on the
basis of conservative rules of thumb.
The great advantage is that, if the piping
system makes it through the quickscan,
no more detailed studies will be
necessary. Should the second step be
HTL is an international provider of
independent bulk liquid storage and
logistics. Owned by Emirates National
Oil Company (ENOC) of Dubai, HTL was
created to consolidate ENOC’s existing
oil and gas terminal investments, and
expand the business globally on the
crest of increasing demand.
International expansion
Having started with terminals in
the Emirates and Saudi Arabia,
HTL expanded from 2003 onward
and today also operates Asian terminals
in Singapore and South Korea, as
well as African terminals in Djibouti
and Morocco. Europe is next, with
construction work on a new terminal
planned to start in Malta later this year.
According to Tebodin project manager
Mr. Mathijs Bicknese, HTL is committed
to high environmental and safety
standards. ‘The company already is a
global leader in the terminal business
and manages more than five million
cubic meters of storage capacity.
The terminals mainly store bulk oil
and LPG.’
4 Tebodin World, October 2011
Liquid hammer studies
Liquid hammer studies fit into a range of consultancy services Tebodin offers to oil and gas storageproviders.
Read more about this phenomenon in the following articles.
Mr. Steffen Walgien
needed after all, then we use advanced
software called ‘WANDA’ for dynamic
simulations of fluid behavior in piping
systems.’
The Tebodin knowledge on liquid
hammer used to be concentrated in the
Netherlands and the Middle East. Over
the past few years it has been actively
developed and dispersed throughout
the organization. ‘Knowledge exchange
takes place not only through training
sessions and expert meetings, but also
during the increasing number of projects
we take on internationally. This way we
can guarantee the highest standards and
safety levels’, concludes Mr. Walgien.
More info: Mr. Björn Erkens
Office Director Rotterdam
+31 181 65 17 11 l b.erkens@tebodin.com
Serving international bulk liquid storage providers
Liquid hammer studies fit into a range of consultancy services Tebodin offers to oil and gas storage
providers, such as Horizon Terminals Limited (HTL).
HSE services
Over the years, Tebodin has provided
consultancy services to the HTL terminals
in Dubai and Fujairah in the United
Arab Emirates, in Yanbu in Saudi Arabia,
and in Djibouti. ‘These include HSE
services such as fire fighting strategies
and design, risk assessments, HAZOP
studies and environmental impact
assessments’, says Mr. Bicknese. ‘We
also performed surge analyses, as well
as site-specific studies such as heat
radiation modeling, layout verifications
and simulations of expansion plans.
Our services are used as layout and
process design input, for internal QHSE
requirements or for compliance with
regulations. We bring together experts
from different offices to get the right
people on the job. Involving the client
in our studies is key in achieving feasible
site safety improvements and practical
engineering solutions. Mr. Idriss Hassan
of HTL Djibouti states that due to
close cooperation, the report turned
out to be very practical and useful for
the improvements of the safety design
and operations. Mathijs Bicknese:
‘Cooperating closely with the client
makes a real team effort of our work,
and has led to numerous follow-up
projects.’ Tebodin has recently been
awarded a complete site risk assessment
of the HTL terminal in Djibouti including
the HAZOP of the entire facility.
More info: Mr. Marco van der Linden
Office Director Dubai
+971 4 221 58 39 l mvdlinden@tebodinme.ae
Maasvlakte Oil Terminal, Rotterdam,
the Netherlands
One of the world’s largest terminals, the
Maasvlakte Oil Terminal on the Dutch
North Sea coast is a joint venture of
several oil companies. The stored crude
finds its way to the participants through
several transport pipelines. Maasvlakte
Oil Terminal asked Tebodin to perform
liquid hammer analysis for every possible
pipeline alignment. As this would have
led to a very sizeable study, quick-scans
were performed on the ‘worst-case’
alignments, after which the critical
ones became the subject of dynamic
simulations.
Odfjell Terminals, Rotterdam, the Netherlands
For Odfjell Terminals in Rotterdam, Tebodin carried out a project in which a rarely used pipeline between the Shell refinery
and Odfjell was made suitable for pumping products in both directions. Tebodin took on the engineering, procurement,
project management and construction supervision for the pump and piping systems on the Odfjell side. With the help of
dynamic simulations, Tebodin defined the minimum closing times for the new inline valves in order
to prevent liquid hammer problems.
LPG bullet tanks (450 m 3 ) on Horizon Djibouti Terminal Limited
From left: Terminal Manager Mr. Idriss Hassan, Mr. Mathijs Bicknese and
HSE Manager Yacin Abdi Bogoreh

Pharma partnership with MSD
Partnering brings so much more than a list of well executed projects. Recently, the Tebodin office in
Eindhoven walked the road to realization and expansion of a partnership with MSD, the second-largest
pharmaceutical company in the world and a global leader in consumer products and animal care.
Reactor vessel at MSD
Pharma demands
In March, Tebodin and MSD signed
an umbrella contract for architecture
and engineering services for small sized
pharma projects in Oss and Boxtel in the
Netherlands. The demands on this partner
were specific. First, a single contract for
the MSD projects, mainly for the site Oss.
Secondly, project execution according
to the stringent local and national
regulations. Thirdly and crucial to MSD:
project support with pharma knowledge,
such as quality by design, a life cycle
approach and validation support.’
MSD research facility
Smart from the start
Tebodin ticked all the boxes, as
corroborated by MSD project portfolio
manager Mr. Paul Gortemaker: ‘Tebodin
is flexible, result oriented with a
hands-on mentality and has the required
process and pharma knowledge to get
the job done. The multidisciplinary
character and pharmaceutical project
approach of Tebodin ensures services
fully geared to the specific project
requirements. Furthermore, Tebodin is
capable of providing a challenging view
to ensure useful input to improve the
Sustainable solutions
process of the project execution form
the concept to realization.’
Full support
By early involvement in MSD projects,
Tebodin can execute projects more
efficient and provide a high level of
quality. Mr. Gortemaker: ‘Tebodin’s
pharmaceutical concept support for
scoping unambiguously define project
proposals that fully support business
needs and decision making for MSD.
The conceptual design approach of
Tebodin results in a complete package
of user requirements being translated
in the project concept. All business
representatives get the opportunity
to add what they believe is needed.
The quality of the design documents
of Tebodin in the basic and detailed
engineering phase enables a right first
time project execution with respect to
quality, costs and time lines.’
More info: Mr. John Horn
Office Director Eindhoven
+31 40 265 22 22 l j.horn@tebodin.com
From left: Mr. Mark Courage (Tebodin), Mr. Paul Gortemaker (MSD)
and Mr. René Delreu (Tebodin)
Tebodin wants to provide smart and sustainable solutions for each client. A group of experts in
the Netherlands attained a sustainability course this summer. The goal is to move sustainability towards
the center of our activities, and to clearly link it to the Tebodin way of doing things.
Sustainability is a concept that everyone
supports. The question is how to
develop the broad notion that all of us
share the responsibility for preserving the
planet and its resources into a practical
approach for day-to-day business.
The good intentions and available
expertise are currently mostly dedicated
to partial solutions.
‘We have an expert group identifying
opportunities in specific projects’, says
Mr. Patrick Pellen, who set up the first
training course. ‘We want to make
sustainability part of our whole thinking
process in every project. To do this,
colleagues need to be aware of the
possibilities and the expertise in our
office network.’
Early adaptors
Of about thirty specialists were trained
to raise awareness of the broad
knowledge, expertise and tools already
available to support clients in sustainable
development. Mr. Pellen: ‘The initial
focal points include Cradle to Cradle,
quick scans, buildings and energy.
Several participants were surprised
to find out how many like-minded
colleagues there are, and how much is
being done already. That sounds like a
great start and an indication of what we
can really achieve for our clients when
we put our minds to it.’
More info: Mr. John Horn
Office Director Eindhoven
+31 40 265 22 22 l j.horn@tebodin.com
Mr. Patrick Pellen shows one of Tebodin’s
electric cars
Economic round table
meeting Vietnam -
the Netherlands
On 28 September H.E. Mr. Nguyen Tan
Dung, Prime Minister of Vietnam and
H.E. Mr. Mark Rutte, Prime Minister of
the Netherlands, hosted an Economic
Round Table in The Hague, the
Netherlands with a top level delegation
of CEO’s of the Netherlands’ business
community.
Tebodin has participated in this meeting,
with the presence of Mr. Pieter Koolen,
chairman of the Board of Directors. The
From left: Mr. Pieter Koolen, H.E. Mr. Nguyen Tan Dung and H.E. Mr. Mark Rutte
Large shopping center
means large crowds
Apsys Group develops and manages
shopping centers in France, Poland
and Russia. Its current portfolio in
Poland includes 14 shopping centers
with a retail space of over 600,000 m 2 ,
with Manufaktura in Łódz´ as the
flagship development.
Construction work on Łacina, which will
be about twice the size of any other
shopping center in Poznan, is planned
to start in 2012 and be completed in
2014. It is part of a wider city renewal
project covering 60 hectares. Łacina is
located in the east of the city, on the
right bank of the river Warta, near the
roundabout Rataje. Tebodin is designing
the reconstruction of the local road
infrastructure.
Apsys project manager Mr. Krzysztof
Woz´niakowski outlines the scale of
the development: ‘The center is going
to have almost 95,000 m 2 of rentable
Artist impression of the Łacina shopping center
aim of the Round Table meeting was
to create an opportunity for a direct
dialogue on a number of strategic issues
facing Dutch companies doing business
in Vietnam, between the 14 CEO’s of the
Netherlands and Prime Minister Dung,
who was accompanied by a delegation
of Ministers and CEO’s from Vietnamese
companies. The Economic Round Table
aims to further strengthen the economic
cooperation between both countries.
In the city of Poznan, commercial real estate developer Apsys is
building one of Poland’s biggest shopping centers. It will attract
a lot of extra traffic.
space, about 300 shops of different sizes,
25 restaurants, a multiplex cinema and a
multi-level car park for 3,200 cars.’
A traffic analysis in 2010 showed the
need for some adaptations to the
neighborhood infrastructure, explains
Tebodin project manager Mr. Krzysztof
Sobolewski. ‘We are reconstructing the
existing local transport system, adding
new elements such as a pedestrian and
bicycle tunnel under the roundabout and
access ways to the car park. The design
work, for the building permit, tender,
and execution stages, is carried out by
a team from our Poznan and Katowice
offices.’
More info: Mr. Robert Wojciechowski
Office Director Poznań
+48 61 668 76 00 l r.wojciechowski@tebodin.pl
Mr. Krzysztof Sobolewski
Tebodin World, October 2011
5

Greenfield plant for Gestamp Sungwoo
Gestamp and Sungwoo, two leading companies in automotive parts, are continuing their collaboration in
southern India. They chose Tebodin India as their EPCm partner for their stamping and assembly plant,
to be built in Chennai.
Following the success of their three
joint Indian operations, Gestamp and
Sungwoo have decided to build a fourth
joint venture plant in Chennai. With
a fast-track project in mind, they have
turned to Tebodin India for support
in engineering, procurement and
construction management. The EPCm
contract followed on Tebodin’s assistance
in the geotechnical, topographical and
contour studies.
Global partner
‘Our main objective is to enable our
clients to achieve their ambitious plans,’
says Mr. T.K. Sudheeran, Tebodin India’s
Office Director. ‘With this purpose in
mind, we have teamed up with
Tebodin offices in the Czech Republic
Tebodin’s OHSE framework:
Passionate commitment to zero harm and zero impact
Tebodin QHSE Director Mr. Alistair Greening explains how people are
the root of - and the key to - an outstanding Occupational Health,
Safety and Environment (OHSE) framework with positive effects
both internally and externally.
Mr. Alistair Greening (left) and Mr. Taco Boerstra,
Director Tebodin office Abu Dhabi
6 Tebodin World, October 2011
and Romania – a global partner for our
global client!’
The Chennai stamping and assembly
The key to zero harm
Mr. Greening sums up the Tebodin
vision for OHSE and the goal of Zero
Harm: ‘We will not deviate from our
goal of Zero Harm in all that we do.’
Care, more than anything, lies at the root
of that goal: ‘Our underlying principle
will always be that we care for people,
the environment and the communities
we work in. We have developed high
standards to ensure health and safety at
our workplaces and to have zero impact
in the communities and environments
we work in throughout the world.’
People are also the key to success
of OHSE, says Mr. Greening:
‘Understanding and applying the basic
principles is the key. Our processbased
management system is a simple
description of what we do. Everyone’s
involvement and adoption of these
About Bayer MaterialScience
With 2010 sales of EUR 10.2 billion,
Bayer MaterialScience is among the
world’s largest polymer companies.
Business activities are focused on the
manufacture of high-tech polymer
materials and the development of
plant, a green field project (along with
its offices, utilities, rainwater harvesting
and parking facilities) will come up
From left: Mr. Vijay Prabhu, Mr. Siva Kumar, Mr. Kevin Jeon, Mr. Iñigo López Brañas, Mr. T.K. Sudheeran
and Mr. Vinod Aroo
processes will lead to an OHSE system
which will be used day-to day and lead
to Zero Harm.’
The assurance of OHSAS
Tebodin has chosen to implement
OHSAS 18001.
Mr. Greening: ‘OHSAS is a globally
recognized management system that
provides assurance to companies
and clients that the promotion of
OHSE is one of the main principles
of the organization. The framework
provides a consistent method for
identifying and controlling health and
safety risks, reducing and eventually
eliminating accident occurrences in the
workplace. It also provides an effective
platform for identifying and complying
with legislation and for the effective
application of training and monitoring.’
The client gets these assurances, and
more, says Mr. Greening: ‘Our planned
risk assessment strategy delivers
innovative projects cost effectively,
with reduced downtime.’
innovative solutions for products used
in many areas of daily life.
The main segments served are the
automotive, electrical and electronics,
construction and the sports and leisure
industries. Bayer MaterialScience is a
Bayer Group company.
Bayer MaterialScience plans to update
and improve the process flow diagrams
for its downstream plants in several
countries around the world. ‘Most of
these plants offer customized polymer
solutions to the local markets’, says
Bayer MaterialScience project manager
Mr. Thorsten Schiffer. ‘In some of
these facilities, the existing process
documentation is already according to
our Bayer standards. Other sites with
different historical backgrounds now
have the chance to profit from the global
in a plot approximately measuring
63,000 m2. The concept design and
basic engineering for the first phase
are well underway, with activity on site
now focused on grading and filling the
grounds before the upcoming
monsoon period.
‘We are confident that with Tebodin,
the new greenfield project would be a
state-of-the-art factory in Chennai’, says
Mr. Subra, CFO Gestamp Sungwoo India.
Ceremonial start
In keeping with Indian tradition,
Gestamp and Sungwoo management
were present in India for the
groundbreaking ceremony called Bhoomi
Puja. Usually bhoomi pooja is performed
prior to the start of any construction,
thereby requesting the permission from
Bhoomi Devi (mother earth) to get her
goodwill and assistance for the trouble
free completion of the construction
project. It is also to seek forgiveness
for the disruptions made for the many
living beings already in and on the land
premises. On the 15th of September
Positive effects
Mr. Greening concludes that OHSE has
positive effects, both internally and
externally: ‘OHSE is a key driver for our
management worldwide. We are also
ably supported by all our professional
and committed people in offices and
in the field who have the passion and
energy to have OHSE as a core principle.
Our QOHSE framework outlines to our
colleagues, contractors, clients and other
stakeholders Tebodin’s commitment
Framework contract with Bayer MaterialScience
Bayer MaterialScience and Tebodin Germany signed a framework contract on the development of a global standard of process flow diagrams
for all downstream production plants.
Mr. Thomas Rothammel (left) and plant project manager for maintenance
Mr. Andreas Nahrstedt
framework contract. We are glad to work
with Tebodin who can provide such
engineering services with employees
speaking the relevant local language.’
Site visits around the world
Tebodin project manager Mr. Thomas
Rothammel: ‘The framework contract
covers every Bayer MaterialScience
downstream plant. Once the global
document standard is agreed upon,
Tebodin will visit and produce an
updated documentation for each site.
All site visits will be organized through
our global network, with the help
of partners in those countries where
Tebodin currently has no office. The
project management is controlled from
Germany and all design and drawing
work will be executed in our Vietnam
office. Currently we just finished the
the Gestamp management team invited
Tebodin India team to join them in
praying, laying bricks and planting trees.
‘It was an honor,’ says Mr. Sudheeran,
‘and a sign that Gestamp Sungwoo
welcomes us as part of their team.’
Mr. Subra of Gestamp Sungwoo during
the Bhoomi Puja ceremony
More info: Mr. Thekkedath Sudheeran
Office Director India
+91 44 434 03 200 l tksudhee@tebodin.in
OHSAS 18001 celebration at the Tebodin office in Dubai, United Arab Emirates
to ensuring the health and safety of
everyone at our workplaces and to have
zero impact in the communities we work
in throughout the world.’
More info: Mr. Alistair Greening
QHSE Director
+31 70 348 09 11
a.greening@tebodin.com
P&IDs of one production site
in Germany together with our
Vietnamese colleagues.’
Support from Vietnam
Tebodin Vietnam is experiencing strong
growth and increasingly delivers sizeable
contributions to projects for global
clients, according to Managing Director
Mr. Ronald de Vries. ‘Even as a relatively
recent addition to the international office
network, we are able to offer valuable
support to other offices. Bayer is a
perfect example of the way we can work
together very closely within a network of
specialists, regardless of their location.’
More info: Mr. Jeroen Schouten
Office Director Gelsenkirchen
+49 209 170 90 0 l j.schouten@tebodin.de

Construction management
for Lafarge
The Tebodin office in Moscow has been performing engineering
services for the Lafarge cement plant in Russia since July 2010.
The current project is being realized in
the Kaluga region, close to the village
Ferzikovo, about 200 km southwest of
Moscow. The designed plant capacity
is 5,000 clinker tons per day (cement
production capacity of about 2 million
tons per year).
The specific feature of the project is that
the Oka river separates the quarry and
the production site. This natural obstacle
has been considered by the design.
The philosophy of this project is
extraction of raw materials from the
quarry, primary crushing on the quarry
site and further transportation of the
preliminary crushed material by a long
Abu Dhabi Marine Operating Company
(ADMA OPCO) operates the offshore
facilities for Abu Dhabi National Oil
Company. It produces oil and gas from
two major fields in the Arabian Gulf,
Umm Shaif and Zakum. A sub-sea
pipeline network transfers the crude
from these fields to Das Island for
processing, storing and exporting. Some
500,000 barrels of oil and one billion
standard cubic feet of natural gas are
produced here every day.
belt conveyor to the production site
on the other side of the Oka river.
From June 2011, in addition to
the current general designer and
procurement contract, Tebodin started
performing Technical Zakazchik services.
Under the new contract Tebodin is
responsible for the technical supervision
(scope of works and works quality),
construction works control, also client
control and further commissioning
on the site.
More info: Mr. Andrey Sosnovsky
Managing Director Tebodin Russia
+7 495 258 80 58 l a.sosnovsky@tebodin.ru
Unique project
Flaring is the last line of defense in the
emergency release systems of refineries
and crude oil processing plants. It
also disposes of waste products and
unrecoverable gases from oil wells.
There are basically two types of flares.
‘The elevated flare has a larger capacity,
but can cause noise pollution and
considerable heat radiation, creating
large no-go areas’, says Tebodin project
manager Mr. Manoj Munishwar at the
Main driver for this has been the
development of new production
assets in emerging markets.
The fall of the Berlin wall in the
nineties for example resulted in
a huge number of projects for
Skoda Auto in the Czech Republic.
More recently we have seen a
huge investment increase in the
automotive sector in both Russia
as well as China and India.
The development of our network in
emerging markets has been roughly
in line with the development of
production facilities for both
OEM’s (such as BMW, Nissan) as
well as TIER 1 and 2 suppliers such
as Robert Bosch, Magna and many
others.
As a result Tebodin is proud to
be working for these reputable
companies in both mature as
well as emerging markets on a
huge number of brownfield and
greenfield projects. If you would
like to know what we could do
for you, please contact us.
More info: Mr. Hans Kleiboer
Director Corporate Business Development
+31 70 348 09 11
j.kleiboer@tebodin.com
New flaring system for Das Island in
Arabian Gulf
Atmospheric Gas flaring can be made reliable, safer and less of a burden on the environment.
For ADMA-OPCO, Tebodin Middle East is working on an improved atmospheric flaring system for
Das Island, where Abu Dhabi’s offshore oil and gas is being processed.
Industrial, Health & Nutrition, Energy
& Environment, Oil & Gas, Chemicals,
Infrastructure, Property
The automotive industry
including all its suppliers has
been one of our key markets
for the last few decades.
Abu Dhabi office. ‘This project is unique
in terms of its scale and the fact that
we are integrating the existing flaring
system with multiple units of smokeless
enclosed ground flares.’
3D PDMS
The new system involves complicated
process safety controls, partly due to
very low working pressures. Existing
South Relief Flare will be relocated and
the area will be graded to install two
new ground flares, each with a capacity
of 50 million standard cubic feet per
day. ‘The integration of new ground
flares calls for complicated interfaces.
The project is supported by a strong
engineering team and in a period of just
nine months, we are using laser scanning
and the 3D PDMS model to get the job
done’, says Mr. Munishwar.
The project is of utmost importance to
ADMA-OPCO also being a first of its
kind, says client project manager
Mr. Abdulaziz Al-Ahmed who is
supported by a responsible project
management team.
Procurement
Tebodin is ready to order procurement
packages for long-lead items such
as the ground flares and the
42 inch butterfly control
BMW - EPCm services for a new car production plant in Shenyang, China
Michelin - EPCm services for development of an existing site into a technologically advanced tire
production center, covering a total area of approx. 100,000 m² in Olsztyn, Poland
Mecaplast - Validation of technical documentation, project management and construction management
for the refitting of two production halls for upholstery for cars at Pardubice, Czech Republic
Mr. Manoj Munishwar
valves and ultrasonic flow meter. ‘We
have involved flare vendors from the
beginning, so that our design is based
on the latest available technology.
This reduces risks during the EPC
stage. ADMA-OPCO appreciates our
knowledge and project management
services. We were right on schedule to
complete the work in September.’
More info: Mr. Taco Boerstra
Office Director Abu Dhabi
+971 2 406 60 00 l tboerstra@tebodinme.ae
Tebodin World, October 2011
7

Detailed engineering for water blending
The Electricity and Water Authority in
Bahrain owns and operates all local
water related facilities. The Authority
plans to have four new stations for water
blending and transmission designed and
constructed, and three existing stations
to be refurbished. The stations generally
consist of ground storage tanks which
feed the pumps located in a pump
house. The pumps either blend the water
and send it for storage on site, forward
the water to another station,
or pump the water to an elevated
storage reservoir on site from which
the drinking water is distributed to
Poland has substantial onshore wind
energy potential, especially in the
coastal northern part of the country.
The financial crisis created obstacles
in fulfilling it, but now Poland’s wind
energy sector is set to grow fast, says
Mr. Marcin Krupiński of Polish Energy
Partners (PEP).
‘At the moment the installed capacity
in Poland is under 1,400 MW. It is
expected to reach 5000 MW in 2015,
and approximately 13 GW in 2020,
when wind power is to have a share of
17 percent in the country’s electricity
production.’
PEP is a developer of energy projects
and offers know-how on financing,
construction and operation. The
company also produces energy from
biomass and wind. ‘We produce over
eight percent of all renewable energy
generated in Poland. Using modern
technologies, we started harvesting wind
energy in 2007.
Tebodin first secured the building permit
with the conceptual design for the wind
farm to be located in north-east part of
Poland. ‘We have broad experience in
this field and have become an important
8
Tebodin World, October 2011
consumers by gravity.
Tebodin is subcontracted by Panorama
to execute the detailed engineering
scope of work. Panorama and Tebodin
are on track to have all stations up
and running within the contractual
period of two years time. The successful
partnership has already enabled Tebodin
to secure the follow up water project
involving the detailed engineering of
four water pumping stations under
the same contractor, emphasizing the
strong long term position Tebodin has
established in the local water sector.
partner for wind farm developers’,
says Tebodin project manager
Mr. Pawel Rzodkiewicz. ‘In this
project we not only design the access
roads, assembly platforms and turbine
foundations, but also the 110kV
substation, high voltage grid
connection and medium voltage
connections. There is an open and
flexible working relationship with PEP,
and we have already been rewarded
with a new assignment involving
the design of a 30 MW biomass
power plant.’
Other ongoing wind farm projects
in Poland we are involved with are
projects for NorventoPolska, GreenBear,
Eolfi and GDF Suez.
More info: Mr. Jaroslav Hrabě
Office Director Warsaw
+48 22 334 41 11 l j.hrabe@tebodin.pl
More info: Mr. Mehdi Honar
Office Director Bahrain
+973 17 70 05 44 l mhonar@tebodinme.com
DSM relocates Vietnamese feed plant
Design of new wind farm in
turbulent market
Wind power in Poland is on the move again. For Polish Energy
Partners, Tebodin is designing a new wind farm in the north east of
the country.
Mr. Bishara Nussair of Panorama Contracting and Engineering Service Ltd. (right)
and Mr. Mehdi Honar of Tebodin in Bahrain
The Asian markets for animal feed are growing fast. As a global client,
DSM relies on Tebodin for the relocation of its feed premix plant in
Binh Duong, Vietnam.
The Vietnam-Singapore Industrial Park in
Binh Duong, now known as VSIP I, was
established in 1996. The 1000 ha park
attracted so many investors that VSIP II
was conceived ten years later. Situated
15 kilometers north of VSIP I, the new
park offers plenty of space to burgeoning
industries.
DSM Nutritional Products is a leading
supplier of vitamins, carotenoids
and chemicals to the feed, food,
pharmaceutical and personal care
industries. ‘Due to strong growth in the
animal nutrition markets of South East
Asia, the company decided to build
a new and larger feed premix factory
in VSIP II’, says Mr. Robert Redman,
general director of DSM Vietnam. ‘We
have a global framework agreement with
Tebodin. They know exactly what we
expect and have the ability to execute
this project according to our standards.’
Appointments
Mr. Richard Oude
Reimerink has
been appointed as
Director Tebodin
Indonesia of Tebodin
Indonesia as per
13 July 2011.
Mr. Kumar
Shanmugham will
be appointed
Director EMC
(Engineering and
Maintenance
Contract) Tebodin &
Partner as of
1 November 2011.
COLOPHON
The plant design will be based on the
successful design from DSM who has
5 plants of similar designs in China and
one in Russia. Tebodin project director
Mr. Aad Speksnijder: ‘The design will
need a few adjustments because of local
regulations plus Tebodin has helped
DSM make some improvements for
local conditions. The heart of the factory
is a turnkey process unit from Buhler.
All other process equipment will be
relocated. In this EPCm project, we are
designing the civil works and the nonprocess
parts. We deliver procurement
and construction management
services, as well as the Environmental
Impact Assessment and full permitting
assistance.’
More info: Mr. Ronald de Vries
Director Tebodin Vietnam
+84 8 38 21 76 55 l ronald@tebodin.vn
As of 19 September
2011 Mr. Maciej
Gwóz´dz´ has been
appointed Office
Director Szczecin,
Poland, next to
his position of Office
Director Gdansk.
As per 1 November
2011 Mr. Wouter
Naaijkens will be
appointed Office
Director Qatar.
Tebodin World - Tebodin Consultants & Engineers house journal is published quarterly.
Editorial/design/production Public Relations Department of Tebodin B.V., in cooperation
with The Freelance Connection, O-pen Coaching & Workshops, Talig, Printing office
De Eendracht and The Attic - Graphics Studio.
Photography Several Tebodin employees and AerolinPhoto B.V. (photo Maasvlakte
Oil Terminal)
Should you require more detailed information concerning any of the subject matter
in this issue, please contact the nearest Tebodin office or the PR Department via
info@tebodin.com.
Western Europe
The Netherlands
The Hague +31 70 348 09 11
Hengelo +31 74 249 64 96
Groningen +31 50 520 95 55
Maastricht +31 43 329 47 77
Eindhoven +31 40 265 22 22
Rotterdam +31 181 65 17 11
Velsen +31 251 26 24 64
Deventer +31 570 63 89 00
Bergen op Zoom +31 164 21 60 00
Belgium
Antwerp +32 3 250 28 01
Germany
Gelsenkirchen +49 209 170 90 0
Schwarzheide +49 35752 94 80 0
Central Europe
Poland
Warsaw +48 22 33 44 111
Gdańsk +48 58 785 36 90
Szczecin +48 91 454 21 36
Poznań +48 61 668 76 00
Katowice +48 32 782 59 99
Cracow +48 12 295 24 50
Czech Republic
Prague +420 251 03 81 11
Pardubice +420 466 05 36 11
Ostrava +420 591 001 591
Slovak Republic
Bratislava +421 232 66 02 00
Hungary
Budapest +36 1 205 96 01
Szeged +36 62 429 738
South Eastern Europe
Serbia
Belgrade +381 11 313 24 65
Romania
Bucharest +40 21 311 71 86
Eastern Europe
Russia
Moscow +7 495 258 80 58
St. Petersburg +7 812 718 37 80
Ekaterinburg +7 343 344 37 70
Rostov +7 863 240 14 70
Ukraine
Kiev +380 44 481 21 21
Lviv +380 32 242 14 31
Kharkiv +380 57 728 12 88
Middle East
United Arab Emirates
Abu Dhabi +971 2 406 60 00
Dubai +971 4 454 28 70
Bahrain
Manama +973 17 70 05 44
Qatar
Doha +974 44 67 56 54
Oman
Muscat +968 24 62 80 00
Sohar +968 99 65 14 49
Saudi Arabia
Jeddah +966 2 669 55 95
Asia
China
Guangzhou +86 20 83 63 60 20
Shanghai +86 21 52 56 95 22
India
Chennai +91 44 434 03 200
Indonesia
Jakarta +62 8128 649 11 26
Vietnam
Ho Chi Minh City +84 8 38 21 76 55
Africa
Libya
Tripoli +218 21 334 03 50
See our website for the latest information on
offices and addresses.
WWW.TEBODIN.COM
no. 3 - October 2011