Bahnhofstraße 43 D-28844 Weyhe, Bremen, Germany
Fon +49 (0) 4203-78291-0 Fax +49 (0) 4203-78291-24
[email protected] www.gcea.de
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The company
We are an innovative company, located to the south-west of Bremen, with vast experience in the field of process plant construction. In addition to the engineering services themselves, we are also proficient in their realisation and execution.
Our wide-ranging portfolio and our technological depth give us a market position that significantly sets us apart from mere engineering offices and traditional plant construction companies.
All our engineering services can be combined, thus enabling us to solve costly interface problems that are typical for plant construction projects.
A wide range of services for innovative solutions Pre-engineering – process planning & project planning – plant realisation
As an engineering service provider for plant construction planning and execution in the
▪ chemical ▪ mineral oil ▪ pharmaceuticals ▪ food ▪ dairy ▪ paper ▪ water management ▪ waste disposal industries, we constantly develop intelligent, customer-specific solutions. Due to today’s demands, environmental protection integrated into production and energy- saving projects are increasingly becoming the focal point of our work.
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On request, we can provide you with the entire “portfolio of plant construction services” from a single source. We offer tailor-made, customer-specific solutions for all sub-areas. Whether it be planning a new plant, extending an existing plant, plant modernisation or the remodelling of process plants in order to optimise processes, we provide the complete range of planning services, from concept development to commissioning the process plant, including the documentation.
Through cooperation with, for example, architects, structural engineers, logisticians, other experts etc., we can offer you the whole planning process from a single source. GCEA coordinates the entire project, from the planning activities to the realisation.
The statutory stipulations, such as BImSchG, WHG, ATEX and TA Luft, and the technical regulations including TRBS and TRWS, as well as FDA, GMP and EHEDG, are taken into account and complied with throughout all the planning and realisation phases.
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The GCEA team
We are an experienced team that continually works on innovations and further developments. The project managers’ knowledge and experience are passed on to the younger members of staff. The knowledge and experience therefore remain within the company and can be used and implemented in your project.
Our engineers and designers take part in on-going training measures and all our customers can expect state-of-the-art services.
Dipl.- Ing. Ronald Groß Managing Direktor
With us at their side, our customers can face the challenges of the present day and of the market.
Our engineers develop new processes or implement existing customer processes, supervise and manage their construction and, finally, optimise them in ongoing operation. Existing process plants are enhanced, optimised and automated in exactly the same way.
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We are:
chemical, process, environmental and automation technology engineers, designers and technical drawers
Short communication channels within the company and the use of intelligent software modules guarantee fast information sharing processes. The engineers who planned your project usually also work on its implementation, thus ensuring a smooth transition.
We are experienced plant construction project managers. Each one of us boasts decades of experience in the business and is proficient with all the tools used for professional project management.
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Our customers
We have customers in a wide variety of sectors of the processing industry
▪ Chemical industry ▪ Mineral oil industry ▪ Pharmaceutical industry ▪ Food and alcohol/tobacco industry ▪ Dairy ▪ Paper industry ▪ Public utilities and waste disposal industry
With each project, we respond individually to all customer-specific needs and implement them systematically in solutions suitable for the specific operational circumstances.
In addition to energy and resource savings, our innovative ideas result in a significant increase in profitability.
Our aim is to ensure customer satisfaction.
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Our project tasks
The main components of our projects are
▪ Situation analyses ▪ Energy savings and reductions in running costs ▪ Process and plant optimisation ▪ Automation of existing process plants ▪ Changes to how existing plant components are used ▪ Extensions, additions, modifications and replacement procurement ▪ Entire new process plant construction, incl. buildings
Storage tanks at a food processing company
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Engineering
Pre-Engineering / pre-planning / consulting ▪ Literature searches ▪ Feasibility studies ▪ Process analysis ▪ Budgeting ▪ Economic feasibility analysis ▪ Concept studies ▪ Performance specifications ▪ Requirements specifications ▪ System and critical point analyses ▪ Situation analyses of the actual conditions on site, performed manually or using scanning technology (surveying technology), with the resultant 3D CAD model for further drawing work ▪ Carrying out laboratory and pilot plant trials ▪ Developing and devising new process concepts ▪ Process selection ▪ Design of plant conversions and new constructions
Process flow diagram of a production process
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Basic & detailed engineering / plans of execution ▪ Determining the process-related basic data ▪ Situation analysis ▪ Process design and planning ▪ Specification of the plant components incl. control engineering equipment ▪ Complex mass and energy balances ▪ Process flow diagrams (schematic flow diagrams) ▪ P&I process flow diagrams with database for creating apparatus, fittings and control engineering lists, as well as their specification sheets ▪ Designing and developing entire plant layouts, including 2D/3D piping planning with bills of quantities for piping ▪ Isometric drawings generated from the 3D model, incl. bill of materials ▪ Plant project planning and apparatus dimensioning / equipment specifications ▪ Tender documentation and bills of quantities ▪ Energy-related analysis of existing process plants ▪ Identifying investment costs and running costs ▪ Safety analyses, FMEA, HAZOP etc. ▪ Explosion protection documentation
3D plan of additional storage tanks
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3D CAD model of a new heat transfer oil process plant
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3D CAD model, situation
analysis using scanning
technology
Existing production plants can be surveyed using a 360° scanner. The 3D model created is edited via a CAD programme. New plants are integrated into the model and old plant components are removed. The model reflects the actual situation and contains all the details that are needed for further planning activities.
Isometric drawing generated from a 3D AD model, incl. Bill of material
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Approval engineering Setting up, operating and changing the mode of operation, the properties and the location of plants that are listed in the appendix of the 4th BImSchV directive concerning the German Federal Immission Control Act (BImSchG) require official approval. We accompany you throughout the entire approval process and we use our in-depth expert knowledge to support you with initial approvals in accordance with Article 4 BImSchG, amendment notifications in accordance with Article 15 BImSchG or approval applications for fundamental modifications to a plant in accordance with Article 16 BImSchG. ▪ Accompanying consulting and support during the entire approval process in accordance with the German Federal Immission Control Act (BImSchG), in the capacity of a planning office and/or creator of draft outlines ▪ Consulting with relation to environmental legislation, including the assessment and classification of the subject matter of your application with respect to the German BetrSichV, GefahrstoffV, TEHG, UVPG, StörfallV and TA Luft regulations, industrial emission guidelines and the relevant technical rules and regulations ▪ Presenting your project to the approval authority as well as clarifying and agreeing on the type and scope of the application documents with the authorities as part of the application conference or of the application hearing ▪ Creating the required approval documents in accordance with the German Federal Immission Control Act (BImSchG) on the basis of the state-specific sets of forms, including the text passages, as well as integrating other applications (e.g. building applications, drainage applications etc.) ▪ In-house creation of the schematic flow, process flow and P&I diagrams with additional information in accordance with DIN EN ISO 10628, as well as all other drawings required for the approval that are non-binding under building law, e.g. source diagram, layout diagram, explosion protection diagram etc. ▪ In-house creation of new explosion protection documents and diagrams or revision of existing ones ▪ Coordinating the specialist assessors involved (explosion protection, fire prevention, immission and emission forecasts, VAwS/WHG, ecological audit, occupational safety) as well as integrating the required reports into the application documentation ▪ Collecting, procuring and preparing all the information needed for submitting the application, such as official layouts, plot certificates, land development plan, land use plan, machines and apparatus lists, hazardous substance register, safety sheets, source of emissions lists and diagrams, hazardous substance storage capacities for assessing the major accident obligations in accordance with SEVESO III, waste balance sheet, volume of waste water, storage, filling and handling plants, production, treatment and usage plants, substances that are hazardous to water, information on the corporate site etc.
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▪ Creating the electronic application documents as well as the printed copies (between 3 and 15 copies depending on the type and scope of the application) required for submission to the approval authorities as well as for the ordering party/applicant’s documentation
Electronic application in line with immission control legislation, via the state of Lower Saxony’s EliA programme
Approval applications and amendment notifications in accordance with the German Federal Immission Control Act (BImSchG)
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Project management
▪ Defining environmental protection measures in accordance with the German VbF, BetrSichV, VawS and WHG regulations ▪ Selecting suitable installation companies and component manufacturers/suppliers ▪ Calling for tenders and comparing them ▪ Preparing contracting negotiations ▪ Controlling (schedule and costs tracking) ▪ Building site management, commissioning and approval inspections ▪ Training the operators and maintenance staff ▪ CE documentation with safety analysis, as well as documentation for maintenance and servicing ▪ Plant safety / health and safety plan ▪ Creation of explosion protection documentation in accordance with ATEX ▪ Safety analysis ▪ Qualification and validation documents ▪ As-built documentation
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Plant engineering: Turnkey implementation
▪ Container construction
▪ Apparatus construction
▪ Steelwork ▪ Assembly work ▪ Pigging systems ▪ Pipeline construction ▪ Trace heating systems
▪ Insulation Food storage tanks
Pipeline construction
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Our core areas of expertise
Chemical and thermal process engineering ▪ Chemical reaction processes ▪ Mixing processes ▪ Extraction of solid and liquid substances ▪ Distillation of organic solvents ▪ Fractionation and stripping columns ▪ Outlet air systems (e.g. absorbers) ▪ Evaporation ▪ Drying processes ▪ Recrystallisation ▪ Emulsification and emulsions ▪ Filling ▪ Loading facilities (incl. tankers and ship loading) ▪ Above ground and underground storage tanks for substances that are hazardous to water, inflammable or explosive (solvents, food etc.) ▪ Storing, transporting, dosing and filling liquid products and bulk materials ▪ CIP cleaning systems (Cleaning In Place), SIP
Ship loading
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Production plant piping
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Water technology process engineering
▪ Membrane processes: micro, ultra and nano filtration as well as reverse osmosis (RO) ▪ Precipitation, flocculation, sedimentation, flotation ▪ Oxidation, degassing ▪ Ion exchange (decarbonisation, softening, demineralisation, heavy metal removal) ▪ Biological processes Adsorption (e.g. activated carbon adsorption for removing AOX, CHC, DOC etc.) ▪ Filtration (sand and multi-layer filters) (iron extraction, demanganization and deacidification via dolomitic filter material, suspension extraction and waste water filtration, dry filtration etc.) ▪ Waste water stripping ▪ Thermal waste water evaporation ▪ Chemical dosing ▪ Sludge treatment
Percolator for CO2 degassing
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Drinking water treatment (filter stages 1 and 2)
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Public utilities and waste disposal facilities ▪ Steam and condensate systems ▪ Heat transfer oil systems ▪ Hot water supply ▪ Warm water supply ▪ Cooling water supply, cooling towers ▪ Ice slurry supply ▪ Industrial and process water treatment ▪ Refrigeration systems ▪ Compressed air and nitrogen supply ▪ Ventilation and air extraction systems ▪ Dust extraction ▪ Waste water treatment, waste water disposal ▪ Water demineralisation systems ▪ Vacuum systems
Warm water generation using steam Page 20
3D CAD representation of a temperature control circuit
3D CAD representation of steam supply pipes
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Customer references
Food industry, Beverages Chemical industry ▪ AZUL–Kaffee, Bremen ▪ ACMOS Chemie, Bremen ▪ Bacardi, Buxtehude ▪ ArcelorMittal, Bremen ▪ Barilla Deutschland, Celle ▪ BASF, Nienburg, Trostberg, ▪ Cargill, Hamburg Oldenburg, Minden ▪ Walsroder Casings, Walsrode ▪ Bio Diesel, Wittenberge ▪ Chr. Hansen, Nienburg ▪ BÜFA Composite Systems, Rastede ▪ Crespel & Deiters, Ibbenbüren ▪ Büfa Reinigungssysteme, ▪ CSM, Delmenhorst Oldenburg ▪ Henry Lamotte Oils, Bremen ▪ CHT, Oyten ▪ Jäckering, Hamm ▪ Emery Oleochemicals, Loxstedt ▪ J.Müller Weser, Bremen ▪ Hansa NFC, Hamburg ▪ JDE, Bremen ▪ HB Fuller, Nienburg ▪ Kellogg, Bremen ▪ Huntsman, Osnabrück ▪ Kühne, Hamburg ▪ Kronos Titan, Nordenham ▪ Martin Braun, Hannover ▪ Lehmann & Voss, Hamburg ▪ Mondelez, Bremen ▪ Lubrizol, Ritterhude ▪ Mondelez, Bad Fallingbostel ▪ Niedersachsen Ports, Emden ▪ Ohly, Hamburg ▪ Oxxynova, Steyerberg ▪ OOWV, Brake ▪ Reagens, Loxstedt ▪ Tchibo, Hamburg ▪ SiegfriedPharma, Minden
Pharmaceuticals industry ▪ Synlab, Bösel ▪ Aspen Bad Oldesloe GmbH ▪ Synthopol, Buxtehude ▪ Bode Chemie, Hamburg ▪ Tesa, Hamburg
▪ BSN Medical, Hamburg Petrochemicals industry ▪ Phyton Biotech, Ahrensburg ▪ Total Bitumen, Brunsbüttel ▪ Schülke & Mayr, Norderstedt ▪ HGM, Bremen ▪ Unilever, Buxtehude ▪ H&R, Salzbergen
Animal feed and pet food production ▪ Mars Petcare Europe, Verden Paper industry ▪ Leiber, Bramsche ▪ Omni Pac, Elsfleth ▪ Saturn Petcare, Bremen
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Legal notice
Company name Groß Consulting Engineering Anlagenbau GmbH
Address Bahnhofstraße 43, D-28844 Weyhe, near Bremen
Telephone +49 (0) 4203 / 78291 - 0
Fax +49 (0) 4203 / 78291 – 24
Legal form Limited company
Commercial register Amtsgericht Walsrode HRB 111519
Proprietor Dipl.-Ing. Ronald Groß, 28844 Weyhe
Managing Director Dipl.-Ing. Ronald Groß, 28844 Weyhe
Company history the company was founded in Bremen in 2001. The corporate headquarters moved to Lower Saxony on 01.01.2004.
Corporate purpose the corporate purpose is running an engineering office, planning and implementing plant construction sites as well as consulting in this field, plus trading and selling technical components, all the related business transactions and participation in undertakings of this kind.
Bank details Kreissparkasse Syke
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