Chemical & Process Industries

The Client
Imperial Tobacco's Horizon plant in Nottingham is one of the largest cigarette plants in the UK. The site processes tobacco from raw leaf to be boxed and packaged ready for sale within one building. The factory dates back to the 1970's where it was originally built for John Player & Sons.

The Challenge
The factory had extensive utility systems for processing and shared building services. A new Expanded Shredded Stem (ESS) process required a supply of steam up to 16 barg and 350 deg Celsius (ie 150 deg superheat) with a controllable temperature across a broad operating range. The existing boilers, installed in the 1970's, were not capable of this duty (shell boilers rated at 10 barg). GSA were initially engaged to carry out a feasibility study to identify the most cost effective approach going forward.

The Solution
Having reviewed all options, including a dedicated boiler to supply the superheated steam to the ESS process, the preferred solution was to replace some of the old boilers with new units that were capable of producing both superheated and saturated steam.

This had the benefit of keeping all of the boilers in one utility area of the factory rather than having remote units feeding individual processes. This also allowed existing water treatment and fuel supply systems to be utilised resulting in new, more efficient boilers. To facilitate the installation of the new boilers without putting the factory steam supply at risk, the installation was done in a sequential manner.

GSA provided engineering services to Imperial Tobacco during the project including the basic engineering design, procurement documents as well as assistance with supplier liaison and bid appraisal. GSA oversaw the design safety process (Hazop, SIL Assessment, pre-commissioning and commissioning checklists etc) and all commissioning & post commissioning activities.

Feedback
The project was completed successfully on time and to budget. GSA continues to enjoy a close working relationship with Imperial Tobacco.

The Client
In partnership with MB Engineering Services, GSA performed a FEED (Front End Engineering & Design) study to design and specify two gas coolers for a major Steel Manufacturing Facility in Brazil.

The Challenge
GSA provided a Project Manager and Lead Process Engineer for the FEED study. GSA also became fully responsible for the project management of designs and installations to support the plant start-up.

The Solution
Process engineering design for the gas cooling facility including:

• Preparation of process flow diagram
• Preparation of heat & mass balance
• Preparation of preliminary piping & instrumentation diagrams
• Design & specification of all main equipment items
• Preparation of mechanical & instrumentation datasheets

Following the sanctioning of capital, GSA were responsible for the project management of all detailed designs including:

• Engineering design
• Safety reviews
• Procurement
• Cost control

GSA also provided engineering support for the installation and commissioning of the facilities against performance guaranteed tests.

The Client
The client contacted GSA to assist with the installation of a new production facility. The client already had a similar production facility in the US with a good understanding of the technology and processes. GSA were contacted to ensure the project was efficiently implemented while adhering to European standards and legislation.

The Challenge
The new production facility presented a range of new risks and hazards resulting in new operations within hazardous areas. GSA provided a full engineering design for the facility including a new bulk tank farm for flammable materials; process safety support service throughout the project; and undertook procurement services for the main equipment items. GSA also delivered a training course to any personnel working on the new process, maintenance, management and safety personnel. GSA advised the client of the shared site services that could service the new production unit.

The Solution
GSA provided the client with:

• Preparation of engineering design
• Preparation of mechanical and instrumentation datasheets
• Vendor specifications for MEI
• Vendor liaison and selection
• Operating procedures and functional specifications
• Attendance at FAT&s
• HAZOP and SIL assessments
• Hazardous area classification documentation & procedures
• Cost control & budgetary costs
• Training

Feedback
The project was delivered on time and to budget.