Engineering & consulting
We are the chemical engineers of Siemens
Siemens Engineering & Consulting is a well-known, experienced supplier of plant and process engineering solutions for the pharmaceutical and chemical process industries. We offer services for the early life cycle phases of production plants and laboratory facilities. You as a customer profit from our holistic view, our excellent know-how and our professional methods, which we have developed as a result of our long-standing experience. We render our services worldwide! - Wherever you need us.
Service-Portfolio
Lifecycle – Conceptual design
Whether new construction or modification - projects in the chemical-pharmaceutical industry always require a sound preparation in order to ensure the successful and cost-effective realization. In the first phase of the plant life cycle we focus on creating a technically plausible and cost-effective concept. This serves as a first basis for your investment decisions and at the same time as the basis for a subsequent Basic Engineering. In addition to the first mass, energy and material balances, a cost estimate with an accuracy of -20% to + 50% is part of the scope.
• Feasability Study
• Scale Up
Lifecycle – Process design
Our process engineers and chemists support you in the development and selection of suitable processes and find an optimum for each production step. Our expertise in process simulation, process control and apparatus design, combined with experimental investigations, creates the optimal process for you.
• Pilot plants
• Process simulation
• Process design package
Lifecycle – Basic FEED
Through competent pre-planning we design your success, translate the results from the concept phase into the planning of a concrete project and provide the basis for a successful realization.
You will receive a basic design package that gives you an in-depth look at the technological solution, the timing of the project implementation, estimates the project costs with an accuracy of -15% to + 30% and forms the basis for a subsequent detailed engineering or FEED.
• Basic Engineering & FEED
• Owners Engineering
• COMOS – P&ID – EI&C
Lifecycle – Detail engineering
The design of the plant and the findings from the approval procedures will be implemented in the execution plans after completion of the basic engineering. We provide you with all necessary planning services to successfully launch your plant.
• Owners engineering
• Integrated engineering/ Comos
Lifecycle – Construction & Start-up
As an allrounder we enable you a clean and delay-free transition from the planning phase to the assembly phase through the early establishment of site support. We support you in all areas of assembly, from the date tracking and reporting to the mechanical completion and commissioning of the plant.
• Project management
Lifecycle – Operations & Improvement
Processes change- capacities are being increased, new regulatory requirements are issued, prices for raw materials, energy and waste disposal are changing, appliances are no longer showing the desired results.
With our many years of experience in debottlenecking and troubleshooting and in-depth knowledge of your processes, we find the weak points in your process and develop effective countermeasures.
Safety consulting
- together we have the goal to operate plants safely
Whether new construction or modification of existing plants:
Our interdisciplinary team of experienced chemists and engineers will determine the safe solution for your process.
For the examination of the safety concept of your process, our accredited experts are at your service according to § 29b BImSchG (Federal Immission Control Act)
Our advice services include:
- Safety discussions, HAZOP, PAAG, SIL classification
- Explosion protection concepts
Functional safety
We offer you standardized processes for faster and safer project implementation and commissioning. Standardized engineering guidelines and verification templates help to avoid errors right from the start. This includes:
- Management and assessment of functional safety and audits
- Planning and development of the SLC (Safety Life Cycle Plan)
- Risk and safety assessment
- Assignment of the safety functions to the protection levels
- Specification of the safety requirements (SRS)
- Verification and validation (e.g. SIL verification, HW / SW audit)
- Test planning
- Training
- Functional safety assessment
Safety calculation
We design safety equipment based on the safety characteristics of the process and the substances. The safety considerations provide the design assumptions or accident scenarios. For these we estimate the consequences of incidents.
We find the optimum solution for the safe operation of your plants in accordance with the regulations using a wide range of methods, from simple flow calculation to dynamic calculation of multi-phase systems (e.g. DIERS method).
- Mechanical safety devices
- Evaluation of the consequences of incidents
- Dispersion calculations
- Release scenarios
- Flow calculations
- Dynamic simulation
- Plant and piping systems
Topics safety laboratory services
Thermal stability
Knowledge of the thermal stability of a substance or mixture is generally indispensable. An untested substance can suffer quality losses and cause unforeseeable hazards during production, storage and transport especially at elevated temperatures. To avoid this, there are screening methods that can be carried out with small samples and in short times, but also larger tests that provide more precise information about the thermal behavior of a sample. For each phase in the handling of new and old substances we offer suitable tests and assessments for their thermal stability.
Intended and not intended reactions
For the safety-related assessment of a process, it is necessary to have knowledge of both the desired reactions and deviations from the intended conditions.
Deviations can be, for example, incorrect dosing or temperature deviations. For the determination of the necessary data (for example adiabatic temperature rise or pressure rise rate) calorimetric methods are suitable, which are carried out either isothermally or adiabatically depending on the problem.
Flammable liquids and gases
Explosion protection is a key issue when handling flammable liquids and gases. Often several parameters must be considered in order to answer the different questions. The first question is whether and when a hazardous explosive atmosphere is to be expected. If a potentially explosive atmosphere is present, the next step is to consider the avoidance of ignition sources. We offer you comprehensive measurement methods both for atmospheric conditions and for process-specific conditions (e.g. closed systems, under pressure, changed oxygen concentration). With this and other data we can develop explosion protection concepts for you and together with you.
Dust clouds and deposited dust
Due to their extremely large surface area and due to mixing with air, dust clouds can react explosively when exposed to an ignition source. Dust clouds can occur in many process steps, e.g. during filling or during micronation.
In our test laboratory we can conclusively clarify whether your product has a risk potential with regard to dust explosiveness. In addition, we can determine the relevant dust explosion data for you by means of further measurements. These are necessary for taking sensible protective measures and design.
Solid products, however, can pose a hazard not only as clouds but also in deposited form. Deposited dust can tend to spontaneous self-ignition or self-heating. This depends, among other things, on the size of a deposit/bulk. In order to make reliable statements for your specific case, we have both isoperibolic and adiabatic tests available.
Physico-chemical data
Physico-chemical data are the basis for several purposes. These include data such as flash point or thermal stability (see the tabs "Flammable Liquids and Gases" and "Thermal Stability") but also basic data such as melting point, relative density, viscosity, water solubility, etc. These data can be used for safety or process engineering assessments and designs or for regulatory purposes.
No matter for what purpose you need these data, we offer the determination of a wide range of physico-chemical data and will be pleased to advise you on how you can additionally use these data.
Regulatory issues
A wide variety of data is required for different regulatory purposes. The data required not only depends on the respective regulatory framework but can also vary depending on the product under consideration (e.g. aggregate state or annual tonnage). Most physico-chemical data cannot be derived from the individual components of a product, unlike, for example, in case of toxicological classifications. It is therefore usually necessary to determine these data experimentally. We offer these determinations among others for the following regulations:
- Classification of dangerous goods for all modes of transport (road, rail, inland waterways, sea transport and air freight) based on the international UN Recommendations on the transport of dangerous goods
- Globally Harmonized System (GHS) (international system for hazardous substances)
- CLP regulation for the classification of hazardous substances within the EU
- REACH for the registration of substances in the EU
- Biocide regulation
