How we add value to your business

Process design Chemical industry How we add value to your business  A total solution - cradle to grave projects or assistance at any stage through ...
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Process design

Chemical industry

How we add value to your business  A total solution - cradle to grave projects or assistance at any stage through the process  Highly skilled people across all disciplines, many with a manufacturing background, listen to your requirements  Flexible ways of working, suited to your needs. We apply an appropriate level of tools and resources, not overkill  Site based activities - commissioning, investigations, troubleshooting, optimisation, and construction support  A philosophy of the highest Environmental, Health and Safety standards runs through everything we do  Regulatory compliance - machinery directive, ATEX/DSEAR, COMAH, pressure systems, IPPC  Lean manufacturing - our in-house skills include process mapping to achieve more efficiency, in-tune with your thinking  3D piping and layout design with intelligent P&IDs  Best practice experience from a broad range of industries.  A focus on continual professional development - why not join one of our monthly process engineering CPD training sessions?

Technologies Fine and speciality chemicals, bulk and industrial chemicals, fibres, polymers, petrochemicals, refinery processes, oil and gas. Basis of design Scope, concept design, functional specification, control philosophy, block flow diagrams. Front end design Process options, process flow diagrams, material/ heat balance, preliminary PI&Ds, user requirement specifications, conceptual Hazop. Detailed design PI&Ds, process equipment design, data sheets, line list information, process safety (including SIL, HAC, relief studies, reaction design), operational guides. Commissioning Commissioning protocols, SOPs, operational improvements, operator training .

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Examples of our customers Airbus Associated Octel BAe Boots BP British Energy Brunner Mond Compact Power Crossfield EnCycle Estech Express Dairies Hickson& Welch Ilford Ineos Silicas Innospec Ipsen Johnson Matthey Lucite Merk Sharp Dome Millennium Chemicals Polymer Latex Rhodia Chirex Rockwood Rugby Cement Sandvik Serono United Utilities Urenco Victrex

19/09/2007 16:41:49

Chemical industry

Case studies Polymer Latex - Alliance Projects Several site based projects including: Thermal Oxidiser design, waste gas destruction with site steam generation and optimisation of final product processing. Design and commissioning of a bulk liquified gas (LPG) storage facility with tanker loading - this upgrade significantly increased the safety of the facility. New bulk liquid nitrogen storage facility for site wide distribution.

Associated Octel - Alliance Contract Projects included: Process study involving modelling of a solid-liquid reaction, which led to a major improvement programme. Front-end designs for a process to make a novel specialty chemical (ca. £10-15m). Design of VOC abatement solutions involving Regenerable carbon beds and novel thermal oxidation.

Johnson Matthey - CSF Auto Catalyst Production MPS provided design, construction and commissioning support for the scale up from pilot plant to full scale production facility. The project included:slurry wetting, milling, mixing vessels, linear dryers, batch ovens, waste gas abatement, chemical storage, and utilities. Following the first successful project, we were invited to complete a large scale expansion project to further increase the production capabilities.

For further information please contact:

Helen Milliken

Alastair McDougall

T 01925 281916 M 07808 177366 E [email protected]

T 01925 281929 M 07739 920997 E [email protected]

www.morganps.com Process flyers v6.indd 2

19/09/2007 16:41:58

Process design

Pharmaceutical and biotechnology

How we add value to your business  30 years of pharmaceutical and biotechnology experience  Architectural design combined with cGMP best practice ensures optimum solutions are found at the concept stage  Our lifecycle approach to commissioning and qualification (C&Q) ensures that C&Q aspects are built into the project systems from the start, resulting in ‘right first time’ testing  Strong skill base at all levels of the business  Customer focussed - close integration with operations  Flexible solutions - site or office based to suit  UK and Global delivery from offices in Warrington, Stratford-upon-Avon, Basel and Shanghai.

MPS’s value adding qualities have been recognised by many clients such as AstraZeneca who recently awarded MPS the design and build of their new flagship Research and Development Facility at Macclesfield, which is the single biggest investment at this site. This follows on from successfully delivered projects for AstraZeneca, at Macclesfield, Alderley Park and Loughborough, run under a long-term alliance agreement. MPS have also developed other successful long-term framework agreements with clients including: Novartis, GlaxoSmithKline, Lonza and Eli Lilly.

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19/09/2007 16:42:01

Pharmaceutical and biotechnology

Case studies GlaxoSmithKline EPCmV of a new bulk manufacturing facility and expansion of existing operations. Fast-track project delivery with integrated Commissioning and Qualification for enhanced project efficiency executed by a site based team working ‘as one’ with GSK.

National Biomanufacturing Centre EPCmV of this world class biopharmaceutical design centre. Challenging multi suite and product manufacturing concepts. Flexible processing options, future proofing and regulatory compliance were key project drivers.

AstraZeneca Alliance design and construction consultancy for multiple projects. Delivery covers primary and secondary facilities including a state-of-the-art purification plant to which utilised clean room environments traditional to secondary pharma but novel in primary.

MPS understands that biotechnology processing techniques are being used across a far wider range of manufacturing sectors than ever before. We provide a specialist service to meet the needs of biotechnology businesses large and small. Often our biopharmaceutical customers face different challenges. While the market in some parts of the world is already quite mature, in others much smaller companies need help on a different scale with issues such as commercialisation, finance and consulting services. Pharmaceutical companies of all sizes are looking to increase their efficiency. Let our experience from other industries work to your advantage – we offer the experience we have developed in lean compliance – satisfying cGMP in the most efficient way. Our team includes experts with extensive experience in the development of pharmaceutical, biotech and operating projects. Talk to us to see how we can help you.

For further information please contact:

Adrian Jones

Helen Milliken

T 01925 281800 M 07740 640047 E [email protected]

T 01925 281916 M 07808 177366 E [email protected]

www.morganps.com Process flyers v6.indd 4

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Process design

HAZOP and Risk assessment services

We offer a comprehensive suite of risk assessment services to the process and related industries, including:

At the heart of our competence is a team of hazard study leaders, with experience in the following sectors:

 Hazard and operability study (HAZOP)

 Pharmaceuticals

 Preliminary risk identification (HAZID)

 Biotechnology

 Layer of protection analysis (LOPA)

 Nuclear

 Safety integrity level analysis (SIL)

 Municipal and industrial waste

 Failure mode effect analysis (FMEA)

 Water and wastewater

 Hazardous area classification

 Food and drink

 Relief stream design

 Chemicals

 Fault tree analysis

 Aerospace

 Basis of safety.

 General manufacturing.

We can advise on, and assist with regulatory Our study leaders have had formal and compliance issues including: on-the-job training in best practice risk assessment techniques and follow  Pressure Equipment Directive (PED) our programme of in-house continual professional development.  Integrated Pollution Prevention and Control (IPPC) Having an independent hazard study leader you ensure impartiality, objectivity, and  Explosive Atmospheres (ATEX) bring additional experience to your team.  Dangerous Substances (DSEAR) We apply the most appropriate tools for  Control of Major Accident Hazards your project from our range of resources, (COMAH) which include a safety library, hazard study software, safety integrity level software,  CDM Compliance and Construction in-house design tools, and experience Safety database.

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19/09/2007 16:42:18

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HAZOP and Risk assessment services

Advantages of a MPS Hazop leader We are not pure ‘consultants’, our Hazop leaders are also designers and are regularly involved with engineering, plant troubleshooting, commissioning. Our broad industry experience helps us share lessons from across industry.

 Large scale laboratory refurbishment project (AstraZeneca)  Safety integrity level assessments (GSK)  Safety integrity level assessment and verification calculations (Cargill)  Functional safety assessment (BP Rhum Project)

Our strong pool of resource has many years of experience including hundreds of Hazop  Functional safety assessment (Britannia Satellites Project) studies. We can advise on, organise, lead, record and follow-up your study.  Probability of failure calculation documents and procedures (Urenco). Some of the Hazop, Hazard and Safety studies we have completed recently: The large multi-disciplinary design team gives back up to ensure quick answers to  Synthesis reactor with phosphorus queries on best practice, common problems oxychloride feed (GSK) and solutions.  Synthesis process with impact explosive material (H&W)  Mixing and packaging plant (Rockwood International)    

Design for LIFE

LIFE (Looking to an Incident Free Environment) is our in-house safety Municipal waste treatment facility culture programme, which extends to all (Estech) our employees. We empower our people Vent scrubber system (Johnson Matthey) to challenge unsafe acts and situations, wherever they are found, and we sign up to Methanol storage system (Sandvik) a personal safety contract, which describes our commitment to safety. Fuel test station (Airbus UK)

 Silica gel plant (Ineos Silicas)  LPG storage facility (Polymer Latex)  Utility systems for decommissioning facility (UKAEA)

For further information please contact:

Helen Milliken

Alastair McDougall

T 01925 281916 M 07808 177366 E [email protected]

T 01925 281929 M 07739 920997 E [email protected]

www.morganps.com Process flyers v6.indd 6

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Process design

Managed services

Familiar scenario?

Let us smooth the way.

Resource requirement

We can help you with: Resource utilisation

Peak level

Reduced overhead Standardisation of specifications, understanding and knowledge Reduce the learning curve - we integrate with your culture, needs and ways of working

Minimum level

Knowledge and technology transfer

Time

Our managed service brings the skills and capability needed to programme manage multiple projects for you, assisting in the effective management of your estates. A flexible and responsive approach calling on our local expertise as it is required. A typical client organisation manages day-to-day projects through its in-house facilities management team and manages major projects through either bought in resource or dedicated project managers. There is a recognised gap that falls between these two areas that could be classified as business change projects. The manufacturing facility below shows an example of range of projects carried out during two year relationship (over 80 projects completed during this period). New perimeter security fencing

Upgrade of GMP manufacturing areas

New cooling towers and dosing systems

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Gatehouse New chimneys gas plant rebuild and water softening plant

Refurbishment of office space

New waste handling facility and fuel tanks

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Managed services

Win Win

A selection of our customers:

For you:

BAA Eli Lilly GlaxoSmithKline Health Protection Agency Ipsen Johnson Matthey Lonza Merck Sharp & Dohme Polymer Latex QinetiQ University College London Hospitals

Increased value. Single point of responsibility – no hassle. Aligned to business objectives. Continuous improvement opportunities, safety, cost, time, quality. Provides another competitive option. Flexible procurement routes, willingness to share risk. Simple commercial principles, easy to administer. Access to local, multi-disciplined, experienced resource. For us:

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Sustainable workload. Retain and develop supply chains and labour force. Develop relationship with customers and local supply chain.

                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          

Business critical

Major projects



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Targeted market Funding

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Strategic Business change projects

Tactical Operational

Target market Facilities management

Churn projects Complexity/Business critical

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alue elivery = V d d n a n esig grated d e t n I + ship elation r + t n eme involv y l r a E Ian Pritchard Helen Milliken For further information please contact:

T 01925 281883 M 07808 906 618 E [email protected]

T 01925 281916 M 07808 177366 E [email protected]

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Process design

Lean thinking

We provide lean thinking to manufacturing clients at each stage of the project lifecycle. Business Improvement means cutting out waste, be that time, movement, transport, materials, in fact anything that is non value-adding. There are many different tools to achieve this and MPS have the right people to advise on the best methods for your business. We are unique in having an in-house team of formally trained lean experts, with experience in applying lean thinking to project processes as well as manufacturing processes. Unlike people further down the supply chain MPS are impartial so we are good at writing the briefs, working with your supply chain and leaning out the processes. Our focus on key markets and client relationships continues to bring in new and repeat business. As well as supporting the development and delivery of major capital projects, we recognise the economic and technical operational challenges faced by our customers. Our lean manufacturing specialists support front-end project definition and development, including; value stream mapping, people, equipment, material, methods, and environment (PEMME) evaluation. We have a broad range of sector experience which makes our people very flexible.

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Lean thinking

Case studies Estee Lauder-liquid filling for cosmetic products New production layout development and definition. Improvement of floor space utilisation to deal with increases in customer demand. Stakeholder workshops looked at current/ future state to develop requirements. Significant improvement in material/people travel distances and cGMP conditions identified. These were reduced by 33 per cent, saving significant reoccurring operational costs.

Gulf Catering Company- baked products, Saudi Arabia Suppliers to all schools, universities, prisons and hospitals in the United Kingdom. GCC difficulties fulfilling order times, due to considerable processing times for baked products, led to support to identify and resolve constraints in their processing lines. Value stream mapping identified significant opportunities to remove processing steps without detriment to the finished products. Twenty-four hours of processing time, refrigeration capacity, energy and over £80,000 worth of consumables were removed from the process

Airbus - Airbus A350 XWB commercial air liner As part of the site development a value stream mapping exercise of the site logistics operations was executed. Current state map of existing traffic flows was developed. This highlighted potential limits to the infrastructure, product/people crossovers and accident rates, non-value adding travel distances and potential zoning opportunities. Site and project requirements were integrated into a logistics plan. A future state map was communicated identifying two, three and four year plans for site expansion and coordinated infrastructure development. Travel distances (staff and products) reduced from 1.5km to 0.25km by relocating and providing dedicated people and supplier routes.

For further information please contact:

John Davidson

Helen Milliken

T 01925 281800 M 07713 790410 E [email protected]

T 01925 281916 M 07808 177366 E [email protected]

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Process design

Understanding your business

‘Can you really understand our business?’ Yes – we work across all technology sectors and have MPS specialists in core markets.

‘Can you help at concept stage?’ Yes – getting involved early on in projects gives maximum value to our customers.

‘Can you demonstrate a strong track record?’ Yes – MPS have 30 years of design, construction management and commissioning experience.

‘Can you support small projects as well as multimillion pound capital investments?’ Yes – different customers need different solutions. MPS’s flexibility is our strength.

‘Can you help us be more efficient?’ Yes – MPS can apply the principles of lean manufacturing to improve your efficiency.

‘Can you provide ongoing support?’ Yes – MPS build relationships that last.

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Our vision

Morgan Professional Services will be the leading provider of integrated design, engineering and project management services, adding value to our clients through the talent and skills of our people.

For further information please contact:

Helen Milliken

Alastair McDougall

T 01925 281916 M 07808 177366 E [email protected]

T 01925 281929 M 07739 920997 E [email protected]

CGD/Broch/1929

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