COMPETENCES
Area of Expertise in Technologies
Oil & Gas Power Plants
Oil & gas power plants have a wide range of applications in the power plant world. From small stand-alone solutions as power supply with gas or diesel engines to large GUD power plants with integrated seawater desalination, these energy sources can be used in many types of plants.
Essenssys can offer full planning services for all types of thermal power plants. In the case of new technologies, we are in close contact with innovative suppliers, universities and research institutes in order to offer our customers added value from experience and visions. Essenssys can also work out individual solutions for the supply of electricity, heat or even cooling for the most diverse fuels that occur in the gas and oil sectors.
Increasing attention is being paid to cogeneration in this area. These CHP plants can be operated highly efficiently and thus make an important contribution to resource conservation. Essenssys can point to many successful references for this area of application and has extensive know-how, especially in the planning of district heat extraction.
The most common types of power plants we design in this area include:
- Gas and steam power plants (GUD plants)
- Gas power plants with gas turbines
- Steam power plants with direct-fired boilers for gas or oil
- Combined heat and power plants (CHP plants)
- Combined heat and power plants (CHP plants)
- Fuel cell power plants
- Power plants with metallurgical gas, threshold gas or other gaseous fuels
Waste incineration
Essenssys has a unique position in the field of waste incineration. We are one of Europe’s leading planning offices in the field of general planning or client planning.
Our planning services for these plants often begin in the concept design or bid support for general contractors or operators. In the execution phase, we can fully take over all planning services for process engineering, layout planning, piping technology, civil engineering, electrical engineering and control technology. Of course, we also support the clients in the approval, management and monitoring of the lot suppliers as well as the coordination of the construction site.
While the first waste incineration plants were optimised with regard to the highest recycling rate, today there is also a trend to design these power plants to be highly efficient. Not only higher steam parameters are required, but also integrative concepts with solar or combined heat and power are being realised. In order to increase the acceptance of waste incineration, unnecessary emissions and odour nuisance must be avoided. New technologies, such as gasification, also help to advance the state of the art. Our experts have many years of experience in these fields. This begins with participation in research projects, through the realisation of complex plants, to the modernisation of old plants.
Waste and substitute fuels also have a wide range of applications in industrial power plants or in the general utilisation of residual materials. A current topic here is, of course, sewage sludge incineration. Essenssys can provide you with comprehensive support in drying, incineration and plant implementation.
Contact us to find a suitable solution for you or to find out more about our references. You can find an excerpt of special projects here.
Renewable energies
Renewable energies play an important role in the German and global energy transition. The areas of application here are diverse and extensive. Essenssys can point to many successful thermal power plant references for biomass combustion, planning geothermal energy plants. This is not only about new buildings, but also about fuel conversion from fossil fuels to renewable energies, be it biomass, biogas or e.g. hydrogen. The various forms of storage are also an important starting point for using the volatility of the different energy generation plants in a system-compatible way.
Essenssys is happy to support you in the planning and implementation of your projects. Typical examples of applications where we can contribute our expertise include:
- Biomass cogeneration plants
- Sewage sludge incineration
- Geothermal energy
- Fuel conversion to renewable energies
- Co-firing of renewable energies
- Energy storage
- Fuel cells
- Power-to-gas (PtG)
- Power-to-X (PtX, P2X)
- Wind power plants
- Solar plants / PV plants
The wide range of applications requires a good set-up. Cooperation with our international partners provides the basis for the full implementation of projects. It is our endeavour to set up an optimal team of experts for our customers in order to successfully implement their international projects. Our network of research institutions and innovative companies gives us the knowledge edge to realise even the most ambitious projects.
We are at your disposal to find the right solution for you. You can find an overview of already realised projects here. Please contact us for a complete list of references.
Energy centres
Energy centres are individually adapted to the site requirements and processes. Fossil fuels, renewable energies or waste products from production can be used as energy sources. There are no restrictions in the power range. From small steam boilers to gas turbine plants or coal-fired power plants, all types of plants are used here. A broad range of expertise is needed to advise customers correctly and to optimise the design of the plants.
Thanks to its expertise, Essenssys can offer comprehensive planning. This starts with the feasibility study or stocktaking, for example also with 3D laser scanning, through to approval, implementation planning, construction supervision or even just modernisation of older plants.
But Essenssys can also advise you on your industrial plant outside the power plant. This can be for overall project management for the conversion of your production plant, as well as for individual planning services, such as construction planning, piping planning or electrical planning.
Take a look at selected references here or contact us for more information or a consultation to find a suitable solution for you.
Environmental technology
The requirements for climate protection are becoming increasingly complex and present companies with ever greater challenges. At the same time, the sensitive issue of emission reduction is constantly in the focus of newly enacted environmental standards.
As specialists in the field of flue gas cleaning, we offer our customers process-optimised solutions that precisely harmonise modern process technology with their individual operational requirements. Our many years of expertise make us your ideal partner for the planning of:
- Dedusting
- Denitrification (SNCR, SCR)
- Desulphurisation (limestone, caustic soda)
- Flue gas condensation
- Carbon Capture Storage / Utilisation (CCS / CCU)
- Heat transfer
- Waste heat utilisation
- Plant optimisation and modernisation
Our range of services includes the following project phases:
- Project development
- Process engineering design and investigation of variants
- Evaluation of the variants and proposal of the most economical solution
- Market analysis
- Cost determination
- Permit Application
- Implementation as general planner
- Implementation planning for the plant constructor
Benefit from our many years of experience, our broad engineering know-how and our customised software tools when designing and optimising your project. Contact us: we will be happy to advise you on new planning, conversion and operational optimisation.
Industrial plants
Industrial plants have very specific requirements that must be met in terms of production, logistics and design. Basically, the following planning services are always required, which Essenssys provides:
- Project management
- Layout planning
- Logistics planning
- Process engineering
- Construction planning
- Technical building equipment
- Piping planning
- Electrical planning
- Construction supervision
You can find a detailed overview of Essenssys competences here. For very specific process topics, we work together with external partners. Through this cooperation we can serve the following industries:
- Manufacturing industry
- Pharmaceutical industry
- Oil & Gas Industry
- Chemical and agrochemical industry
- Food industry
We will be happy to advise you in the areas of new planning, conversion and also operational optimisation. Contact us and benefit from our many years of experience, our broad engineering know-how and our customised solutions.
Fields of Expertise
Project management
Project management is a key part of the project. Therefore, expertise, a holistic view and a goal-oriented project structure are required to ensure success in the project. Essenssys puts together a project-specific team of experts and can cover the following topics:
- Overall project management
- Contract management
- Tender planning
- Project controlling
- Scheduling
- Claim management
- Interface Management
- Supplier management
- Cost control
- Implementation planning
Process engineering
Designing modern, efficient and durable plants requires experts with excellent knowledge of systems and components. The Essenssys team is able to perform this role in full. The competences are divided into the following three areas of expertise:
Arrangement planning
In order to ensure smooth operation, simplify installation and maintenance concepts, but also keep investment costs low, a great deal of experience is required for the correct layout planning. Essenssys can draw on a large pool of completed projects and its experts have many years of experience in plant construction. 3D planning is state of the art for us. New concepts such as 3D laser scanning, Building Information Modelling (BIM) or 4D planning are also known to us. In the layout planning, the plant can be fully planned in the following steps:
Concept planning
- Project specifications for plan creation (part of the project manual)
- Setting up the 3D model and databases
- Arrangement variants
- As-is survey
- 3D laser scanning
Approval planning
- General plan of material flows
- Site plan
- Views of the entire plant
- Floor plans
- Transverse and longitudinal sections
- 3D views incl. surroundings
Implementation planning
- Site plan
- Axis plan
- Installation site identification
- Load plan
- BIM
- 3D views
- 4D planning
- Component drawing
- Assembly concept plan
- Checking and approval of supplier plans
Civil engineering
Civil engineering comes into play in every plant design, be it for foundations, building design or for the technical building equipment. essenssys can offer a comprehensive portfolio of services in this area and, especially with its specialist group for water systems, has unique expertise with numerous patents to optimise the cold end of a power plant. The specialist areas at Essenssys are divided as follows:
Construction and architecture
- Conceptual building design
- Building permit
- Basic and detail engineering
- Road design
- Tender documents
- Supervision and monitoring of construction work
Structural engineering
- Structural steel & solid construction
- Foundation design
- Structural calculation
- Statics
- Structural design
- Formwork plan
- Reinforcement plan
- Structural steel drawings
Technical Building Facilities, Cooling water systems
- Concept planning
- Basic engineering and partly detail engineering
- Tender documents
- Supervision and monitoring of execution
Water systems
- Cooling towers
- Fire extinguishing systems
- Drinking water systems
- Sewerage systems
- Sewage systems
- Underground network
- Special topics such as decontamination consulting
Site supervision
- Site management
- Health and Safety Management
- Construction site scheduling
- Construction site reporting
- Quality inspection
Piping design
The piping system has a great potential to optimise a plant and consequently to reduce investment costs. However, this is also accompanied by the risk of reduced service life, consequential damage and operational malfunctions. Essenssys experts have a unique position in the industry in the field of piping design. Thanks to many years of experience and the reverse engineering approach, they have succeeded in mapping realistic and customised calculation models even for ultra-supercritical piping systems, recognising critical material stresses due to volatile plant operation and precisely determining condensate quantities in the piping system during start-up and shutdown.
Essenssys expertise includes the following piping systems:
- Water-steam cycle
- District heating
- Steam networks
- Refrigeration networks
- Industrial piping
- Flue gas piping
- Compressed air piping
- Special applications
Optional – The following services, amongst others, can be provided:
- Pipeline dimensioning
- Route planning
- Basic and detail engineering
- Isometric representation
- Fluid dynamic calculation
- Pressure surge calculation
- Condensate calculation
- Determination of material load
- Support concept
- Insulation concept
Electrical and control technology
The electrical and I&C systems play a special role in the planning of a plant. Here, there is a permanent development progress concerning the automation and monitoring of a plant. Essenssys has the expertise to offer holistic planning and consulting services.
Planning, tendering and coordination of:
- Machine/block and auxiliary power transformers
- Generator feeder, generator circuit breaker
- LV transformers
- MV and LV switchgear
- Uninterruptible power supply, DC systems, batteries
- MV/NV motors, actuators
- Earthing, lightning protection, equipotential bonding
- Short-circuit, load flow and harmonic calculations
- Cable route planning, cable design, cable management
- Communication systems, hazard detection systems, video surveillance
- Lighting, emergency lighting
- Process control technology incl. function diagrams
- Process instrumentation
- Field cabling
- Process and Quality Management
At Essenssys, Process and Quality Management is not only responsible for the internal management of processes and quality assurance, but also offers its services to our customers:
- Quality Assurance and Control
- Document management
- Creation of project manuals
- Development of document standards
- Training of the KKS system
- Support in the application and implementation of the Pressure Equipment Directive
- CE certification (more here)
- Risk analysis
- HAZOP
- Supplier audits
