Headcount Solutions Ltd

Arch Chemicals - Critical Production Upgrade

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Arch Chemicals appointed Headcount with overall responsibility for the fast–track design and construction management of the capacity expansion of their Oxidation process. The project centred on the upgrade and replacement of a glass lined reactor, together with all associated process and utilities upgrades and civil/structural works to accommodate the larger vessel.

Because of Arch’s production schedules, the annual summer shutdown of 2 weeks was allocated for this critical capacity upgrade. Headcount assembled a small team of experts based on the client site to pre-plan and execute this important capacity boosting project. They were supported from Headcount Engineer Services head office;

Process Design


Utilities Design

Steam, Condensate, Cooling Water.

Equipment Specification

Reactor Vessel, Heat Exchangers, Bursting Disks,              Pressure Relief

Civil / Structural Design

Structural arrangements, GA’s, Concrete plinths, Bases, Specifications.

Piping / CAD

General arrangements, P&ID’s, Asbuilts. GA’s, Isometrics.

Planning / Scheduling

MS Project, Client Weekly updates.

Management / Control

Design changes control Procurement,


Purchasing, Equipment FATs,

Design Approval

Drawing check, Approval

Construction Management

Installation management, Sub-Contractors, completion certification

Quality Management

Document Control, Document issue.


Test Packages, Equipment checks


As-built drawings, Project Folders, Equipment manuals