overhaul hypercompressor& booster primary ......hyper and bp, from planning to execution april...
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© Copyright 2021. Burckhardt Compression AG. All rights reserved.
OVERHAUL HYPER COMPRESSOR & BOOSTER PRIMARY (BP)FROM PLANNING TO EXECUTIONWinterthur, April 2021Falk Jähnigen, Thiago Heinen
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Hyper and BP, From Planning to ExecutionApril 2021
Page 2© Burckhardt Compression AG
Content Planning and execution of overhaul for LDPE compressors
1 x Hyper F8 1 x B/P 6B5A In service since 2002 Capacity increase in 2010
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Hyper and BP, From Planning to ExecutionApril 2021
Page 3© Burckhardt Compression AG
Content Planning and execution of Overhaul for LDPE compressors
1 x Hyper F8 1 x B/P 6B5A
1Identification
2Scope
Definition
3Detail
Planning4
Execution5
Closure
2.5 years before overhaul
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Hyper and BP, From Planning to ExecutionApril 2021
Page 4© Burckhardt Compression AG
Customer Request Hyper F8: on-site overhaul BP: on-site overhaul Evaluate foundation Evaluate main motor
Manpower: coordination, supervision and mechanics by BCAG Definition and supply of spare parts Schedule of activities, guaranteed duration
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Hyper and BP, From Planning to ExecutionApril 2021
Page 5© Burckhardt Compression AG
Modernization of plant and components Feasibility studies RCA
Our Background and Customer Needs
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Hyper and BP, From Planning to ExecutionApril 2021
Page 6© Burckhardt Compression AG
LDPE process evaluation Other brand compressors
Overhaul Reverse engineering
Our Background and Customer Needs
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Hyper and BP, From Planning to ExecutionApril 2021
Page 7© Burckhardt Compression AG
Scope Definition Compressor mechanical inspection
Frame alignment Piston rod run out Tightening anchor bolts
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Hyper and BP, From Planning to ExecutionApril 2021
Page 8© Burckhardt Compression AG
Scope Definition Complete BP vibration check, including piping
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Hyper and BP, From Planning to ExecutionApril 2021
Page 9© Burckhardt Compression AG
Scope Definition Complete BP vibration check, including recommendations
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Hyper and BP, From Planning to ExecutionApril 2021
Page 10© Burckhardt Compression AG
Scope Definition Motor inspection: Life expectancy analysis by OEM
Good condition for both B/P and Hyper
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Hyper and BP, From Planning to ExecutionApril 2021
Page 11© Burckhardt Compression AG
Scope Definition Motor inspection: Life expectancy analysis Foundation consultancy
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Hyper and BP, From Planning to ExecutionApril 2021
Page 12© Burckhardt Compression AG
Report of inspections, with technical recommendations
Scope Definition: Supporting Documents
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Hyper and BP, From Planning to ExecutionApril 2021
Page 13© Burckhardt Compression AG
Overhaul Acquisition Plan
Spare Parts
Tools
Repair – Services Center
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Hyper and BP, From Planning to ExecutionApril 2021
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Scope Definition: Supporting Documents Proposal of interventions: schedule (± 10% accuracy)
Option 1: incl. foundation repair– Complete removal of compressors
Option 2: without foundation repair– Replacement and repair of capital parts
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Hyper and BP, From Planning to ExecutionApril 2021
Page 15© Burckhardt Compression AG
Detailed Commercial Planning Commercial offer for overhaul execution
Description of scope Matrix of responsibilities Manpower & contracting
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Hyper and BP, From Planning to ExecutionApril 2021
Page 16© Burckhardt Compression AG
BC Strategy Planning and execution of TAM for LDPE compressors
1 x Hyper F8 1 x B/P 6B5A
1Customer Request
2Scope
Definition
3Detail
Planning4
Execution5
Closure
1 year before overhaul
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Hyper and BP, From Planning to ExecutionApril 2021
Page 17© Burckhardt Compression AG
Execution of Technical Planning
Preparation
Checks & Measurements
Compressor Maintenance
Service on Accessories & Foundation
Startup of Compressor
Manpower Requirements
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Hyper and BP, From Planning to ExecutionApril 2021
Page 18© Burckhardt Compression AG
PreparationSmall team one week in advance of stop
– 1 Site manager BCAG– 1 Shift leader Hyper - Day shift BCAG– Burckhardt Compression Admin– Customer (Team)
Safety training & medical check (Corona) Preparing of job site Our first site visit and observations
– Hyper cylinder lubrication unit high vibration– BP compressor high piping vibration
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Hyper and BP, From Planning to ExecutionApril 2021
Page 19© Burckhardt Compression AG
Checks and MeasurementsStart of the overhaul
First site visit of complete workforce– 1x Site manager BCAG– 2x Teams BP (Day / Night) BCAG– 2x Teams Hyper (Day / Night) BCAG– 1x Mechanic per team from customer
Checks and measurements according to planning
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Hyper and BP, From Planning to ExecutionApril 2021
Page 20© Burckhardt Compression AG
Compressor MaintenanceThe execution
Maintenance according to planning Not planned work on Hyper (additional)
– Cylinder lubrication Hyper complete overhaul with customer mechanics Supervision support by BCAG
– Removing of complete cylinders 3 & 8 due to damaged elastic rods coupling surfaces
Not planned work on BP (additional)– Repair of broken screw on one distance piece– Repair of damaged sealing surface cooling
jackets
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Hyper and BP, From Planning to ExecutionApril 2021
Page 21© Burckhardt Compression AG
Service on Foundation & Accessories Alignment of crankcase Checking of motor bearings (with ABB
under BC scope)
Overhaul of oils skids & cleaning of gas and oil piping (by customer)
Not planned work on Hyper (additional)
– BC Support on gas piping installation– BC Support on flushing of oil systems
Not planned work on BP (additional)
– BC Support on flushing of oil systems– BC Support on dampener / pipe slighting
supports alignment
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Hyper and BP, From Planning to ExecutionApril 2021
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Controlling during the Overhaul Progress
– Daily reporting to customer
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Hyper and BP, From Planning to ExecutionApril 2021
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Startup of the Compressor Start of lubrication systems Restart of compressor/plant
under BC presence (only small start up team)
Two BCA supervisor present during operation (two days)
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Hyper and BP, From Planning to ExecutionApril 2021
Page 24© Burckhardt Compression AG
Project work reports Meeting with customer
Lessons learned Opportunities for next TAM Future projects
Closure
1Customer Request
2Scope
Definition
3Detail
Planning4
Execution5
Closure
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Hyper and BP, From Planning to ExecutionApril 2021
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Conclusion Benefits for our customer
Strong technical background Decision process is supported by concrete data Planned and delivered in time
– Documentation is revised by experienced engineers, 4-hands principle– External specialists under request
Flexibility and customization BCAG single sourcing: reliable supplier in complex environment
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Speaker 1: Falk Jähnigen, Burckhardt CompressionSpeaker 2: Thiago Heinen, Burckhardt Compression
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