overhaul hypercompressor& booster primary ......hyper and bp, from planning to execution april...

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OVERHAUL HYPER COMPRESSOR & BOOSTER PRIMARY (BP)FROM PLANNING TO EXECUTIONWinterthur, April 2021Falk Jähnigen, Thiago Heinen

Hyper and BP, From Planning to ExecutionApril 2021

© 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



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



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



Modernization of plant and components Feasibility studies RCA

Our Background and Customer Needs



LDPE process evaluation Other brand compressors

Overhaul Reverse engineering

Our Background and Customer Needs



Scope Definition Compressor mechanical inspection

Frame alignment Piston rod run out Tightening anchor bolts



Scope Definition Complete BP vibration check, including piping



Scope Definition Complete BP vibration check, including recommendations



Scope Definition Motor inspection: Life expectancy analysis by OEM

Good condition for both B/P and Hyper



Scope Definition Motor inspection: Life expectancy analysis Foundation consultancy



Report of inspections, with technical recommendations

Scope Definition: Supporting Documents



Overhaul Acquisition Plan

Spare Parts

Tools

Repair – Services Center



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



Detailed Commercial Planning Commercial offer for overhaul execution

Description of scope Matrix of responsibilities Manpower & contracting



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



Execution of Technical Planning

Preparation

Checks & Measurements

Compressor Maintenance

Service on Accessories & Foundation

Startup of Compressor

Manpower Requirements



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



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



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



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



Controlling during the Overhaul Progress

– Daily reporting to customer



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)



Project work reports Meeting with customer

Lessons learned Opportunities for next TAM Future projects

Closure

1Customer Request

2Scope

Definition

3Detail

Planning4

Execution5

Closure



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

Speaker 1: Falk Jähnigen, Burckhardt CompressionSpeaker 2: Thiago Heinen, Burckhardt Compression