engineering & revamp capabilities · •hazop studies •compressor control description...

ENGINEERING & REVAMP CAPABILITIES

Rakesh Kulkarni

Engineering Sales Manager

8th & 9th May 2019

Göteborg , Sweden.

INTRODUCTION

Engineering & Revamp Capabilities

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The Full Range –

Compressor Components and Services

COMPRESSOR

COMPONENTS

Valves

Piston rod packings

Packing rings

Oil scrapers

Piston rings

Guide rings

Hyper Compressor

components

More components

SERVICES

Burckhardt Valve Service

Spare parts logistics

Field service

Technical support

Component repair

Engineering services

Revamps

Condition monitoring

and diagnostics

Training

We keep reciprocating

compressors running endlessly

LOWEST

LIFE CYCLE COSTS

LONG RUNNING

TIMES

HIGHEST

AVAILABILITY


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ENGINEERING AND REVAMPCAPABILITIES


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Overview Engineering & Revamp Portfolio

What is Revamp &

Engineering at

Burckhardt Compression

Every change on an existing

machine or equipment

Professional Project

Management

Customer orientated solutions

Quality, Design,

Manufacturing

Modernizing, Upgrades, Retrofits,

Overhauls

Relocation of components and

plants

Enhanced safety for men and machine

Documentation

OBC Other brand

compressors

Reorganize

Renovate

Refurbish

Revise

Re-engineer

Turnkey Applications

"All actions which have the objective of retaining or restoring an item in or to a state in which it can perform its required function. The actions include the combination of all technical and

corresponding administrative, managerial, and supervision actions.” (European Federation of National Maintenance Societies)


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Overview Engineering & Revamp Portfolio

Well defined Actions for Superior Solutions

Improved

reliability and

availability

Increased

performance

and life time

Enhanced

efficiency and

compliance


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Well Established Methods for Meeting Your

Requirements

Solid foundation for successful projectsConstant interaction between customer and Burckhardt Compression

Evaluation

Engineering

Products &

services

Site

activities

Customer

requirements

Perfect

operating

compressor

system

according to

defined

specifcations


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Products and Services

Compressor Components

Engineering & Studies

Auxiliary EquipmentServices & Support &

Projects

MODERNIZATION

UPGRADES

MODIFICATIONS


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Engineering Studies

Auxiliary Equipment

Services & Support

MUM

Wear and Capital Parts

• Burckhardt Plate Valve™

• Burckhardt Poppet Valve™

• Redura® Piston Rings, Packing Rings, Oil Wipers

• Piston Rod Glands and Packings

• Piston Rods and Pistons

• Full High Pressure Equipment, Packing Cartridges and Plungers

• Cylinder Liners

• Shaft Sealing Systems

• Bearings

• Cylinders, Crossheads, Connecting Rods, Crank Shafts, Housings

• 2nd hand Compressors

Maintenance Tools

• Barring Gears

• Special Tools

• Fast and easy tightening and coupling Systems

Monitoring and DiagnosticsSafety Systems

• PROGNOST NT

• PROGNOST SILver

• SENTRY

Capacity Control Systems

• Valve unloading Systems (air, oil or electric actuated)

• Clearance Pockets and Dead Space Pockets

Compressor Control Systems

• Control System Units and Packages

• Cabinets/Racks

• Software Solutions


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Auxiliary Equipment


Engineering Studies

Auxiliary Equipment

Services & Support

MUM

Vessels and steelwork

• Dampers / Separators

• Absorbers / Drain Systems

• Coolers / Heat Exchangers

• Piping (Pre-fabricated / Loose)

• Tubing

• Filters / Strainers

• Pipe Supports

Skid units

• Oil Supply Units

• Cooling Water Units

• High Pressure Lubrication Pump Units

• Skid Packaging

Drive systems

• Electric Motors (High Voltage / Low Voltage)

• Frequency Converters

• Gear Boxes

• Belt Drives

• Coupling Systems

Process Valves

• Safety Valves

• Control Valves

• Process Valves

• Manual Valves

Electric, Instrumentation & Control

• Control Cabinets

• Local Instrument Boards

• Instrumentation / Hook-ups

• Software Engineering / Update

• Compressor Control

• Cabling

• Pressure, Temperature, Flow, Level & Vibration Indication


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Engineering & Studies


Engineering Studies

Auxiliary Equipment

Services & Support

MUM

Basic Engineering Feasibility Studies

• Feasibility check of new Demands

• Compressor and Plant Assessments

• Failure Analysis

• Material Tests and Analysis

• Oil Test (Pumpability)

• Proposals for suitable Modification, Upgrade and Technical Improvement Options on:Auxiliary Equipment, Drive System, Control Systems, Monitoring Systems, Compressor Components and Technology

Analytical Engineering

• Compressor Performance Calculations with RecipCalc (thermodynamic)

• Valve Performance Optimization

• Impact on Foundation (Forces and Moments)

• Torsional Analysis

• Pulsation and Vibration Studies

• Finite Element Analysis (FEA) Studies

Detail Engineering

• P&ID Diagrams / Isometric Drawings

• General Arrangements / Foundation Drawings

• Circuit Diagrams, Terminal Diagrams, Interface Diagrams, Logic Diagrams, Connecting Diagrams, Hardwired Lists

• Instrument Lists

• 3D Modelling (Plant, Compressor)


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Services & Support


Engineering Studies

Auxiliary Equipment

Services & Support

MUM

Services

• Pressure Tests on Components and Equipment

• Repair Solutions

• Quality and Inspection Services

• Instruction manuals

• Expertise

• E-Shop (Spare Parts Online)

• Training Center

• Additional:

• TS / TSS

• 24/7 Emergency Hotline

• Root Cause Analysis

Support

• Maintenance Concepts

• Stock keeping Expertise

• Application Expertise

• Return on Investment Calculations

• Reliability Studies FMEA, RCM and RBI

• HAZOP Studies

• Compressor Control Description

Projects

• Project Mgmt

• Turnkey Installations

• Site Mgmt

• Field Service Mgmt

• Installation and Commissioning

• Relocation of Compressor Systems

• Compressor Test Runs

• Overhaul / General Overhaul

• Revamp Projects

• Modernization of Compresso Systems


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GHH

NP

Sumy

OBC – Various Range of Brands

Supply of compressor

modifications and components

for Burckhardt and Other Brand

Compressors (OBC)

Typical compressor

manufacturers (OEM’s):

Neuman&Esser, Dresser Rand,

Nuovo Pignone, Borsig, GHH,

Sumy, Peter Brotherhood,

Ingersoll Rand, FAUR, LMF,

Esslinger, Clark, Linde, Burton

Corblin, etc.

Compressor Modifications, Revamps

and Components

JSW

BC

LMF

DR

Borsig


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BC’s advantage in competition

OEM with more than 175 years of experience in building

compressors and equipment

Leading component technology by continuous R&D investments

In-house design and manufacturing of compressor (key)

components

Worldwide service and distribution network

Very well trained people

Expanded and reliable supply chain

Leading quality system

Complete range of services out of one hand


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Collaboration of Revamp/Engineering

Worldwide

assistance

Custom engineered

solutions

Comprehensive

plant design

Continuous

innovation

Lowest life

cycle costs


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Network Around the World

Burckhardt Compression

Subsidiaries und Service

Centers

AgentsBurckhardt Compression

Manufacturing Locations


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Assessment

Condition assessment includes:

– Foundation and grouting

– Anchor bolts and compressor level

– Compressor oil leak survey

– Critical compressor components

– Cylinder lubrication group

– Stock of spare parts

– Auxiliary units

– Vibration measurements if possible

– Monitoring analyzing

Above finding basis for:

– Reconditioning activities / steps

– Scope of reconditioning spare parts

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Assessment

Inspection

Repair / Maintenance

Replacement

Upgrade

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CASE STUDIES

Review of completed engineering and revamp projects


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RELOCATION & MODERNIZATION OF COMPRESSOR

Air Separation Plant, Oxygen

Laby® Compressor-Sweden

• Scope of supply

– Increase production capacity at the air

separation plant in Sandviken, 500 km away

– Meet new operating conditions

– Overhaul and upgrade of compressor parts to

the latest technology

– Compressor relocation including all auxiliaries,

such as cooling system, dampeners, oil

system, supports and piping system

– Installation & Commissioning activities at new

plant


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Compressor Revamp & Re-rating


Major overhaul of oxygen

compressor for capacity

upgrade

• Scope of supply

– Re-Rating of compressor for 25%

increase in volume

– BC provided the client calculations

for capacity re-rating

– New motor, pulley & belts fitted to

increase output

• Achievement

– Successful uprating and

commissioning completion

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Compressor Revamp & Re-rating

BC provide


Major overhaul of oxygen

compressor for capacity

upgrade• Client : Location Kalix, Sweden

• Achievement

– Successful uprating

– OEM Parts

– Compressor skid installation &

commissioning completed in 7 days

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Major Revamp of R22 Gas Compressor


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Industrial Gas -Diaphragm Compressor Overhaul


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Reverse Engineering

New frame for Hitachi secondary

compressor

• Scope of supply

– One frame including guide plates and

crankcase lubrication piping system

• Time frame

– 15 months delivery time

• Challenge

– Exchange part for cracked frame

– Minor design differences between

BC design and Hitachi design

– Hitachi = Licensed BC Hyper F type


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Cylinder Revamp

New cylinders for Sumy primary

compressor

• Scope of supply

– 2 pcs of cylinders including internals

• Time frame

– 10 months delivery time for the parts

• Challenge

– Adapt new BC cylinder to existing Sumy frame

– Adapt new piston rod to existing rod coupling


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Engineering Service

Pulsation and Vibration study BC

Hyper F8 capacity increase,

• Scope of supply

– Revision of study, original 2002

– PV study acc. API618 4th edition appr.3

• Total order amount

– 50 kCHF

• Time frame


• Challenge

– Support location and pipe arrangement

checked on site

– Measurements on site

– Teamwork with customer required


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Change of Control Panels

Change of Control Panels (1987)

• Scope of supply

– 4 Compressor Panels

– 1 Cooling Water Panel

– Set of documentation

– Site installation

• Time frame


– 9 weeks installation

• Challenge

– Purge System of the old panels

– Installation under running conditions

– Two old water panels combined in one l


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Turn Key Project

Compressor Revamp F6 Hitachi

3 Lines

• Scope of supply

– Measurement of existing Hitachi parts

– Manufacturing of parts

– Delivery of parts

– Site Installation in 3 steps (each 24

days)

• Time Frame

– Delivery Time for parts: 8 month

– Site Activities: 24 days each overhaul


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Turn Key Project

• Challenge

– BC lead coordination for plant

installation

– Client main position against BC

– DAP Incoterms

– Conditions of existing equipment

– Payment conditions

– Penalties & Claim Management


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Turn Key Project


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Engineering & Revamp Projects

Thank you


10.05.2019

engineering & revamp capabilities · •hazop studies •compressor control description...

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