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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
Hyper and BP, From Planning to ExecutionApril 2021
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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
Hyper and BP, From Planning to ExecutionApril 2021
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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
Hyper and BP, From Planning to ExecutionApril 2021
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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
Hyper and BP, From Planning to ExecutionApril 2021
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Modernization of plant and components Feasibility studies RCA
Our Background and Customer Needs
Hyper and BP, From Planning to ExecutionApril 2021
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LDPE process evaluation Other brand compressors
Overhaul Reverse engineering
Our Background and Customer Needs
Hyper and BP, From Planning to ExecutionApril 2021
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Scope Definition Compressor mechanical inspection
Frame alignment Piston rod run out Tightening anchor bolts
Hyper and BP, From Planning to ExecutionApril 2021
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Scope Definition Complete BP vibration check, including piping
Hyper and BP, From Planning to ExecutionApril 2021
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Scope Definition Complete BP vibration check, including recommendations
Hyper and BP, From Planning to ExecutionApril 2021
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Scope Definition Motor inspection: Life expectancy analysis by OEM
Good condition for both B/P and Hyper
Hyper and BP, From Planning to ExecutionApril 2021
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Scope Definition Motor inspection: Life expectancy analysis Foundation consultancy
Hyper and BP, From Planning to ExecutionApril 2021
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Report of inspections, with technical recommendations
Scope Definition: Supporting Documents
Hyper and BP, From Planning to ExecutionApril 2021
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Overhaul Acquisition Plan
Spare Parts
Tools
Repair – Services Center
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
Hyper and BP, From Planning to ExecutionApril 2021
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Detailed Commercial Planning Commercial offer for overhaul execution
Description of scope Matrix of responsibilities Manpower & contracting
Hyper and BP, From Planning to ExecutionApril 2021
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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
Hyper and BP, From Planning to ExecutionApril 2021
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Execution of Technical Planning
Preparation
Checks & Measurements
Compressor Maintenance
Service on Accessories & Foundation
Startup of Compressor
Manpower Requirements
Hyper and BP, From Planning to ExecutionApril 2021
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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
Hyper and BP, From Planning to ExecutionApril 2021
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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
Hyper and BP, From Planning to ExecutionApril 2021
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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
Hyper and BP, From Planning to ExecutionApril 2021
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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
Hyper and BP, From Planning to ExecutionApril 2021
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Controlling during the Overhaul Progress
– Daily reporting to customer
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)
Hyper and BP, From Planning to ExecutionApril 2021
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Project work reports Meeting with customer
Lessons learned Opportunities for next TAM Future projects
Closure
1Customer Request
2Scope
Definition
3Detail
Planning4
Execution5
Closure
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
Speaker 1: Falk Jähnigen, Burckhardt CompressionSpeaker 2: Thiago Heinen, Burckhardt Compression
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