Protecting Your Assets

Solar Expands Facilities

Sensors forTurbomachinery

Protecting Your Assets

Solar Expands Facilities

Sensors forTurbomachinery

August-September 2008

www.compressortech2.com

August-September 2008

300 West First StreetAlice, Texas 78332 USA

361.668.83111.800.72.ENDYN

361.668-3906 (fax)www.endyn.com

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Energy Dynamics Ltd. (EnDyn) be-gan in 1978 in a single office andsmall warehouse in Alice, Texas,U.S.A. The original concept of thecompany was a customer-centeredbusiness focused on providing qual-ity Superior and Ajax engine andcompressor parts. Thirty years laterthe company has stayed true to itsinitial business plan, still specializingin the manufacturing of parts for theSuperior and Ajax product lines,while also evolving into a globalprovider of engineering and techni-cal expertise, service and training forall medium-speed industrial enginesand compressors.

With a 52% growth in sales overthe last five years and plans to ex-pand its Alice, Texas, facility in early

2009, the company shows no sign ofbecoming complacent.

“Our focus is on the customer,”said Kevin Downes, director of salesand marketing for EnDyn. “We relyon our customers for feedback, fordirection, for improvements, as wellas daily business. The term ‘customerservice’ or ‘service excellence’ isthrown around a lot these days, butthat is every ounce of what we do.And our employees are focused onmeeting customer requirements. Notwhat we think they might need, butwhat they require.”

“We’ve been very fortunate to main-tain our qualified, experienced staff,”said Tracy Little, president of EnDyn.“If you look around at the people inkey positions within our company,they’ve been around a long time. It’snot like some companies in this busi-ness where turnover is continuousand a company finds themselves re-training people weekly or monthly.We’ve got people in place that knowwhat they are doing and I think thecustomer gets a lot of confidencefrom that experience.”

EnDyn utilizes a global network ofagents, representatives and distribu-tors and currently has a presence inover 26 countries.

“From the very beginning, EnDynhas concentrated on internationalmarkets. In the first 10 years ofEnDyn’s existence, its primary marketwas North and South America,” saidLittle. “A large percentage of the effortwas servicing those markets. Then wegrew into Middle East, and thenEurope and Africa. In the last 10 yearswe’ve expanded into China andSoutheast Asia.”

EnDyn divides itself into three divi-sions: Parts, Service and Manufacturing.

The Parts Division revolves aroundtwo product lines, Superior and Ajax,

AUGUST-SEPTEMBER 2008 COMPRESSORTechTwo

n Power cylinder head repair and assembly area. Here, remanufactured heads are cleaned,hydrotested and mag-particle inspected. Each seat and valve is lapped by hand to ensure aquality assembly.

ENDYN CELEBRATES 30 YEARSContinued Growth on the Horizon

By Brent Haight

n EnDyn invests inpatterns and toolingresulting in high-qual-ity castings and forg-ings to control 100%of manufacturing ofeach PowerPart.

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which are trademarks of Cameron. Additionally, EnDyn isthe sole South American representative for all Altronic Inc.ignition and control products. The parts division includessales, engineering, quality control, purchasing, inventorycontrol and technical training.

“We promote ourselves as a 100% parts supplier for theAjax and Superior product lines,” said Downes. “Whateverthe customer needs, we are a one-stop shop for thoseproduct lines.”

EnDyn offers new parts for Superior and Ajax enginesand compressors — manufactured in-house. Its productline, known as PowerParts, is sold worldwide to users inthe oil, gas and power generation industries. Additionally,EnDyn provides remanufactured, exchange and used as-semblies and parts, including complete engines and com-pressors. PowerParts are distributed throughout the UnitedStates, Canada, South America, Europe, Middle East, Asia,Africa and Australia. The company sells direct to the enduser and through strategically located stocking distributorsand representative agencies. Complete support is providedto all sales and marketing outlets from the corporate head-quarters in Alice, Texas.

“It is important to point out that EnDyn continues to per-form developmental work on this legacy equipment,” saidLittle. “We are active in doing R&D work on the Superiorand Ajax equipment and are continually bringing new prod-ucts to the marketplace. We feel that we do a pretty goodjob of listening to our customers about reliability issues andopportunities for improvement and take those to our engi-neering department. Within the last few years, we’ve spentmore than US$1.3 million on patterns and tooling alone.”

EnDyn maintains a multimillion-dollar inventory sup-ported by a computerized inventory control system, whichcontinually monitors parts availability, production schedul-ing and stock levels. Included in this inventory is EnDyn’scustomized Just-In-Time overhaul, preventive maintenanceand upgrade kits for the Ajax and Superior product lines.

“On a daily basis we deal with international purchasingagents who have limited equipment knowledge,” said Little.

“They know part numbers and they know quantities butdeliveries in the international market has always been achallenge. You can’t just walk across the street to get whatyou need. So the customer fills their warehouses with parts,in overstocked quantities, to keep the equipment running.They could have enough parts in stock to overhaul everyengine in their fleet. But on an annual overhaul schedule,they might only overhaul one or two units. As customersgo through an overhaul cycle, they build up their inventoryon individual line items. They maintain that high levelthroughout non-overhaul cycles so they have excess inven-tory. Our Just-In-Time Overhaul and Maintenance Kits bringall those parts together so that the customer knows what isbeing used for a major overhaul and doesn’t skew their in-ventory minimums and maximums. We customize the kitsto the customer’s needs and the type of overhaul. The ideais that within one or two crates is everything they need.This way, they don’t have to purchase 500 line items, stock500 line items and pull those 500 line items before an over-haul only to learn that you still need two pistons, for exam-ple. With our JIT Overhaul Kits, everything comes in onepackage. With this approach, the customer can reduce theirinventory considerably.”

The Service Division of EnDyn provides technical ser-vices and repackaging for the natural gas gathering, trans-mission and power generation industries. Field service, in-house overhaul and repair, reconditioning, machining,compressor repackaging, replacement parts and a leasecompressor fleet are among the services offered.

“Because we are a service shop, we work on all typesof equipment,” said Downes. “Customers may have aChicago Pneumatic, or an Ariel, or Ingersoll Rand. Ourexpertise and order of priority is Superior and Ajax en-gines and compressors, but we have the knowledge andexperience to work on all medium-speed industrial en-gines and compressors.

“Our warranty is very competitive within the industry,”added Downes. “Our new parts warranty is two years. Ourremanufactured equipment comes with a one-year war-ranty. The way that we remanufacture the equipment al-lows us to substantiate that warranty.”

“One of the things that is unique about having equipmentreconditioned by a company like EnDyn — our core busi-ness is the manufacture of new parts, we don’t deviate to adifferent inspection program when it is a reconditionedcomponent,” said Jack McMonagle, EnDyn’s vice president

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n Exchange Engine program provides reconditioned and exchangeparts and assemblies remanufactured to “as new” specifications witha one-year warranty.

n EnDyn’s Repair Center, located within its Service Division, containsan engine test stand capable of load testing Superior, Ajax, Waukeshaand Caterpillar engines up to 1600 brake horsepower (493 kW).

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of operations. “A crankshaft that has been reconditionedcomes in the same door as a new crankshaft and goesthrough the same inspection process as the new one. That isthe reason we use the term ‘zero hour recondition.’ Everycomponent we remanufacture has been inspected to ‘newpart’ criteria.”

EnDyn’s Alice, Texas, repair center is a 33,000 sq.ft. (3066m2) facility that includes overhaul/repair bays, sub-assemblyrepair shops, unit fabrication/packaging bays and a fullyequipped machine shop. The repair center also contains anengine test stand capable of load testing Superior, Ajax,Waukesha and Caterpillar engines up to 1600 brake horse-power.

“Not only do we remanufacture engines, but each engine isload tested on our water brake dynamometer,” saidMcMonagle. “We load test our engines to ensure a quality re-build so they are ready to go when they hit the field.”

The company added its machining division in 2001 withthe acquisition of Monroe Industries, now named EnDynManufacturing. Located in San Antonio, Texas, the 22,500sq.ft. (2090 m2) facility is a manufacturing, fabrication andgeneral machining center that services the construction, min-ing, safety, medical, and oil and gas production industry.Equipped with 20 CNC machines and 10 manual machiningcenters, the machine shop offers complete turnkey solutionsto machining needs, including material procurement, heat-treating, turning, milling, grinding, honing, welding, plating,assembly, packaging and delivery.

Little, one of the original founders of EnDyn, has wit-nessed many changes within the industry over the last 30years.

“When we first started, it was a highly competitive mar-ket,” said Little. “Competition was great for the customersand good for the business in general. As we went throughthe ’80s and ’90s things changed. In the ’80s the oil and

gas industry went down quite a bit. EnDynwas more involved with the production sideof the business, gas gathering and gas trans-mission, which is more stable than drilling.When we got into the late ’90s, we saw lotsof consolidation, we saw entire companiesand equipment disappear. The concernwe’ve had is the fixed population of en-gines that we are servicing and the fixedpopulation of customers. We continue toexpand our products and services, takingsteps to continue to increase sales. Fromour standpoint, we’ve been very successfulwhile maintaining ourselves as a small, family-type operation.”The biggest challenge facing the industry to-day, in Little’s opinion, is locating and keep-ing personnel. “I’ve never seen it this badbefore,” said Little. “It has become very diffi-cult to recruit personnel into the oil and gasindustry, whether its technicians or manage-ment. We conduct training programs world-wide. Our customers are having the sameproblem we are, finding additional person-

nel, especially on the technical and mechanical side. Thereis a wave of young, inexperienced folks in our industrythat are hungry for information. We are interested in teach-ing folks what we know about equipment from an opera-tion and maintenance standpoint. We offer a formalizedprogram that often turns into a roundtable discussion de-pending on the interaction of the students. There’s very lit-tle, if any, marketing going on. These are purely opera-tional and maintenance training programs. When we havethe opportunity to conduct a training program, we are in-troducing ourselves to more potential customers. Whenyou know what you are talking about and know what youare teaching, it builds confidence within the customer’smind and, in turn, he might give you the opportunity to dobusiness with them.” n

n EnDyn’s ISO 9002 Quality Assurance and Control Program utilizes state-of-the-art equip-ment, such as this portable coordinate measuring machine (CMM) that provides highly ac-curate measurements of every PowerPart.

n EnDyn maintains a multimillion-dollar inventory supported by acomputerized inventory control system, which continually moni-tors parts availability, production scheduling and stock levels.

REPRINTED FROM AUGUST-SEPTEMBER 2008 COMPRESSORTechTwoCopyright Diesel & Gas Turbine Publications

Printed in U.S.A.

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