SUCCESS STORIES CREATING VALUE FOR CUSTOMERS...Success stories creating value May 9, 2019 Page 12...

SUCCESS STORIES CREATING VALUE FOR CUSTOMERS

Landvetter, May 9th 2018

Danilo Werner, Region Europe / Global Sales and Market Development

Success stories creating value

May 9, 2019

Customer from Chlorine Industry

Country: Israel

Location: Dead Sea

Production of Bromium; Magnesium; Potash; Chlorine

Detail: 428m below sea level; +45°C


May 9, 2019

Situation for DSM in 2015

1 Compressor Operation – Low reliability - #1

1 Compressor Operation – Low reliability - #2

1 Compressor Out of operation - #3

1 Compressor Out of operation - #4

• Necessary 2 compr. to keep the plant in operation

• #3 and #4 needed major repair

• DSM was planing to repair the compressor at site

• Limitation of resources at site


May 9, 2019

What convinced our partner on-site

‘‘Lack of project management skills on-site. We will not get out of this situation

alone – Burckhardt will help us’’

‘‘‘Your will receive new compressors - warranty as new’’

‘‘Less expensive compared than doing it by ouselves’’

‘‘Quality of Burckhardt Compession – Included mechanical test run’

‘‘Lower risk at the Service Center working under 45°C or in a Chlorine Site’’

‘‘We will upgrade your compressor with latest technology’’

‘‘Strong consultancy support on-site’’


May 9, 2019

Sales Project – PO

2015

2016

2017


May 9, 2019

Project Execution

Removal of the

compressor

Arrival at the service

center


May 9, 2019

Project Execution


May 9, 2019

Project Execution

Laser control

of the

crankcase

Complete

repair


May 9, 2019

Project Execution

Cylinder:

Inspection

Machining

Test

Pinting

Parts:

Repair

&

Replacement

&

Re-use


May 9, 2019

Project Execution

Compessor:

Assembley

Test Run

Customer Visit

Disassembley

Packing

Shipping


May 9, 2019

Project Execution

2016 201720182019*

Foundation Repair

Compressor Install

Compressor Test

Commissioning

Warranty support

Next Compressor


May 9, 2019

Results and Time line

2016 2017 2018

55131

200118

Inst

Inst

53702 Inst

53701 Inst

2019

• All complext compressors repairs in HQ to ensure best possible quality

• Learning Organization: Delivery time was reduced after 1st project

• Quality increased, as condition of compressor was repeating over time

• Installation executed with supervsion of FSR (separated order)


May 9, 2019

DSM from risk of total collapse back to normal

operation with great efforts of various teams.

Risk of total

collapse

Order to

BC

Inspection

Site back to

operation

3 Follow up

orders

Measurements

Repair

Assembly

Test run

Installation

Satisfied

customer

Procurement Malen

9 months

Pressure testQuality


May 9, 2019

Customer Moment: Repsol Polímeros - Turnaround 2018

Overhaul of BC compressors in Repsol Polímeros LDPE plant

Scope: Complete overhaul of the LDPE lines 1 and 2

2 primary and 2 F6 Hyper Compressors


May 9, 2019


Job preparation

May

1st

preparation

meeting

20182016

March

Challenging

news

May

> 2 year preparation period

Scope definition

Checking spare

parts inventory

Defining required

resources

Tu

rna

rou

nd

an

tic

ipa

tio

n

June

Resources

re-scheduling


May 9, 2019


Activities

Repair of the plungers (subcontracted)


May 9, 2019


Activities

Repair of the line 2 Hyper lube pumps at HQ during the overhaul


May 9, 2019


Activities

Replacement of one of the Hyper motors (not in our scope)


May 9, 2019


Activities

Reaming of the hyper/motor adaption flanges


May 9, 2019


Activities

Machining of the crankcase/distance piece surfaces

(subcontracted to Metalock). Job cancelled 3 months prior to the

turnaround. Foreseen for next turnaround.


May 9, 2019


Human resources

site coordination - BCES

primary line 1 - 2B3C1.38 S/N 40419

1 BCAG supervisor (Jan Siczek)

1 Repsol lead mechanic

2 outsourced lead mechanics

primary line 2 - 2B3C1.38 S/N 40420

1 BCAG supervisor (Jan Siczek)



hyper line 1 - F6 S/N 40421

1 BCFR supervisor (Franck Fontaine)



hyper line 2 - F6 S/N 40422

1 BCAG supervisor day shift (Miguel Tafula)

1 Repsol lead mechanic day shift

2 outsourced lead mechanics day shift

1 BCES supervisor night shift (Miguel Zamarra)

2 outsourced lead mechanics night shift

technical support - BCAG


May 9, 2019


Job execution The turnaround started the 14th may and the

last compressor was started the 6th July.


May 9, 2019


Execution

Some unscheduled activities had to be

carried out, like the dismantling, cleaning

and painting of the primaries cylinder

cooling chambers.


May 9, 2019


Execution

We have coordinated all the motor

replacement related activities to avoid any

damage on the hyper bearings or

crankshaft/camshaft.


May 9, 2019


After job completion

All wear parts and many capital parts replaced

Some activities had never been carried out, like replacing the o-ring

between distance piece and crankcase bodies of the primaries.

New design oil wiper packings were installed on Hyper in line 1

New electric motor for Hyper in line 2

Compressors ready to run for 5/6 years until next turnaround.

Lessons learnt

It’s important to start preparing the turnaround as soon as possible

to maximize business opportunities

We need to be prepared for all kinds of surprises – flexibility is very

important.


May 9, 2019


What Our Customer Says

"The work carried out by Burckhardt Compression was very

good – the planning, technical support, follow-up, last-minute

spare parts orders and unscheduled repairs, as well as

administrative issues. They never had any difficulties adapting

to Repsol’s requirements and last-minute requests, even

though the turnaround timetable created some additional

difficulties for both parties."

André Afonso

Reliability Engineer, Repsol Polímeros


May 9, 2019


May 9, 2019

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SUCCESS STORIES CREATING VALUE FOR CUSTOMERS...Success stories creating value May 9, 2019 Page 12...

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