Process specific solutions
A great deal of equipment within a typical
refinery could benefit from changes in
design or simply an upgrade to more
modern materials in order to increase
reliability. Improvements to bearing
designs on larger pieces of equipment
for instance can increase service life and
reduce time spent on regular maintenance.
The impeller design in many multi-stage
compressors could be improved as part
of a scheduled maintenance program
in order to deliver greater output which
would allow a more flexible working
envelope and improve efficiency. Sulzer
has the expertise and facilities to enable
the engineering teams within the refinery
to achieve their goals in terms of reliability
while also delivering a cost effective
program.
application of surface treatments can also
productivity, the refinery's engineering
be used to extend the operational life of
team is able to build a partnership with the
the pumps. In each case, if Sulzer is dealing
local service provider and continue making
with the component, it is examined and
improvements.
the most appropriate actions are proposed
to the client.
For the majority of cases involving
component failure, Sulzer can offer
considerably reduced lead times for
a completed repair when
compared to the OEM. For
example, an emergency repair to a
steam turbine which had a cracked
low pressure casing saw a team of
Sulzer engineers on site within
24 hours. The overall shutdown
period was just 9 weeks, which is
remarkable when compared to
the 14 months that had been
offered by the OEM.
Improving long-term reliability
With so many production processes
involving a multitude of pumps,
compressors, turbines and motors, it is
essential to have a well-developed asset
management system in order to reduce
the amount of reactive maintenance
within the refinery. As these assets mature
so an increased amount of intervention
will be required and it is the responsibility
of the site engineering team to ensure
that the most cost effective solution is
implemented.
The global network of Sulzer engineers has
considerable experience in maintaining
Even when replacement parts appear to
and managing mature equipment by
Innovative solutions can also be applied
be unavailable, Sulzer has the necessary
applying experience and the latest
to the huge number of pumps installed
technology to reverse engineer new
technological innovations to extend the
within the facility. Remanufacturing of
components, manufacture them from the
life cycle of these vital assets and maximize
impellers, balancing and bearing overhauls
latest materials and even correcting any
productivity. All of this knowledge and
can all be accomplished within scheduled
design flaws in the original. By using skills
expertise is available through the local
maintenance intervals, while the
such as these and seeing the benefit to
service center that in many cases may
already be very close at hand.
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PECM Issue 21