Support Network Critical To Coker Crane Success Laughlin Sutar Konecranes DCU Mumbai 2016 PDF

Support Network Critical
to Coker Crane Success
Mark W. Laughlin
Regional Product Manager – Coke Handling
Konecranes America
mark.laughlin@konecranes.com
Anil Sutar
Coker Team India Leader
WMI Konecranes India, Pvt. Ltd.
anil.sutar@konecranes.com
© 2014 Konecranes Plc. All rights
1 Konecranes India Story / Mark W. Laughlin reserved.
SUPPORT IS KEY:
Successful operation needs trained

operators and maintenance personnel:
• Protective features require periodic maintenance/ “Mostly quiet…”
replacement:
• (2) Existing P&H brand
– Encoders for position sensing
cranes, Jamnagar (1987)
– limit switches for travel limits, brake wear
sensing, wire-rope mis-reeving
– Skew sensors 2004
Existing – P&H

SUPPORT IS KEY:

• Protective features require periodic maintenance/
replacement:
• Panipat delivered
• Failures of some systems cause un-trained (supported by KC-Thailand)
operators to lose confidence, turn features “Off”…
– Skew control 2005
– Sway control
– Semi-automation
Existing - KC
Existing – P&H

SUPPORT IS KEY:

• Protective features require periodic maintenance/
replacement:
• Failures of some systems cause un-trained • Pune office opened
operators to lose confidence, turn features “Off”…
• Trained, motivated Operators are the first-line of 2007
defense for Maintenance Team:
– Performing pre-shift safety checks
– Reporting alarms/symptoms accurately
– Adjusting/repairing as instructed
– Observing Operating procedures
“…safety features have been
extremely helpful in avoiding any KC Service Branch
Existing - KC
undesirable and unsafe incidents…” * Existing – P&H
* See Article: Support Network Critical to Coker Crane Success

BUILDING A NETWORK:
When first delivering to India, an

in-country service network was needed:
• Personnel trained at Konecranes facilities in
Houston and Finland
• (2) Jamnagar cranes
– Electrics Factory – Finland
delivered
– Inverter & PLC courses
– Project Management Training / Houston
– Shop Assembly and Testing / Houston 2008
KC Service Branch
Existing - KC
Existing – P&H

BUILDING A NETWORK:

Houston and Finland
• Bina crane delivered
• Tech Support was positioned near refinery sites • Delhi support added
2009
KC Service Branch
Existing - KC
Existing – P&H

BUILDING A NETWORK:

• Baroda crane delivered
Houston and Finland
• Baroda support added
• Tech Support was positioned near refinery sites • Bathinda crane delivered
• Later, Service branches were opened to provide
additional support 2010
KC Service Branch
Existing - KC
Existing – P&H

BUILDING A NETWORK:

• Mangalore crane delivered
Houston and Finland
• Guwahati crane delivered
• Tech Support was positioned near refinery sites • Kolkata Branch opened
• Finally, a dedicated Coker Crane Service Team…
Coker Team India was formed:
– Get the right resource to site
– Customer-focused response
– Trained experts with a Team Culture
“…all of our customers KC Service Branch

Existing - KC
get an improved experience.” Existing – P&H

BUILDING A NETWORK:

Houston and Finland
• Tech Support was positioned near refinery sites • Vadinar cranes (2) delivered
• Finally, a dedicated Coker Crane Service Team…
Coker Team India was formed
• Konecranes Services now partnering with bucket
mfg., Anvil Attachments, Ltd.:
– Spare Parts
– Inspection services
– Bucket rebuilds KC Service Branch
Existing - KC
Existing – P&H
– Replacement buckets
MEASURING SUCCESS:
How can we measure success ?

• Coker Team India is active supporting both
Indian and international customers
– Saudi Arabia • Paradeep crane delivered
– Philippines • Saudi Arabia cranes (4)
– Soon Oman, Belgium, Turkey… delivered
2013
Plus:
Saudi Arabia (4)
KC Service Branch
Existing - KC
Existing – P&H

MEASURING SUCCESS:

• (11) of the Konecranes coker sites in India operate • Kochi crane delivered
• Philippines cranes(2)
with only one crane…a testament to reliability
delivered
2014
Plus:
Saudi Arabia (4)
Philippines (2)
KC Service Branch
Existing - KC
Existing – P&H

MEASURING SUCCESS:

• (11) of the Konecranes coker sites in India operate
with only one crane…a testament to reliability • Chennai crane delivered
• Chennai Branch opened
• Very high levels of customer satisfaction where
Konecranes operates and maintains
2015
Plus:
Saudi Arabia (4)
Philippines (2)
KC Service Branch
Existing - KC
Existing – P&H
On Order

MEASURING SUCCESS:

• Coker Team India is active supporting both • Oman cranes (2) delivered
Indian and international customers • Turkey cranes (2) delivered
• (11) of the Konecranes coker sites in India operate • Belgium crane in process
• Jamnagar crane in process
with only one crane…a testament to reliability
• Haldia crane in process
• Very high levels of customer satisfaction where
Konecranes operates and maintains
2016
• Continued business - Konecranes has received
orders for 15 cokers for India
• Konecranes brand cokers have handled an
estimated 200 million metric tons of coke in India
with no prolonged downtime* Plus:
Saudi Arabia (4)
Philippines (2)
Oman (2)
Turkey (2)
Belgium (1)
“The downtime for these cranes
KC Service Branch
is extremely low…” Existing - KC
Existing – P&H
On Order

MEASURING SUCCESS:

Konecranes branded coker cranes sold to Indian Customers:
Operating Years are Approximate, as of: 2016.75
Coke estimated
Handling
Crane Years Specified produced tons/ year Coke Handled Konecranes Konecranes
Bucket Size No. of "Factor"
Ordered Qty. Lift Operating Op-Yrs Tons/Day per Day handled x 350 to Date Maintaining Operating
(m3) Cranes (times coke
Capacity (per crane) Produced per crane days/year (t) ? ?
handled)
(tpd) (t)
2016 1 32 MT 15 M. Mech. [ Not yet in Service ] -- -- -- -- -- -- --
2011 1 55 MT 30 M. Mech. 0.5 1 0.5 4,172 4,172 2 2,920,400 1,460,200 Yes Yes
2010 2 40 MT 20 M. Mech. 4.25 2 8.5 7,154 3,577 2.3 5,758,970 48,951,245 Yes Yes
2010 1 10 MT 3.6 M Mech. 4 1 4 244 244 2 170,800 683,200 Yes No
2009 1 41 MT 20 M. Mech. 2 1 2 3,300 3,300 2 2,310,000 4,620,000 Yes Yes
2009 1 40 MT 20 M. Mech. 4.5 1 4.5 3,150 3,150 2 2,205,000 9,922,500 Yes Yes
2008 1 44 MT 25 M. Mech. 5.25 1 5.25 3,314 3,314 2 2,319,800 12,178,950 Yes Yes
2007 1 33 MT 15 M. Mech. 5.5 1 5.5 1,417 1,417 2 991,900 5,455,450 Yes No
2006 2 35 MT 20 Yd. Mech. 7.5 2 15 12,504 6,252 1.5 6,564,600 98,469,000 No No
2003 1 44 MT 25 M. Mech. 10.75 1 10.75 3,100 3,100 2 2,170,000 23,327,500 Yes No
15 = Total Cranes Total CraneOpYrs = 55.50 38,355 25,411,470 203,607,845
350 x Op Days / Year
13,424,250 = Total Coke Produced 25.4 203.6
13.4 mil t Million mt Million mt

MEASURING SUCCESS:

“Typical” Break-down has been approx. 2 days
Coker Specialists respond quickly and problems are resolved
Recently (2) significant Break-down incidents:

• Derailing (Aug-2016) :
o One crane in a 2-crane facility derailed
o Time was spent checking wheel and rail alignment
o But failure was found to be in Skew-Control software
o Software was re-loaded, system recalibrated, crane running fine
o This is longest shutdown reported to date… 19 days
• Encoder signal failure (July-2016):
o Problem was first mis-diagnosed (by KC) as bad encoder
o Time was wasted obtaining/installing replacement
o Trouble was actually damaged encoder cable, replaced/resolved
o This is second-longest shutdown… 10 days
MEASURING SUCCESS:

But the good news is…
• 55.5 OpYears / 200 million metric tons handled:

o No Hoist/Close Motor failures
o No Gantry/Trolley Motor failures
o No Gear failures
o No Drum failures
• Main failures, ReGen Units and Inverters
o Several due to improper storage prior to install
o Most failures on Commissioning or shortly after
o Operationally:
– 4 failed ReGen Units
– 1 Gantry Inverter
o Otherwise, a few encoders, sensors, bearings…

FULL-SERVICE SUPPORT:
A variety of Services available:

• Crane operators
• Maintenance personnel
• Inspection services
• Technical support
• Training

FULL-SERVICE SUPPORT:
…with a variety of Service Products:

• Mainman reporting
• TRUCONNECT© remote monitoring
• RopeQ wire rope diagnostics
• RailQ runway rail alignment
• CMS diagnostic data analysis
• yourKONECRANES.com© web portal

KONECRANES INDIA TODAY:
KC Coker locations:
• Panipat (2003)
• Jamnagar
(3 KC 2006/2006/2015, 2 P&H 1998/1998)
• Bina (2007)
• Baroda (2008)
• Bathinda (2009)
• Mangalore (2009)
• Guwahati (2010)
• Vadinar (2 KC 2010/2010)
Plus:
• Paradeep (2011) Saudi Arabia (4)
• Kochi (2013) Philippines (2)
Oman (2)
• Chennai (2014) Turkey (2)
Belgium (1)
• Haldia (2016)
KC Service Branch
Existing - KC
(17 cranes as of July-
July-2016, incl P&H brand) Existing – P&H
(Year Ordered) On Order

CONCLUSION: COKE HAND
LING BUCK
ET CRANES BY
KONECRAN
Ordere d
Customer
ES
2016 Jaco
bs, Eng ineer Project
2016 Larr ing
sen & Tubr Exxo nMo
2015 Relia o bil-B aton Roug Licensor
nce Industrie IOCL-Hald e, LA Qty. Capacity
2014 Technicas Reu s, Ltd. ia Refin ery, (Unknow n) Bucket Operating
nidas (UTE Jamnaga India 2 14 ton
Years are Approx
Type
2014 TSGI
im ate, as of:
) r J3 Expa nsion Foster W heeler
7 Yd. Mec Start Yr 2016
Fluor Eng STAR-Turk , India 1 32 MT h. Bridge Cran Operating
ineering, N.V ey, Agean Foster Wheele
15 M. Mec e Cranes
2014 Moti Refin ery r
1 h. Op-Yrs
va Enterpris ExxonMo bil, Foster 40 MT Semi-Gantry [ Not yet in
Service ]
2014 Flint es, LLC Antwerp Refin Wheele r 22 M. Mec
Hills Resc Motiva, Port ery 2 19 MT h. Semi-Gan [ Not yet in
Service ]
2014 Dael ., Pine Bend Arthu r, TX (Rep
Foster Wheele
r 10 M. Mec h. try
im Petr ofac Rose mont l.) 1 43 MT Semi-Gan [ Not yet in
Service ]
2014 Eng JV , MN, Repla (Unknown) 25 M. Mech . try
ineer s India Sohar Refin cement 1 25 ton 14 Semi-Gan [ Not yet in
Service ]
2013 Phil , Ltd. ery (SRIP), (Unknown)
Yd. Mech . try
lips 66, Rode Chennai Petro Oman 1 18 ton 10.5 Brid ge Cran [ Not yet in
Service ]
o, CA CB&I ( AB B - Lum
2013 Essa . Corp (CPC m us )
2 Yd. Mech. e 2016
r Projects Rod eo, CA, L), India CB&I 0
The keys to coker crane success:

(India), Ltd. Replacem 30 MT Bridge Cran 1
2012 Dael ent
(A B B - Lum
m us) 17 M. Mech e 0
im Indu strial Koc hi Refi 1 33 MT . Semi-Gantry [ Not yet in
Service ]
2011 Toyo Co., Ltd. nery (BPC (Unknow n) 21 M. Mec
Engr . / India Petron RMP L), India 1 9.5 ton h. [ Not
2011 Tech n Oil Co. -2, Philip pine CB&I ( A B B -Lum
5.0 Yd.M ech. Semi-Gantry yet in Service
]
m us )
nip-India IOCL-Para s 1 37 MT Bridge Cran [ Not yet in
Service ]
2010 Essa dip, Orrissa, Foster W heeler
23 M. Mec e 2016
r Refining, NOC L, India 2 25 h. Sem 0
2010 IOT Ltd. Cud dalor e, (TN), Foster W heeler MT 11 M. Mec i-Gan try 1
Infrastruc Essar, Vadi India 1 55 MT h. [ Not yet in 0
2010 Chiy t. & Serv ., nar, Guga CB&I ( A BB -
30 M. Mec Semi-Gan Service ]
oda Corp . Ltd. rat, India Lum m us )
1 h. try 2014
/ CYS E IOCL-Guw 32 MT Semi-Gan 2
2009 Aram ahati, Assa CB&I ( AB B -
Lum m us ) 15 M. Mec try 2016.0 2
co (Con ocoP Jubail Exp. m, India 2 h. 4
2009 Punj hillips) Ref. Saud (Unknown) 40 MT Semi-Gan 0
i Arabia 20 M. Mec try 1 0
Lloyd, Ltd. Yanbu Exp 1 10 MT h. Semi-Gan [ Not yet in
2009 Nafto . Ref., Saud Foster Wheele
r 3.6 M Mec try 2012.7
Service ]
gaz India MRP L, Man i Arab ia 2 45 MT 21.5 h. Dbl. Leg 5 3.25
2008 Fluo Ltd. galore, India Conoc oPhillip
s M. Mech. Gantry 2012.7 2
r HME L, Bath CB&I (A B B -
2 45 MT 21.5 Semi-Gan 5 3.25 6.5
2008 Punj inda , Pun Lum m us)
M. Mech. try 2014 1
Lloy d, Ltd. TOTAL, Port jab, India 1 3.25
2008 Fluo Arthur, TX CB&I (A B B -Lum 41 MT Bridge Cran 2
Experience:
m us) 20 M. Mec e 2015 1 2
r IOCL -Bar oda, Conoc oPhillip
1 40 MT h. Semi-Gan 1
2007 Nafto Gugarat, India s 20 M. Mec try 2015 2
gaz India Marathon , 1 44 ton 25 h. Semi-Gan 1 2
2007 Fluo Ltd. Detr oit, MI Foster Wheele
r Yd. Mec h. try 2012.25 1
r BORL, Bina 1 44 MT Bridge Cran 3.75 1
2006 Bech , (MP ) India ConocoPhillip
s 25 M. Mec e 2010 1
tel - France Marathon , 1 30 ton 17 h. 3.75
2006 Fluo Garyville, CB&I (A B B -Lum Semi-Gan 6 1
r LA m us )
1 Yd. Mec h. try 2011 .5 6
Reliance Jamn ConocoPhillip 33 MT Bridge Cran 4.5
2006 Fost agar, India s 15 M. Mec e 2013 1
er Wheeler Teso ro Gold 1 30 ton 17 h. Semi-Gan 3 4.5
2005 Bech Iberia en Eagle , Foster W heeler
Yd. Mech. try 2011.25 1
tel, Con ocoP BP Spain CA 2 35 MT Brid ge Cran 4.75 3
2004 Cono hillips ConocoPhillips
20 Yd. Mec e 2009 1
• Total combined operating time for Konecranes and

coPhillips Borger Refin 1 44 ton 25 h. 4.75
2003 Lars ery, TX Foster W heeler Semi-Gan 7 1
en & Tou bro 1 Yd. Mech. try 2009.25 7
Alliance Refin 17 MT Brid ge 6.75
2001 Bech ery, LA Conoco Phillips 8 M. Mech. Crane 2008 2
tel IOCL-Panipat, 1 30 ton 17 13.5
2000 Fost Haryana, India ConocoPhillips Semi-Gan 8 1
er Wheeler 1 Yd. Mech. try 2008 8
Hovensa, St.C CB&I ( AB B - 18 ton 10.5 Brid ge Cran 8
2000 SK roix Lum m us ) Yd. Mech. e 2007 1
Engin eerin Sinc or, Vene 1 44 MT Bridge Cran 9 8
2000 Bech g zuela ConocoPhillips
25 M. Mec e 2006 1
tel PEM EX, Mad Foster Wheele
1 45 ton 25 h. Semi-Gan 10 9
1998 Cons ero r Yd. Mech. try 2006.0 1
orcio Cont Marathon, 2 25 MT 11.5 Bridge Cran 10 10
rina Garyville,
P&H coker cranes is now over 1,800 Operating Years

Foster Wheele
1997 Chiy LA r M. Mech. e 2003 1
oda Corp. VEHOP, Vene 2 27 ton 18 Semi-Gan 13 10
1996 Fost zuela ConocoPhillips
Yd. Mech. try 2002 1 13
er Whe eler Mela ka Refin ConocoPhillips
1 27 ton 17 Semi-Gan 14
ery Yd. Mec h. try 2002 2
Lyondell Citgo 2 22 MT 12.5 Bridge Cran 14 28
ConocoPhillips
, TX Yd. Mec h. e 2002 2 28
Foster Wheele
1 15 MT Bridge Cran 14
r 8 M. Mec h. e 2000 1 14
2 27 ton 18 Bridge Cran 16
Yd. Mec h. e 1999 2 32
Semi-Gan 17
try 1998 1 17
• Over 55 Operating Years for Konecranes Indian cokers

18
2 36

LING BUCK
ET CRANES BY
KONECRAN
Ordere d
Customer
ES
2016 Jaco
2016 Larr ing
sen & Tubr Exxo nMo
Years are Approx
Type
2014 TSGI
im ate, as of:
15 M. Mec e Cranes
1 h. Op-Yrs
Service ]
Service ]
Foster Wheele
r 10 M. Mec h. try
Service ]
Service ]
Yd. Mech . try
Service ]
2 Yd. Mech. e 2016

2012 Dael ent
(A B B - Lum
Service ]
]
m us )
Service ]
23 M. Mec e 2016
1 h. try 2014
Lum m us ) 15 M. Mec try 2016.0 2
r 3.6 M Mec try 2012.7
Service ]
2 45 MT 21.5 Semi-Gan 5 3.25 6.5
M. Mech. try 2014 1
Experience:
m us) 20 M. Mec e 2015 1 2
r Yd. Mec h. try 2012.25 1
s 25 M. Mec e 2010 1
r LA m us )
1 Yd. Mec h. try 2011 .5 6
Yd. Mech. try 2011.25 1
20 Yd. Mec e 2009 1

25 M. Mec e 2006 1
1 45 ton 25 h. Semi-Gan 10 9
rina Garyville,

Foster Wheele
Yd. Mech. try 2002 1 13
ConocoPhillips
, TX Yd. Mec h. e 2002 2 28
Foster Wheele
r 8 M. Mec h. e 2000 1 14
Yd. Mec h. e 1999 2 32
Semi-Gan 17
try 1998 1 17

18
2 36
Technology:
• Konecranes suite of software features for
Safety, Reliability and Productivity

LING BUCK
ET CRANES BY
KONECRAN
Ordere d
Customer
ES
2016 Jaco
2016 Larr ing
sen & Tubr Exxo nMo
Years are Approx
Type
2014 TSGI
im ate, as of:
15 M. Mec e Cranes
1 h. Op-Yrs
Service ]
Service ]
Foster Wheele
r 10 M. Mec h. try
Service ]
Service ]
Yd. Mech . try
Service ]
2 Yd. Mech. e 2016

2012 Dael ent
(A B B - Lum
Service ]
]
m us )
Service ]
23 M. Mec e 2016
1 h. try 2014
Lum m us ) 15 M. Mec try 2016.0 2
r 3.6 M Mec try 2012.7
Service ]
2 45 MT 21.5 Semi-Gan 5 3.25 6.5
M. Mech. try 2014 1
Experience:
m us) 20 M. Mec e 2015 1 2
r Yd. Mec h. try 2012.25 1
s 25 M. Mec e 2010 1
r LA m us )
1 Yd. Mec h. try 2011 .5 6
Yd. Mech. try 2011.25 1
20 Yd. Mec e 2009 1

25 M. Mec e 2006 1
1 45 ton 25 h. Semi-Gan 10 9
rina Garyville,

Foster Wheele
Yd. Mech. try 2002 1 13
ConocoPhillips
, TX Yd. Mec h. e 2002 2 28
Foster Wheele
r 8 M. Mec h. e 2000 1 14
Yd. Mec h. e 1999 2 32
Semi-Gan 17
try 1998 1 17

18
2 36
Technology:
• Konecranes suite of software features for
Safety, Reliability and Productivity
Service:
• Support for Konecranes products wherever
buyers install it
• Team India Experts for Indian and
international locations
• Operation, Maintenance, Training…
“We’ll send Team India…”

KEY TAKE-AWAYS:

Operators:
• Whether operation is by Owner, Contractor or
Konecranes, Operators Must be Trained
Maintenance:
• Whether Maintenance is by Owner, Contractor or
Konecranes, Maintenance people Must be Trained
Partner:
• Work with a partner who is local, dedicated, and
customer focused
Equipment:
• With the above, plus the right equipment and
appropriate spares... Success !!

MAIN RESULT:
Satisfied
Customers !!

Thank you !!
WMI KONECRANES INDIA PVT LTD
19, Level 2, Muttha Towers, Don Bosco Road,
Yerwada, Pune 411 066 India
SUPRA ENGINEERING
71-74, 2nd Floor, Suryakiran Complex, J. P. Road,
Vadodara – 390 015, Gujurat, India

25 Konecranes India Story / Mark Laughlin reserved.

Support Network Critical To Coker Crane Success Laughlin Sutar Konecranes DCU Mumbai 2016 PDF

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Support Network Critical

to Coker Crane Success

Successful operation needs trained

© 2014 Konecranes Plc. All rights

Successful operation needs trained

© 2014 Konecranes Plc. All rights

Successful operation needs trained

undesirable and unsafe incidents…” * Existing – P&H

* See Article: Support Network Critical to Coker Crane Success

When first delivering to India, an

© 2014 Konecranes Plc. All rights

When first delivering to India, an

© 2014 Konecranes Plc. All rights

When first delivering to India, an

© 2014 Konecranes Plc. All rights

When first delivering to India, an

“…all of our customers KC Service Branch

get an improved experience.” Existing – P&H

© 2014 Konecranes Plc. All rights

When first delivering to India, an

How can we measure success ?

© 2014 Konecranes Plc. All rights

How can we measure success ?

© 2014 Konecranes Plc. All rights

How can we measure success ?

© 2014 Konecranes Plc. All rights

How can we measure success ?

© 2014 Konecranes Plc. All rights

How can we measure success ?

© 2014 Konecranes Plc. All rights

How can we measure success ?

Recently (2) significant Break-down incidents:

How can we measure success ?

• 55.5 OpYears / 200 million metric tons handled:

© 2014 Konecranes Plc. All rights

A variety of Services available:

© 2014 Konecranes Plc. All rights

…with a variety of Service Products:

© 2014 Konecranes Plc. All rights

© 2014 Konecranes Plc. All rights

The keys to coker crane success:

• Total combined operating time for Konecranes and

P&H coker cranes is now over 1,800 Operating Years

• Over 55 Operating Years for Konecranes Indian cokers

© 2014 Konecranes Plc. All rights

The keys to coker crane success:

• Total combined operating time for Konecranes and

P&H coker cranes is now over 1,800 Operating Years

• Over 55 Operating Years for Konecranes Indian cokers

© 2014 Konecranes Plc. All rights

The keys to coker crane success:

• Total combined operating time for Konecranes and

P&H coker cranes is now over 1,800 Operating Years

• Over 55 Operating Years for Konecranes Indian cokers

“We’ll send Team India…”

The keys to coker crane success:

© 2014 Konecranes Plc. All rights

© 2014 Konecranes Plc. All rights

© 2014 Konecranes Plc. All rights

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