CUSTOMER TRAININGINTRODUCTION

COMPRESSOR SERVICE

Kolkatta

5th October 2004

Prepared by Ken J Taylor

Project Manager
Hoerbiger Group, Asia / Pacific
 Presentation Summary

Aiming for Best Practices in Compressor Maintenance & Training

Hoerbiger, as is the case with many other international manufacturers face the challenge to manage a
technical workforce which can continue to sustain a high standard of quality products and services to
industry. Whilst also being constantly challenged with harsh economical realities weighing heavily on
tighter resource constraints.

As a manufacturer and service provider, Hoerbiger are required frequently to deliver a range of skills to our
clients on a range of technical issues to do with the reliable performance of compressors to maintain a level
of retained knowledge in the work force. New projects are continually being driven in an effort to increase
technical competency and re-enforce disciplines of standardisation in work place practices. Projects
ranging from the design, manufacture of components through to servicing of compressors throughout
Hoerbiger internationally.

Some examples are presented in this lecture of approaches being undertaken to ensure Hoerbiger can
remain a world class leader in Compression Technology.

Emerging Technologies in Preventative Maintenance

Out-of-compliance equipment (including compressors) cost the industry billions of dollars in losses per
year. This is a direct result of poor maintenance care practices. HOERBIGER has studied this concern
and is developing MCS (Mobile Care System) a tool which can guide workforces effectively towards
uncovering these costly inefficiencies.

This presentation includes the integration of a project “MCS” which intends to promote field inspection
activities. Helping to monitor the well being of equipment for the purpose of optimising performance,
resources and budgets $$$

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 COMPRESSOR SERVICE

¾ Operating Limits
¾ Reporting Non Compliances
¾ Inspection Standardisation
INVENTORY
MANAGEMENT MAINTENANCE
MOBILE CARE SYSTEM
(MCS)
WORK
STANDARDS

EARLY
DETECTION
MAINTENANCE
HISTORY

FOOT Patrols

¾ Compressor Information Tools OPERATIONS

¾ Reinforcing Mechanical Disciplines SCS
¾ Overhaul Report Standardisation Superior
Compressor
Services

Creating systems that can deliver Reliable Performance

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 The problem .. ?

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 Oops ..

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CREATING the RIGHT ENVIRONMENT !

Come to an understanding of the limitations in existing business systems studying the true work
environment and recognise the weaknesses in work force skill sets.

Focus on developing information friendly systems which nurture efficient, informative

work practices which encourage personal development whilst actively performing duties ..

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 Best Practices in Compressor Maintenance & Training

THEORETICAL vs PRACTICAL

TRAINED for COMPETENCE PROGRAM

(Basic Principles)

DEVELOPMENT of INFORMATION SYSTEMS

which approach ?

Increased level of interest and understanding is being achieved in the

workforce by offering a more logical balance of theory and practical
experience in field documentation and electronic information systems.

Need to strike a balance that makes approaching compression technology

an interesting learning experience for everyone participating !

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 PREVENTATIVE or REACTIVE ? >

Samples Field Force Automation >

Caution

N
Integrating SMART systems to
C better inform personnel and help
simplify reporting techniques

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JUSTIFYING Field Force Automation (Emerging Technology)
BASIC CARE SAVINGS ESTIMATES
LUBE PLANT IF FAULT NOT FOUND
Potential
Potential Production
The following table was prepared by the Machine No Service Type Fault Maint Cost loss
G1008 Vac tower bottoms Single stg centrif Hot motor $10,000 $10,000
senior reliability engineer at Mobil Leaking brg housing seal $10,000 $10,000
G2002 Propane circulation Multistage pp Water in turbine oil $20,000
Adelaide Refinery in 1999, and reflects Seal barrier fluid circulation &
contamin $15,000
the estimates saved by the early G2002S Propane circulation Multistage pp Oil contamination $10,000
Seal barrier fluid probs $15,000
detection of machine failures using field Bearing housing oil leak $10,000
Oil pump vibration $5,000
force automation techniques. G3022 Furfural treat 2 stage pp Oil contamination $15,000
Double seal N2 gas leaks $10,000
Oil contamination $15,000
CW leak into bearing housing $10,000
The cost to commission Basic G3022S Furfural treat 2 stage pp CW blockage $10,000
Oil contamination $15,000
Care refinery wide, including pumps G4035S Dry solvent 2 stage pp No oil in motor $10,000
Loss of seal fluid - both pots $15,000
(turbine/ electric), compressors, crude G6001 Biturox bottoms PD gear pump Lubric bottle losing oil $15,000
Lubric bottle losing oil $15,000
heaters, boilers and fin fans, (fully
DIRECT BENEFIT =
customized) including hardware and
G8001A Boiler Feedwater Multistage pp Lube oil line leak
Low lube pressure
Oil leak
$5,000
$5,000
$10,000
High bearing temp $10,000
man power is approximately A$150,000. G8001B Boiler Feedwater Multistage pp Oil filter blockage $10,000
Oil pressure low $10,000
Oil leak $10,000
LUBE OIL PLANT Bearing housing oil leak $10,000
G8022 Cooling water 2 stage pp Motor oil low $5,000
Water in gearbox oil $10,000
(excludes Fuels Refining savings) G9038 Firewater Single stage pp Oil leak on engine $5,000
G36B Fuel oil PD gear pump Noisy bearings - replaced $5,000

A$750,000 per year G7A Boiler Feedwater Multistage pp Water in oil

Low oil pressure
$15,000
$40,000 $60,000
Noisy bearings - replaced $15,000
Oil pump failure $40,000
G7B Boiler Feedwater Multistage pp Poor CW flow to cooler $15,000
Low oil pressure $40,000
Noisy bearings - replaced $15,000
G7C Boiler Feedwater Multistage pp Low gearbox oil pressure $10,000
Oil contamination $20,000
Oil contamination $40,000
C2001 Propane compressor Recip Lubricator faults $20,000(extended service life possible
Water in oil $10,000 $5,000
C3001S Vacuum compressor Nash liq ring Poor seal water flow $10,000
C4002 Propane compressor Centrif multistageGovernor oil leak $5,000 $30,000
C5001 Offgas compressor Recip Lubricator faults $10,000
C5002 Treat gas compressorRecip Lubricator faults $10,000
C5003 Tail gas compressor Recip Lubricator faults $10,000
Hot motor $20,000
C8003 Air compressor Centrif Oil level in motor $10,000
D4010-1/2/3/4 MEK Dewaxing filtersRotary drum Wire slippage x 15 $210,000 $240,000
Speed variator/gearbox noise $60,000 $120,000
B8001 Boiler Fired tube FD FD fan turbine bearing leaks $10,000 $60,000
B8002 Boiler Fired tube FD FD fan turbine bearing leaks $10,000 $60,000

TOTALS $965,000 $595,000

Gr TOTAL over 2 years $1,560,000

Say $750k /year
 Trained for Competence PROGRAM (workshops)

Training Centre

Production Overhaul

Pumps are typically driven direct by the crankshaft or

by electric motor (typically auxiallary pumps
(feed pressures are typically 2 - 6 bar)

Supplying lubrication to the crankshaft bearings big

end / small end bearings crosshead guides
 Trained for Competence PROGRAM (design & performance)

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 Trained for Competence PROGRAM (design & performance)

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 Trained for Competence PROGRAM (design & performance)

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 Trained for Competence PROGRAM (utilities)

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 Trained for Competence PROGRAM (operation)

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 Best Practices in Compressor Maintenance & Training

9 Relevant collection and reporting

of work force findings

9 Synchronised Record Management

PAPER <> ELECTRONIC = same

Refer to sample document

= TRAINED for COMPETENCE

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 Best Practices in Compressor Maintenance & Training

9 Inventory Planning
9 Core References to “machine” data

9 Procedures

Refer to sample document

= TRAINED for COMPETENCE

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