Flow Control Service

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1 Flow Control Service

2 At your service This booklet is designed to give you an overview of Metso s modular Flow Control Service portfolio. Ranging from managed to individual technical services, our portfolio is designed to deliver the solutions that make the biggest difference to your production and business profitability as a whole. We ensure your business objectives are met by: Offering our personal commitment to resolving customer issues Using intelligent tools that focus activity on the areas where the optimal business return can be obtained Providing highly skilled service teams that follow Metso standards worldwide to guarantee high-quality results Thank you for your business. The Metso Flow Control Services team

3 Contents Our way of working Business solutions Services Case studies

4 Flow Control Service Our way of working

5 Our service team Committed to safety: Our goal is zero accidents. Closer to you: Our service technicians and engineers are located wherever they are needed to best support your business needs. Excellence: Global competence management ensures our service experts have world-class skills and follow a common methodology wherever they are in the world. A global network: Your personal Metso team is supported by a global network of service centers and experts. Personal commitment: Our service is provided by individuals who are passionately dedicated to customers and their needs.

6 Delivering services for the best results Facilities: Service Centers for global presence Resources: Over 400 highly-trained experts at your service locally Tools and systems: The latest, safe and proven tools to support our processes HSE: Commitment to highest standards of health, safety and protection of environment Processes: Service Center work flow Metso Service Site Visit Standard High quality Cost efficiency Safe working Minimal environmental impact

7 Our presence closer to you Our presence today Service 400+ professionals Flow Control Service Center Full Metso service support Service support 20+ Countries 40+ Service centers

8 Service Center work flow Service item received Inspection of item Awaiting for customer approval Receiving of spare parts Service work Final inspection Shipping Create work order, order binder and shelve. Perform inspection and shelve. Define needed spare parts. After customer approval order spare parts. Book resources. Receive/choose parts and components. Load on pallet with service work order. Perform work according to procedures. Stamp job number on the valve and report hours, parts and actions. Perform tests and make test report. Assess order compliance and visual quality. Determine final acceptance and make service report. Serviced items are shipped. Add Service TAG Remove Red Service TAG Remove Yellow Service TAG Remove Light Green Service TAG Remove Green Service TAG

9 Service Site Visit standard Study: Get to know customer information. Assess the scope of the service order and HSE requirements. Check: Verify the scope of the service order. Check customer resource planning and review any open HSE questions. Communicate: Get acquainted with site and agree on a communication plan. Run a risk assessment. Execute: Actively listen and communicate according to plan. Inform customer of issues. Keep work space clean and safe. Finalize: Provide customer with a short summary of work. Recommend useful new services or solutions. Clean and return any customer s tools. Report: Make the service report within a week, including HSE observations. Assess the need for a follow-up.

10 Service agreements Agreed service levels: Clearly defined performance targets and responsibilities. Transparent pricing: Clear visibility and control of service costs over the service agreement period. Close working relationships: The closer we work together, the more effectively we can fulfill your objectives. Increased service scope: Service agreements allow a broader range of services to be offered to you locally.

11 Flow Control Service Business solutions

12 Helping you meet your goals Customized: Tailored to meet your individual needs. Customer needs Intelligent: Focused efforts, where and when needed, deliver superior results and value for your money. Plant availability Process performance Risk control Lifecycle: Maximizes your return throughout the lifecycle. Business solutions Broad scope: From field devices to process controls and plant management systems. Intelligent Shutdown Intelligent Maintenance Device Management Safety Improvements Proven: Built around tried and tested Metso products and services. Services and products

13 Business solutions Risk control Risk control: Helps you minimize production, safety and environmental risks. Process performance Process performance: Helps you optimize your processes to get the most out of the least. Plant availability: Helps you maximize the availability of production equipment. Business solutions: Comprehensive, cost-effective, long-term thinking solutions to help you overcome challenges and reach your business goals. Customer needs Plant availability Get business results Intelligent Maintenance Intelligent Shutdown Device Management Safety Improvements Business solutions

14 Business solutions and services Service Intelligent Shutdown Intelligent Maintenance Device Management Safety Improvements Control valve testing Installed base analysis Maintenance supervision On-call visit Maintenance and repair Resident engineer Service container Smart device check Spare parts Startup supervision Training Valve leak testing ValveTriage Service

15 Flow Control Business Solutions Intelligent Maintenance Value proposition: Higher equipment availability and significantly reduced maintenance costs can be delivered by concentrating maintenance resources to where they are needed most. Solution: We analyze your equipment and identify the criticality of each element We develop a maintenance plan based on criticality We carry out condition analysis wherever possible to determine wear and the need for maintenance actions Where condition analysis is not possible, we carry out preventive maintenance We carry out high-quality repairs and refurbishments to return equipment to peak condition Where it is more efficient for service delivery, we put resident engineers on site Intelligent Maintenance Maintenance planning and execution Installed base analysis Criticality analysis Condition analysis Visual inspection Maintenance and repair Spare parts

16 Flow Control Business Solutions Intelligent Shutdown Value proposition: We offer a single shutdown package, from planning to execution, designed to minimize shutdown time and costs by targeting maintenance only to devices which require it. Solution: We analyze your devices in advance and identify any maintenance that can be done outside the shutdown We carry out condition analysis to identify devices showing signs of wear or failure We develop a maintenance plan showing devices needing removal, to be maintained in place and requiring no action We order any spare parts that are required We optionally provide a service container storing spare parts and tools that may be required We ensure in advance you have the right information, the correct number of people and the right skill sets to implement the identified repairs Intelligent Shutdown Installed base analysis Pre-screen shutdown list Condition analysis Maintenance and repair Service container Startup supervision

17 Flow Control Business Solutions Device Management Value proposition: Optimizes your spare parts inventory to reduce costs while ensuring critical spare parts are available to quickly get your process fully operational following a failure. Solution: We work together with you to identify your spare parts requirements We analyze your plant and build a stocking strategy based on products, budget and availability targets We remove obsolete or unnecessary stock from the inventory We transfer stock to Metso premises (if required) and disassemble spare parts into their components We train your staff on the new spare parts process We provide inventory management daily operations providing spare parts, receiving damaged spare parts and restocking as needed Device Management Criticality analysis Installed base analysis Inventory audit Lifecycle plan Inventory setup Daily operations

18 Flow Control Business Solutions Safety Improvements Value proposition: Helps create a safer and more secure working and production environment, ensures that the plant complies with health and safety regulations and that safety targets are met. Solution: We work with you to understand your safety requirements and what this means for your valves and pumps We audit field devices to ensure that they are being correctly maintained according to manufacturers specifications We repair safety related field devices to ensure that they are maintained according to manufacturers specifications We carry out valve leakage tests to minimize safety and environmental impact Safety Improvements Criticality analysis Control valve testing Smart device check Valve leak testing Spare parts Maintenance and repair On-call visit Training

19 Flow Control Service Services

20 Flow Control services Service Control valve testing Installed base analysis Maintenance supervision On-call visit Maintenance and repair Resident engineer Service container Smart device check Spare parts Startup supervision Training Valve leak testing ValveTriage Service Description We utilize condition analysis for control valves to reveal latent and developing problems. We assess and record installed base information and device condition. We offer on-site support for maintenance activities carried out by customer s own or contractor s service team. We provide an engineer on-site to carry out trouble shooting actions or consultancy. We repair and recondition valves to meet their original performance level. We offer an on-site expert to provide continuous local expertise supported by Metso service network. We offer a customized container for spare parts and tools that may be required during a shutdown. We provide batch analysis for smart devices revealing the most poorly performing devices. We provide genuine replacement spare parts and related know-how for Metso products. We provide on-site troubleshooting support to ensure a smooth production start-up after a shutdown. We offer predefined and fully customized training. We carry out condition analysis for all valves that have tightness requirements. We provide continuous condition analysis for field devices (for example, control valves) by monitoring and analyzing process data.

21 Flow Control Service Case studies

22 Business Solutions case studies Intelligent maintenance improves maintenance efficiency without compromising quality Background: Braskem is the largest petrochemical company in South America and 5 th largest in the world Braskem s Triunfo plant produces more than 1,200 Kt per year of ethylene and other hydrocarbons Target was to maintain equipment availability and improve maintenance efficiency to bring down maintenance costs Solution: Intelligent maintenance business solution implemented to analyze internal and external condition of valves, schedule maintenance based on condition and carry out high-quality repairs. Results: 36% saving in maintenance costs Only 24% of valves required removal for maintenance Job safety increased Improved environmental compliance Our customer s view: Not only have we saved in maintenance and inventory costs, but we have also increased the reliability and the performance of our field equipment. Nelzo Luiz Neto da Silva, Maintenance Coordinator, Braskem Triunfo

23 Business Solutions case studies Device management solution reduces inventory costs and capital expenditure Background: The world s leading producer of nickel and palladium The Harjavalta plant produces nickel salts for the European market Target was to reduce inventory costs and space needed and ensure spare parts inventory aligned to installed base Solution: Device management business solution implemented to audit spare parts stock and the process, identify surplus inventory and reduce the number of models in use over time. Results: 71% reduction in customer inventory in 2 years Spare part equipment coverage up from 40% to 90% Significant reduction in material costs 100% on-time delivery Our customer s view: Agreements are made between companies, but genuine cooperation and teamwork is built around people. Mikko Marjakoski, Chief of maintenance, Harjavalta plant

24 Business Solutions case studies Intelligent shutdown reduces shutdown costs and time by focusing effort where needed Background: CMPC is the largest Chilean pulp company and the world s 5 th largest pulp supplier The Santa Fe Mill near Nascimento produces bleached eucalyptus pulp with two fiber lines Target was to maintain valve availability while reducing maintenance costs and resources Solution: Intelligent shutdown business solution implemented to analyze valve condition in advance and remove only under-performing valves for high-quality repair. Results: Less than 20% of the control valves needed removal for service 70% drop in maintenance costs compared to sister line where all critical valves were taken out (reduced scaffolding, construction, inspection and repair costs) Maintained target availability for valves Our customer s view: Maintenance costs optimization of control valves, based on predictive maintenance philosophy, allows us to allocate resources to other important maintenance activities at the mill. Javier Gonzalez, Electrical and Instrumentation Superintendent, CMPC Santa Fe Mill

25 Business Solutions case studies Tighter process control combats rising energy and raw material costs Background: SABIC is one of the world s largest chemicals, fertilizers, plastics and metals producers with annual sales of $75 billion SABIC Innovative Plastics (SABIC-IP) produces a variety of plastics for OEMs in the automotive and computer electronic markets Target was to stabilize plant processes to reduce energy and maintenance costs Results: Annual energy savings of $1 million Oscillating loops reduced from 40% to 16% Loops unable to hold setpoint reduced from 12% to 2% Our customer s view: By tightening this upstream control and optimizing the hydrogen process, we are able to save over $1 million per year in energy consumption. Keith Phillips, Control Engineer, SABIC-IP Solution: Metso ExperTune PlantTriage implemented and consultancy provided.

26 A selection of our customers Oil, gas and biofuels Pulp and paper Chemicals Metals Industrial gas

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28 CBS001EN Product names in this brochure are all trademarks of Metso Automation Inc. Metso Automation Inc.