Field service brochure. From troubleshooting to installation

Transcription

1 Field service brochure From troubleshooting to installation

2 Value engineering raised on global experience Over 50 years of challenges in the expansion joint industry proves that EagleBurgmann KE is one of the world s most experienced and innovative expansion joint manufacturers. Experience is sourced from all continents and various market sectors to provide our customers with the latest technologies and solutions. Metal and fabric expansion joints are flexible connections, installed in piping and ducting systems to accommodate expansion and vibration caused by changes in temperature, pressure and media comprise. EagleBurgmann KE s major focuses: Value engineering to decrease operational downtime Lean manufacturing to reduce costs 3D smart design to maximize overall service life EagleBurgmann KE s comprehensive service: Evaluations and troubleshooting Initial dimensional measurements Installation and refurbishment Supervision and training surveys Emergency services Final inspection by experienced Service Engineers EagleBurgmann KE is approved to: PED 97/23/EC ISO ISO 9001 ISO OHSAS ASME U Stamp ASME R Stamp Other approvals are available upon customer request EagleBurgmann KE is a respected member of: The European Sealing Association (ESA) Fluid Sealing Association (FSA) Expansion Joint Manufacturers Association (EJMA) Euro-Qualiflex EagleBurgmann KE is proud of the appreciation given from hundreds of customers around the world. EagleBurgmann KE s global manufacturing footprint: Europe Americas South East Asia India We have a worldwide sales network supported by EagleBurgmann and Freudenberg offices. 2

3 P4. Global presence, diverse experience P5. Troubleshooting to installation P6. QHSE - commitment to safety P7. Certified & documented P8. References 3

4 EagleBurgmann KE global presence, diverse experience Expansion joints are vital components in most plants and refineries. They are installed as flexible connections in air and flue gas pipe and ducting systems to take up or compensate for thermal expansion, vibration and misalignments. Global coverage With strategically located field service centers all over the world, EagleBurgmann KE can reach any onsite destination within hours of initial contact. Diverse experience From planned installations of huge quantities of expansion joints to single emergency service jobs, our field service team has the experience and skills to do the job correctly, on time and safely. 4

5 Field Service troubleshooting to installation Before installation EagleBurgmann KE s understanding of complex systems and application engineering has made us a preferred expansion joint partner globally. Our vast experience and knowledge enables us to consult with troubleshooting of critical expansion joint applications and diagnosing problems in piping systems and related equipment. Our troubleshooting capabilities include: Consulting and technical support Failure analysis Implementation of corrective actions FEA analysis Thermographic analysis Complete evaluation report Maintenance & Turnkey installations Installation of expansion joints must be executed quickly, correctly and by trained specialists familiar with these critical components. EagleBurgmann KE can assist you with your metal or fabric expansion joints anywhere in the world within 48 hours. In addition to installation services, we also offer inspection services for your installed expansion joints. Our maintenance & turnkey installations include: Expansion joint removal & installation Supervision and coordination Training Refurbishments of bellows & hardware Refurbishment of steel frames and soft parts Reverse engineering & design optimization Periodical inspections Emergency services EagleBurgmann KE work around the clock to keep your plant or refinery online. With service centers conveniently located around the world, we are able to be onsite within hours of contact. Our emergency service include: Troubleshooting Onsite repairs of fabric expansion joints which includes insulation replacements and chemical barrier repairs Onsite clamshell repairs of metal expansion joints for temporary elimination of leakage Emergency hotlines Metal +1 (619) Fabric +1 (859) FEA analysis showing the heat distribution to the pantograph. Periodical inspections are recommended to avoid replacements of expansion joint outside planned outages. Emergency installation of a 47.2 clamshell bellows in a flue gas piping system within 24 hours. 5

6 QHSE Commitment to safety! Quality/HSE Policy EagleBurgmann KE vision is to be the world s most respected and most customer-oriented sealing solution provider. To achieve this we are committed to: Meeting customer s expectations and market needs by creating a passionate environment in which we fulfill customer requirements Preventing injury and ill health Integrating health, safety and environmental management within all business processes, to secure compliance with legal requirements and industry standards, relevant for our business Developing an innovative environment through which we continuously improve safety, environmental awareness and use of natural resources while improving quality Taking ownership and responsibility for working safely and improving processes Working, sharing and learning as one team within EagleBurgmann companies Continuously growing by involving all key stakeholders in formal objective settings, evaluation of them and through organizational behavior. We achieve this by: Focusing on our core values and manage through respect, openness and commitment Controlling and improving all our business processes from sales, new product ideas, development of product and processes to manufacturing, delivery and after sales service. Priority on Safety EagleBurgmann KE is part of the international Eagle- Burgmann Group, a joint venture of German Freudenberg and Japanese EKK. The organization s commitment to creating a strong safety culture and environmental protection is firmly anchored in the Group s Guiding Principles. Our onsite specialists, including fitters, welders and supervisors participate in periodical safety training as well as site specific safety courses. EagleBurgmann KE s safety training includes: Assurance that all employees understand and accept EagleBurgmann s safety values Establishment of procedures that support current industry safety practices Emphasize mindful conduct when working onsite Integrate diverse safety requirements from customers and site contractors Compliance with regulatory agencies. 6

7 Certified & documented Working at various plants and refineries require not only general knowledge and training in safety, but some sites also require specific certifications to enter their facility. Our service team therefore undergo periodical safety training for specific industries or types of hazards, performed and certified by an accredited third-party training facility. Offshore In the offshore industry, safety courses in various procedures is mandatory. The Basic Offshore Safety Course (BOSC) focuses on HUET (Helicopter Underwater Escape Training), escape chute, helicopter safety, lifesaving equipment, personal safety, first aid & fire fighting, etc. Our service employees working in exposed areas are H2S certified which include training in when and where the hazards may occur, how gas dissipates under different conditions, protection equipment, detection & alarm, first aid and confined space. SCC/VCA certificate SCC is Safety Health & Environmental Checklist Contractors, containing training in greater safety awareness and certification of SHE management systems. SSG A safety and work environmental course on rules and risks based on particular industrial facilities. The course includes a tool that supports Systematic Fire Safety Work. Site specific safety courses Several industrial plants have defined their own set of safet requirements, which our service team must comply with when working onsite. Internal EB training All members of our service team undergo internal training on an annual basis. The training maintains and updates information about EagleBurgmann safety requirements, safety culture, onsite behavior, onsite use of PPE. Welding certificates Our field service team is comprised of certified welders in accordance to DS/EN 287-1, EN ISO 9606, ASME IX. Welding procedures WPQR: W PS: EN15609 ASME: IX Welding processes 135 (EN), GMAW (ASME) 141 (EN), GTAW (ASME) 136 (EN), FCAW (ASME) 111 (EN), SMAW (ASME) Material groups 1.1 (carbon steel) 1.2 (carbon steel) 8.1 (stainless steel) (Nickel based steel) 7

8 References Refining & Petrochemical Cartridge expansion joints Supply and installation of Cartridge FCCU Refinery Catlettsburg, KY, USA Year 2014 Expansion joint 55 refractory lined, cold wall, universal expansion joint with two-ply testable (1) 48 single metal expansion joint cartridge for upper air to regenerator (1) Bellows material B Gr. 1 LCF Temperature 1,000 F Pressure 60 psi Catalyst, hot air Other Bellows were hydro tested in-house Elbow expansion joint Supply and installation Petrochemical plant, styrene production France Year 2008 Application Reactor effluent gas line Reactor effluent gas line Reactor effluent gas line Expansion joint 38 pressure balanced elbow (1) 78 tied universal elbow (1) 102 pressure balanced elbow (1) Material B H modified B H modified B H modified Temperature 257 F 320 F 676 F Pressure FV/37 psi FV/51psi FV/10.2 psi Benzene/Toluene Ethylebenzene Vapour of styrene Other PED PED PED 8 Clamshell installation Supply and installation of a clamshell expansion joint incl. dye penetrant test Refinery Application Piping system connected to a heat exchanger Belgium Year 2009 Expansion joint 37 ID clamshell solution with reinforcement rings (1) Pressure psi Comments The bellows was engineered at our Lakeside facility and manufactured at our Ringkøbing facility. The installation was performed by 4 EagleBurgmann KE welders within 7 days.

9 References Gas turbine Replacement of 701F EE00 fabric expansion joint Supply and replacement of an exhaust fabric expansion joint Combined cycle power plant Guangzhou, China Year 2014 Expansion joint 200 Combine-X fabric expansion joint (1) Temperature 1200 F Gas Replacement of 501F exhaust expansion joint Supply and installation of an exhaust fabric expansion joint Combined cycle power plant Johnson, RI, USA Year 2012 Expansion joint Combine-X fabric expansion joint (1) Gas Comments The exhaust expansion joint was a new and improved design for this type of gas turbine. 7FA FlexSeal upgrade Replacement and upgrade of the forward and aft expansion joint for a 7FA gas turbine exhaust system Combined cycle power plant Alabama, USA Year 2013 Expansion joint Combine-X belt including bolster, pre-bolster and joining kit (1) Expansion joint including 347SS ID flange assembly, OD carbon steel flange assembly and 8 section of diffuser casing profile to be used as needed to repair cracks. FlexSeal upgrade (1) Including 403SS pre-bolster studs and washers, heavy hex nuts 316SS, heavy hex nuts 304SS, washers 316SS and washers 304SS. FlexSeal upgrade: Flange hardware kit (1) FlexSeal Inconel 718 Leaf Seal replacement kit (1) Fluaflex 55 for the HRSG inlet (1) Onsite installation Temperature 1150 F Gas Comment The installation included: FlexSeal upgrade kit and Leaf Seal kit 7FA FlexSeal upgrade kit, Seal Leaf kit and 347SS flange mounting hardware/upgrade. 9

10 References Turnkey service Penetration seals Turnkey replacement of fabric penetration seals of two NEM boilers Combined cycle power plant Application HRSG Sequin, TX, USA Year 2014 Expansion joint Fabric penetration seals (115) Steam Comments Complete removal of old penetration seals and replacement of new fabric expansion joints on top and bottom of of the 2 boiler units. The job was completed in 6 days. Turnkey replacement of Flexgen Removal of old expansion joint, supply and installation of new fabric expansion joint Combined cycle power plant Kelanitisa, Sri Lanka Year 2012 Expansion joint x 19.3 mm Flexgen (1) Temperature 1,112 F Gas Turnkey replacement of fabric expansion joints Removal of old expansion joints, design, supply and installation of various replacements Conventional power plant Dong Energy Power, Esbjerg, Denmark Year 2014 Application Electrostatic precipitator inlet Prilary air line Airpreheater outlet Expansion joint x Fluaflex (4) ID 47.6 Fluaflex (3) x 246 Fluaflex (1) Temperature 232 F 608 F F Flue gas Air Air Other The expansion joints were designed by EagleBurgmann KE and installed by our Field Service team during a 3 week scheduled maintenance shutdown. 10

11 References Emergency Emergency repair of leaking bellows Repair of a leaking bellows Petrochemical plant St. James, Louisiana, USA Year 2014 Expansion joint 90 clamshell, incl. bolt-on root rings (1) Temperature 750 F Pressure FV/700 psi (tested to 1,000 psi) High pressure steam Other ASME Emergency refurbishment of pressure balanced unit Inspection, engineering, drawings, bellows design analysis calculation, supply and installation Ethylene plant USA Year 2013 Expansion joint 47.2 pressure balanced unit (1) Comments The pressure balanced unit was refurbished and installed in the duration of only 9 days Emergency repair of leaking bellows Design, method statement, risk assesment, production and installation Offshore Application Turbine North Sea Year 2005 Expansion joint 78.7 clamshell (1) Other A planned drilling operation was jeopardized due to leakage of a bellows in a turbine. A fill design, method statement and risk assesment package was immediately prepared and an oversize clamshell was produced and shipped. The remote destination and cramped working conditions were challenging, but the EagleBurgmann KE Field Service team performed an excellent installation under severe time pressure. 11

12 Argentina Australia Austria Belarus Belgium Bulgaria Brazil Canada Chile China Colombia Cyprus Czech Republic Denmark Ecuador Egypt Estonia Finland France Germany Great Britain Greece Hungary India Indonesia Iraq Israel Italy Japan Jordan Kazakhstan Korea Kuwait Latvia Libya Lithuania Malaysia Mauritius Mexico Morocco Myanmar Netherlands New Zealand Nigeria Norway Oman Pakistan Paraguay Peru Philippines Poland Qatar Romania Russia Saudi Arabia Singapore Slovenia Slovak Republic South Africa Spain Sweden Switzerland Syria Taiwan Thailand Trinidad and Tobago Tunisia Turkey Turkmenistan Ukraine United Arab Emirates Uruguay USA Uzbekistan Venezuela Vietnam KE1072 / GB.US EagleBurgmann Expansion Joint Solutions, Denmark EagleBurgmann Expansion Joint Solutions is a leading global organization in the development of expansion joint technology; working to meet the challenges of today s ever-changing environmental, quality and productivity demands. Our flexible products are installed in thousands of plants, refineries and on equipment worldwide where reliability and safety are key factors for operating success. Everyday more than 6000 EagleBurgmann employees contribute their ideas, solutions and commitment to ensure our customers worldwide can rely on our products and services. For more information visit EagleBurgmann KE Inc. Fabric Expansion Joints [T] +1 (859) [E] KEinfo@us.eagleburgmann.com Metal Expansion Joints [T] +1 (619) [E] EJsales@us.eagleburgmann.com 12