Is it possible for a plant to feel good all round? PLANT SERVICE FROM INFRASERV KNAPSACK. ENGINEERING AND CONSTRUCTION PLANT SERVICES SITE OPERATION www.infraserv-knapsack.de
Plant services The feelgood factor is not a term you hear mentioned very often in connection with industrial plant. And yet, for its efficient operation, proper care plays a crucial role. If maintenance and service are managed properly, downtime is reduced while lifespan increases significantly. With InfraServ Knapsack, it is not only industrial plants that feel good. From your perspective as a customer, it pays to rely on a diversified and proven partner. InfraServ Knapsack has many years experience in the servicing and operation of plants for the chemical industry as well as for other sectors with particularly high safety requirements, such as the petrochemical industry, power stations and the glass industry. Extensive expertise in the control and implementation of plant maintenance ensures maximum plant availability and legal certainty for plant operators with regard to their maintenance obligations. Direct access to its own workshops for component construction and repair speeds up the processes and enables high-quality solutions from a single source. This integrated approach is particularly effective in the complete realisation of complex projects as well as for routine maintenance and replacement work. InfraServ Knapsack offers high-quality solutions ranging from individual projects through to main contracting and full-service models for outsourcing, which means you will no longer have to worry about maintenance. DOES A PLANT NEED MORE THAN JUST one PARTNER? Plant services from InfraServ Knapsack. In times of increasing cost pressure and flexibility in requirements, choosing the right partner becomes a significant competitive factor. This applies in particular to the planning, implementation and maintenance of critical production processes. This is where you need a partner who is willing to take entrepreneurial responsibility for shared success. A partner that is actually many partners because it offers a solution to all the tasks that plant and site operators face. The plant services offered PROCESS ANALYSIS MAINTENANCE TECHNOLOGY Operation-led Project planning maintenance Assembly Project-led Maintenance maintenance Main contracting models Full-service models Maintenance optimisation The team makes the difference SHUTDOWN MANAGEMENT Planning Coordination E xe c u t i o n InfraServ Knapsack is that partner and, as a designer, constructor and operator of plants and entire sites, is a driving force within the process industry. Our extensive expertise, acquired over more than 100 years, covers the whole lifecycle of industrial plants from the planning and approval of a plant through to its operation, maintenance and ongoing optimisation. InfraServ Knapsack uses highly qualified employees with multidisciplinary specialist knowledge in process, control and electrical technology and experience in operational implementation for all tasks relating to plant services. 2 3
Maintenance HOW DOES A PLANT STAY FIT INTO RIPE OLD AGE? Maintenance from InfraServ Knapsack. The value of any production plant depends on its availability. In order to secure this in the most sustainable and efficient manner, maintenance is of crucial importance. With the broadest spectrum of services and extensive experience in maintaining plants in the chemical and process industries, InfraServ Knapsack ticks all the right boxes. In-house repair workshops and resources for assembly/testing ensure a high level of flexibility and adherence to schedules. Customer interfaces are reduced and can be assigned more clearly e.g. in relation to guarantee issues. A high standard of quality and safety is ensured through ongoing employee training, regulatory compliance and monitoring of operations. In addition to implementing measures, InfraServ Knapsack can develop individual maintenance strategies for the deployment of staff, materials and spare parts. Operation-led maintenance Even everyday, recurring maintenance tasks require highquality solutions and careful implementation. InfraServ Knapsack coordinates the activities and carries them out to a reliable standard of quality. Coordination Coordination of all maintenance-relevant activities for customers existing plant, package units, equipment and components Implementation Carrying out of all maintenance-relevant tasks: servicing, inspection, repair, elimination of faults and optimisation Support with maintenance-related activities Support with production-related tasks Elimination of faults Management of an around-the-clock shift system to eliminate faults from plant and perform all necessary fault elimination work Skilled electricians with operational responsibility Provision of skilled electricians with operational responsibility for plants and buildings 4 5
Maintenance Project-led maintenance InfraServ Knapsack s strengths as a multi-disciplinary service provider are most evident during the implementation of complete projects and assembly work. An integrated approach allows all disciplines and trades to be covered in all project phases. Furthermore, all recurring tests required by law can be performed in all the relevant areas of installation and building services engineering. Project coordination Coordination of projects Responsible handling of all tasks within the framework of projects relating to different disciplines and trades: plant assembly, steel construction, structural and civil engineering, provision of safety coordinators Heavy plant assembly InfraServ Knapsack has many years extensive experience with mobile cranes, hydraulic hoists and special tools for assembly and transport as well as extensive special equipment for heavy plant and equipment assembly. Installation and replacement of components and plant parts in existing plant in the process industry. Construction of new plant as part of plant construction projects Coordination and scheduling of cranes and work platforms on behalf of customers Pipeline construction, steel construction Manufacture of complex pipes and pipeline systems for the process industry in all pressure ranges and standard piping materials to international guidelines Manufacture/coordination of steel construction systems in accordance with project requirements Delivery including all necessary documents Complete responsibility for materials management Ancillary maintenance disciplines and trades The outsourcing of all ancillary disciplines and trades to Infra- Serv Knapsack brings more efficiency through grouping them together. All services are recorded and invoiced transparently using measuring systems. Coordination of ancillary maintenance disciplines and trades in customer plants: scaffolding, insulating technology, corrosion protection and industrial cleaning E/I&C assembly Assembly and installation of electrical equipment as well as plant, control and lighting technology Preparation and assembly of cable routing systems and cable conduits including mounting systems Professional installation of cables and wiring Assembly of terminal boards, distribution switchboards and electrical control panels as well as other installation components Carrying out of all work in networks of up to 6 kv, cable terminals and sleeves of up to 240 mm² Constructional disciplines and trades InfraServ Knapsack has extensive knowledge of the structure of plants for the process industry and many years experience with construction contracts at operational chemical plants. Performance and coordination of constructional disciplines and trades: civil engineering, steel construction, concrete refurbishment, refractory linings, acid-resistant coatings Recurring tests InfraServ Knapsack takes responsibility for the performance and management of compulsory recurring tests on components and plant. Thanks to extensive technical facilities and detailed preparation of legally conforming test concepts, transferring responsibility for performing the tests maximises legal certainty for customers and reliably protects them from legal complaints and criminal proceedings. Lifts, hoists and lifting accessories Power-operated doors and gates BGVA 3 testing of Stationary and Non-stationary Production Facilities Racking checks Hose tests Lightning protection tests Explosion protection tests Weighing technology Plant diagnostics Performance and evaluation of: vibration measurements, thermography, endoscopy and oil analyses Authorised representative services Radiation protection officer Expert for mechanical and electrical explosion-hazardous areas (officially registered, qualified person) Expert for crane systems 6 7
Maintenance Main contracting models By grouping disciplines and trades together in customised specifications and combining recurring work in job packs for InfraServ Knapsack to carry out autonomously, customers can significantly reduce their coordination costs. Specifications are presented transparently using computerised processing of orders and documentation. In this way auditing compliance is also increased considerably. All other tasks related to the coordination and performance of maintenance remain the responsibility of the customer s own personnel. Combining various individual services in specifications or job packs Project coordination Operational support Assembly and pipeline construction Ancillary maintenance disciplines and trades Constructional disciplines and trades The main contracting and full-service models allow you to reduce in-house costs gradually for many areas of plant service without giving up control and responsibility. IMPLEMENTATION LEVEL Ancillary maintenance disciplines/trades Technical building equipment Operational tasks 100 % 75 % 50 % 25 % 0 % Elimination of plant faults Shutdown planning/ execution System supplier for individual discipline and trade groups Constructional special disciplines/ trades Recurring testing Assembly Increase in variability Starting point: in-house share Main contracting Full service Full-service models So that maintenance costs can be structured as adaptably as possible, companies can outsource all of their tasks to Infra- Serv Knapsack. The different disciplines and trades are grouped together on an individual basis into an overall package with InfraServ Knapsack taking charge of its implementation. The customer simply retains responsibility for carrying out assessments and, naturally, responsibility for the budget. All services provided are presented very transparently, if possible via a link to the customer s ERP system. RESPONSIBILITIES Maintenance learning loops Operator responsibility 100 % 75 % 50 % 25 % Budget responsibility Complete assumption of all maintenance services Operational support Assembly and pipeline construction Ancillary maintenance disciplines and trades Constructional disciplines and trades Maintenance documentation 0 % Maintenance management Increase in variability Responsible management in line with the customer s business objectives and project coordination Order responsibility Maintenance engineers Starting point: in-house share Main contracting Maintenance coordinators Full service 8 9
Maintenance Process analysis technology Maintenance optimisation Customers can also make use of InfraServ Knapsack s many years of experience in the maintenance of process industry plant in a wide variety of sectors in the form of analysis and optimisation solutions. Based on holistic need- and processbased analysis, optimised maintenance concepts for the whole lifecycle of the plant are developed and support provided during their implementation. Advice Moderation Training Optimisation tools (e.g. lean maintenance, 5S method, FMEA, TPM, Technical Risk Management) CAN SAFETY BE SUPPLIED ON AN INDUSTRIAL SCALE? Process analysis technology from InfraServ Knapsack. In the process industry in general and in the chemical sector in particular aspects such as product quality, environmental protection and health and safety are heavily influenced by the concentrations on site of various substances and raw materials. Depending on the context, the slightest deviation can have serious consequences. Process analysis technology supplied by InfraServ Knapsack provides highly reliable systems for continuous measurement and recording of concentrations at your plants. Measurement results are available instantly. To ensure optimum technical safety and quality, the service package from InfraServ Knapsack encompasses much more than just the technology employed. At the project planning stage, customers receive vendor-independent advice on how to use various measurement procedures to devise analytics that are economical to operate yet always transparent and appropriate to their specific circumstances. Our engineering experts can also be involved at this stage manufacturing components in-house enables us to produce the required analysis systems on an individual basis. After installing the systems, InfraServ Knapsack will also retain responsibility for ongoing maintenance, carrying out inspections, servicing, calibration and providing a 24-hour fault elimination service. PROJECT PLANNING / PRODUCTION ASSEMBLY MAINTENANCE Formulating and agreeing requirements with the customer Concept development/ application advice Selection of measurement procedures and/or analyser type Production of analysis system Assembly of on-site analysis system/off-site assembly Commissioning Integration into existing process control system Sample conditioning Maintenance and inspection Repair, fault elimination Calibration and alignment 10 11
Shutdown management How do you get things moving during a shutdown? Shutdown management from InfraServ Knapsack. With the integrated process optimisation of plant shutdowns, operators can minimise the costs incurred due to loss of production. InfraServ Knapsack takes charge of the planning, coordination and execution of partial and complete shutdowns. Taking into account the size, complexity and risk potential of individual plants, customised shutdown concepts are developed to the highest safety and quality standards. The constituent steps of the shutdown are entered into a database, systematically executed and monitored, so that the customer can follow the whole transparent process. During the shutdown itself, InfraServ Knapsack is able to fulfil requirements for any spare parts or repairs at short notice through direct access to its own workshop and production capacity without compromising the project schedule. With a large proportion of the staff involved in the execution stage being InfraServ Knapsack employees, the highest quality standards and adherence to schedules and budgets are guaranteed. SHUTDOWN PLANNING SHUTDOWN COORDINATION SHUTDOWN EXECUTION Planning and entering of plant in planning tool Detailed planning and scheduling Shutdown management/ supervision based on available planning documents and schedules for all relevant disciplines and trades in the stoppage timeframe Execution of all scheduled shutdown activities, based on available planning documents and schedules, at the customer s request for all relevant disciplines and trades in the stoppage timeframe Execution of all unscheduled shutdown activities 12 13
IS IT POSSIBLE TO SHOW EVIDENCE OF GOOD WORK UP FRONT? CAN WE TAKE A BIG STEP FORWARD FOR YOU TOO? Our customers come from the following industries: Chemical Petrochemical Power stations Glass Our clients are international companies that make use of our specialist and organisational skills. Our customers all repeatedly place their trust in the performance and expertise of our services. We would be happy to give you more details of relevant reference projects. InfraServ Knapsack looks forward to rising to your challenge. Customised targeted solutions are found when partners work in close collaboration. And every good collaboration starts with a consultation. InfraServ Knapsack cordially invites you to book an appointment. Find out all about our wide-ranging expertise and solutions in detail. InfraServ Knapsack s certifications include: DIN EN ISO 9001:2008 (Quality management systems) DIN EN ISO 14001:2004 (Environmental management systems) Safety certificate contractors (SCC 2006 version) DIN EN 16001:2009 (Energy management systems) Pressure Equipment Directive 97/23/EC Accreditation to AD2000 HP0 (Construction of pressure vessels and piping) Accreditation as a welding operator to ISO 3834-2 Welding of steel structures to DIN 18800-7:2002-9 ÜChem Specialist Company in accordance with 19 of the German Federal Water Act (WHG) Waste Management Company in accordance with 52 of the German Closed Substance Waste Management Act (KrW-/AbfG) Fon +49 2233 48-1212 info@infraserv-knapsack.de InfraServ GmbH & Co. Knapsack KG Chemiepark Knapsack Industriestraße 300 50354 Hürth Germany www.infraserv-knapsack.de 14 15
InfraServ GmbH & Co. Knapsack KG Chemiepark Knapsack Industriestraße 300 50354 Hürth Germany Fon +49 2233 48-1212 E-Mail info@infraserv-knapsack.de www.infraserv-knapsack.de Published by: InfraServ Knapsack Designed and edited by: Marketing, InfraServ Knapsack Layout: Hochhaus Werbeagentur GmbH, Cologne