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KLINGER The Netherlands
Nikkelstraat 23067 GR Rotterdam
Klinger Service Center Limburg
Business Park Stein 208A6181 MB Elsloo |
BioMCN Delfzijl: Phased replacement of control valves
Phased replacement of control valves delivers more efficiency immediately
When BioMCN took over the plant, they knew exactly what challenges lay ahead. This was a well-functioning but outdated plant built in 1972. Modern methanol production in an old setting, in other words. The control valves had been neglected for years. Until Jan Lowies, maintenance manager at BioMCN, decided things had to change.
It was a confluence of circumstances: an old plant with obsolete control valves that were no longer available ánd not checked during shut-downs. "That wasn't necessary," Lowies explains. "The pipeline as a whole was checked. Those control valves were not subject to inspection." Until Lloyds gave the control valves a new status, requiring them to be inspected as well, and Lowies included the valves in his multi-year plan. "Because those valves are old, they have naturally had their best time at some point. I want to know what work is coming up. I want to be prepared."
All specifications in view
So the control valves were included in the multi-year plan. "We started with the valves at the most critical places in the process, 9 of them," continues Jan Lowies. Together with Marian Bosker (Purchaser) and Rob Fok (Project Manager), he formed the team that mapped out all the specifications.
Marian Bosker: "It may seem like a matter of picking and buying, but appearances are deceptive. Those valves from 1972, the 105-gauge valves, have not been made for a long time. So we had to look for a valve with new technology that meets today's requirements. Oh yes, and it also had to fit in a plant that was over forty years old."
It produced a detailed list of wishes and requirements that the control valve and the supplying company had to meet.
"A long preliminary process, in which the team worked very carefully," Marian said.
Delivered on time
Meanwhile, when the specifications were well in hand, the schedule was under quite a bit of pressure. "The shut-down was coming and we really wanted those first nine valves replaced," says Jan. "With the quote from KLINGER , we immediately felt they were the party who could deliver what we needed. On time!" adds Marian. "Because that was one of the most important criteria.
Marc Westerhuis of KLINGER was therefore immediately up and running after receiving the application. "We initially looked at what they needed. And by that I don't mean 'a control valve,' I mean the essence of the question: new technology that needs to function in an old factory. Then we started looking at what solution would best fit that. As is often the case, this involves customization; a tailor-made valve. We had to put the whole valve, with all the small parts, back in time. Then we started looking for options. What materials are available now? What alternatives fit, and meet the requirements? Technology of today in a setting of forty years ago, that was our starting point."
More efficiency
So Marc didn't "run to the warehouse for a box of control valves. "We don't just supply our customers with a product. We supply products that contribute to the whole. They have to function well, of course, but preferably give more efficiency" Marc continues. And that return is in the product, but also in the service. "We make sure that everything is delivered on time. That all the accompanying documents are in order. That the product contributes to sustainability goals. BioMCN has the ambition to largely go green. We are happy to work on that. KLINGER is ISO14001 and 9001 certified," Marc explains.
One chance
Marc made the offer that BioMCN had confidence in. "We shouldn't think about finding out during a shut-down that a party can't deliver on time. Or that then it turns out that something doesn't work or fit properly. Extending a shut-down or having to shut down again after start-up, that costs tons. You really don't want that," Bosker says. KLINGER thus had one chance. "We had even kept the old valves for a while, just in case... But what we were aiming for happened: everything worked right away. That saved us time, effort and energy, but mainly a lot of stress."
Finishing the list
Not only were the nine control valves replaced during this shut-down, 45 other valves - out of more than 250 control valves in the plant - were checked and assessed. Jan Lowies: "We drew up a list of control valves and we are working through it in phases. You can see that in the multi-year plan. Some we will overhaul first at the next shut-down. But some are simply at the end of their service life. At some point a valve like that runs out. You see that, then it no longer closes properly. If overhauling costs 60 or 70 percent of the cost of the valve, we'll replace it."
Documentation
That it doesn't stop once the control valves are delivered is obvious to Marc. "We like to advise and think along. We follow developments and the market closely and test our own processes against this. Lloyds does the checking of the system at BioMCN and the requirements are becoming more stringent by the year. We understand the need, for example, to be able to submit all the documentation required properly, quickly and easily. We are happy to work with them to have everything in razor-sharp order."
More stable load
Jan and Marian are satisfied. Marian: "KLINGER understands the need to deliver on time, and deliver well. These control valves are in critical areas of the process, nothing can go wrong! We were confident that it was going to be fine. That may not be a hard specification, but it is very important." Since the last shut-down, the plant has been running record production. "We are now running 100 tons per day more than before the shut-down. The load on the plant components is more stable. That pays off," Jan concludes.
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