ADVERTORIAL procedures and recording the results in a Structured Maintenance System (Data Driven Maintenance Management) within an HCP, allows for the association of operational data with the actual condition of the worn components (wear, incipient failure, lube oil deterioration, gas leakage, etc.). This enables better machine diagnostics, improved machineprocess interface analysis, and supports a continuous performance improvement strategy.
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TYPICAL OUTPUT OF PORTABLE DIAGNOSTICS ON A RECIP COMPRESSOR large ethylene centrifugal compressor train due to production reasons. Their goal was to minimize both the scope of work and the inspection time. Our joint team developed a data driven software model to assess the performance of the compressor train. The diagnostic model helped determine the actual condition of the compressor train and analytically identify the real maintenance needs with minimal intervention required. The KPIs for Polytropic efficiency depletion and Dry Gas Seals buffer pressure trends were compared with the historical data. The analysis revealed that there was no need to open the compressor for an internal inspection or to replace the labyrinth seals. Instead, the only maintenance recommended based on the analysis was to replace the dry gas seals. By delaying the overhaul, this customer saved approximately $2 million USD.
FIELD SERVICE: Site machine overhauls Blackstone is specialized in the overhaul of rotating machinery and stationary equipment. Blackstone offers a range of services including basic, intermediate,
major, and emergency overhauls, which are performed by highly skilled millwrights and Technical Advisors, or Technical Advisors leading a customer team. The effectiveness of these overhauls is significantly enhanced when they are conducted within an HPC. By utilizing all data obtained from prior diagnostic work, optimal planning of the overhaul can be achieved. Furthermore, our site level activities provide a critical base line and empirical data that support future diagnostics. Site level activities provide an opportunity to capture dimensional data and build material assessments to better inform parts strategies and potential upgrades. Our goal is to minimize the impact of the shutdowns and ultimately reduce costs for our customers without compromising on quality or safety.
REPAIRS: Engineered shop repairs and refurbishment Maintaining process machinery involves more than simply replacing or refurbishing worn parts; it is an opportunity to ascertain their operation from an engineering perspective by inspecting the disassembled components. This is particularly important for the LDPE plants, where even the smallest scratch on a pressure-containing part of the hypercompressor can lead to dangerous fatigue failure. Additionally, repairs performed in a specialized shop following standardized
PARTS: Spare parts inventory and supply management HPCs can also include inventory management & supply of wear, operational and capital parts, if required. The set of the above-mentioned services enables a Trend Analysis of the KPIs (KPIA) to assess wear rates and/or incipient failures and allows for accurate life cycle planning. If procuring parts from obsolete supply chains, orphaned fleets, or hard to source rare parts proves difficult, the HPCs offer reverse engineering and manufacturing services. Recent years have seen major advancements in metrology tools and technology, such as 3D laser scanning and Positive Material Identification (PMI), which we continue to invest in. Leveraging our extensive experience and advanced technology, Blackstone’s Parts Liberty team is uniquely positioned to deliver equivalent or upgraded high-quality and locally sourced components. These parts are designed with maintenance in mind, and manufactured to meet or exceed OEM specifications. Blackstone and CST view service as a continuous process rather than a series of discreet events. We are passionate about serving the machines. We consistently review, analyse, plan and execute services for these machines and their critical components throughout their operational lifespan. Though these machines are entrusted with numerous custodians and guardians over time, Blackstone and CST aspire to be the primary healthcare provider for their entire life.