PLANT SERVICE FROM INFRASERV KNAPSACK. IS IT POSSIbLE ...

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

2
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 signi-
ficant 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.
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, mainte-
nance and ongoing optimisation.
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-ser-
vice models for outsourcing, which means you will no longer have to worry about maintenance.
The plant services offered
MAINTENANCE
PROCESS ANALYSIS
TECHNOLOGY
SHUTDOWN MANAGEMENT
Operation-led
maintenance
Project-led
maintenance
Main contracting models
Full-service models
Maintenance optimisation
The team makes the difference
Project planning
Assembly
Maintenance
Planning
Coordination
E xe c u t i o n
Plant services
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.
3

4
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 high-
quality 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
Maintenance
5

Project-led maintenance
InfraServ Knapsack’s strengths as a multi-disciplinary ser-
vice provider are most evident during the implementation of
complete projects and assembly work. An integrated ap-
proach 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
6
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 equip-
ment 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 plat-
forms on behalf of customers
Pipeline construction, steel construction
– Manufacture of complex pipes and pipeline systems for
the process industry in all pressure ranges and stan-
dard 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 techno-
logy, 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 installati-
on 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
Maintenance
InfraServ Knapsack has extensive knowledge of the struc-
ture 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
7

8
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, custo-
mers can significantly reduce their coordination costs. Spe-
cifications 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
System supplier for individual discipline and trade groups
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 pa-
ckage with InfraServ Knapsack taking charge of its imple-
mentation. The customer simply retains responsibility for
carrying out assessments and, naturally, responsibility for
the budget. All services provided are presented very trans-
parently, if possible via a link to the customer’s ERP system.
Complete assumption of all maintenance services
– Operational support
– Assembly and pipeline construction
– Ancillary maintenance disciplines and trades
– Constructional disciplines and trades
Responsible management in line with the customer’s
business objectives and project coordination
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
Technical building
equipment
RESPONSIBILITIES
Ancillary maintenance
disciplines/trades
Constructional
special disciplines/
trades
Maintenance
learning loops
Maintenance
documentation
Order responsibility
Operational tasks
100 %
75 %
50 %
25 %
0 %
Recurring testing
Operator responsibility
100 %
75 %
50 %
25 %
0 %
Maintenance coordinators
Elimination of plant faults
Assembly
Shutdown planning/
execution
Budget responsibility
Maintenance
engineers
Increase in variability
Starting point:
in-house share
Main contracting
Full service
Maintenance management
Increase in variability
Starting point:
in-house share
Main contracting
Full service
Maintenance
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)
10
CAN SAFETY
bE SuPPLIEd
ON AN INduSTRIAL
SCALE?
Process analysis technology from InfraServ Knapsack.
In the process industry in general – and in the chemical sec-
tor in particular – aspects such as product quality, environ-
mental protection and health and safety are heavily influ-
enced 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
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
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
Maintenance and inspection
Repair, fault elimination
Calibration and alignment
11

12
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.
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
Shutdown management
SHUTDOWN PLANNING SHUTDOWN COORDINATION SHUTDOWN EXECUTION
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
13

14
IS IT POSSIbLE
TO SHOW EVIdENCE
OF gOOd WORK uP FRONT?
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’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)
CAN WE TAKE
A bIg STEP
FORWARd FOR YOu TOO?
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.
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
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