Revision of a "Hyper" in Accordance with an ... - Neuman & Esser

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8 SERvICE Bo B o r e a l i s The NEAC Masterpiece: Revision of a "Hyper" in Accordance with an Ambitious Schedule Top Project Management Paves the Way Within the scope of a major shutdown of the entire production, the first meeting regarding full inspection of the 30-year-old GGH Hyper Compressor at Borealis in Schwechat, Austria, one of Europe's leading plastics manufacturers, was scheduled for the NEAC Compressor Service. After NEAC had already successfully carried out the overhaul of an identically constructed machine in the previous year, they were entrusted with the task of the revision of a second compressor. This time, the challenge was an increased scope of work and delivery with a reduced time window. In the first round of discussions, the aim was to define the scope of work and the project plan with Borealis. At the same time, interfaces were defined and responsibilities established. The experience gained by all parties involved during the first revision was also transfered to the upcoming project. As a result, work procedures, processes and logistics could be optimized. Stoppage of the system and the simultaneous major revision of the neighboring OMV refinery proved to be particularly complex. The result of this was that some 3,000 employees from third-party companies worked on two premises at the same time. The top priority, therefore, was to work independently – the right "playground" for NEAC. During the standstill, NEAC held the sole responsibility for the coordination of the various disciplines and work on the lD4 booster. Foundation refurbishment, driving mechanism repair and the revision of the "bypass units" had to be coordinated, implemented and controlled. This required professional project management. NEAC Knows How to Make Proper Use of the Time Available NEAC demonstrated its special creativity for this project in order to catch the critical path. Thus, the company took on the demanding and complex processing of the crankcase for the first time with a new partner company in Austria and used new 3D laser equipment which proved to be an invaluable instrument for the precisely accurate and efficient installation of the driving mechanism. The coordination of repair measures required directly with the customer at the components concerned helped considerably to save further time as, speaking from experience, these procedures are often lengthy during everyday business. In addition to repairing the crosshead assembly group, the repair of "shoes" was a special requirement for the areas of planning and coordination. All the work was carried out in the NEA machine factory. All six shoes could be provided with a new babbitt layer in record time and the remaining bypass unit components repaired. Completion, alignment and approval of these units took place using a 3D laser system and was conducted by an in-house laser specialist and the Quality Department at the company's Übach headquarters. Simultaneously, crankcase machining and foundation refurbishment took place in Vienna, the latter under the responsibility of NEAC.
The Factors of Success NEAC was especially happy to have found a competent local partner for crankcase machining. Moreover, the detailed specifications and constant exchange with Borealis regarding the repair measures resulted in the repair of the crankcase with no complications whatsoever. Even unplanned incidents such as damages to the outer bearing or the influence of the local weather could not adversely effect the completion date. For this project, special attention is given to the reinstallation of the drive mechanism and the new bearings for the crankcase. They were precisely aligned and controlled to a few hundredths of millimeters using the 3D laser system. The NEAC specialists had a new and positive experience in the field of work safety with the use of bicycles on the company's premises. The high health and safety standards from Borealis required a special bicycle driver's license and wearing a special protective helmet for this purpose. To conclude, NEAC was also able to impress once again during the final meeting and subsequent review: you couldn't overlook the customer’s joy when they already held the entire documentation including all the reports in their hands only two weeks after completion. 9
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Revision of a "Hyper" in Accordance with an ... - Neuman & Esser

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