Волков Станислав | 19.03.2015 ) benefits of sulzer ...’олков...

Волков Станислав | 19.03.2015 )

Benefits of SULZER CHEMTECH manufacturing

localization In Russia for Customers projects

implementation

RPEF, Moscow, 21.04.2015. Volkov Stas

Introduction to Sulzer - JGC Corporation / 11 04 2014 | slide 2

Sales offices

Canada

USA

Mexica

Russia

Chins

Singapure

- HQ India

Switzerland

Mass Transfer Technology.

Global footprint

Manufacturing/Design Service centers

Brazil

Main manufacturing /design centers

Moscow

Saint Petersburg

Serpukhov

Mass Transfer Technology | slide 3

Sulzer Chemtech

Mass Transfer Technology

Process Technology Tower Field Service

Mixpac

Sales of CHF 750 Million

4200 employees

Your Partner in Separation

and Mixing Technology

Your Partner in Process

Solutions

Your Partner in Revamps,

Maintenance and Installation

Your Partner in Metering,

Mixing and Dispensing

Sulzer Chemtech


Global Leader in Mass Transfer Equipment

Trays

Rings

Packings

Distributors

Gas inlets

Collectors

Supports

Gas inlets

KnitMesh

Mellachevron

Shell Swirltube

Packed or Tray Column Gas/Liquid Separator


A Broad Range of Innovative and

High-performing Products

Inventor of Structured Packing

Structured Packings Random Packings Trays

Pioneer in Tray Technology

Driver in G/L Separator Breakthrough L/L Separator Technology

Provider of Random Packing

Pace-setting Technology

Gas/Liquid

Separators Static Mixers Liquid/Liquid

Separators


The Highest Level of Application Know-how

Application Experience

Innovation

Over 100 highly experienced

application managers in

Upstream, Refinery,

Petrochemical and Chemical

Extensive experience

in over 500 applications

Process design known how

in over 100 processes

Over 400 patents

Over 200 publications

Over 30 trademarks

Over 100 000 columns in operation

Over 40 000 Gas/Liquid separators

in operation

Over 100 000 mixers in operation


Comprehensive Engineering and

Technology Service

Hydraulic

Analysis

Customer Hydraulic

Design Software

SULCOL

Laboratory and

Pilot Tests

Engineering

Studies

Process

Studies

• Hydraulic of

internals

• Maldistribution

• Debottlenecking

• Energy saving

• Moving columns

• Process

optimization

• Troubleshooting

• CO2 absorption

• High pressure

testing up to

50bara

• Gas/Liquid and

Liquid/Liquid

separation

• Engineering / Re-

Engineering

• Mechanical

strength analysis

• FEM and CFD

analysis

• Allows design of

structured packings,

random packings,

proprietary and

conventional trays

• Reading of

ProII/SimSci, Aspen or

Excel files


Sulzer Chemtech Manufacturing in Switzerland


Sulzer Chemtech Manufacturing in India


Design and Project management in

Russia

Workshops for trays, packing and other

Internals manufacturing

Manufacturing of mixers

Sulzer Chemtech LLC in Russia


Sulzer Chemtech LLC– manufacturing facilities

in Serpukhov

Office building (550 m2) Structured packing manufacturing

workshop 750 m2 Trays & internals manufacturing

workshop 1500 m2

The service center and manufacturing Facilities

are opened in Serpukhov 2009.

Sulzer is Custom made solution provider –

“haute couture”.


Custom made approach is the key


Manpower does matters!!!

Project managers

Process engineers

Mechanical engineers

Operators

Logistics & Purchasing

Accounting

Young engineer

goes to the

workshop!


Sulzer Chemtech in Russia

Manufacturing Facilities

Logistics & Purchasing . Export & Import

Project management

Local regulations and Sulzer Quality management

Distributors testing rig.

Mechanical engineers , drawings and production files archive

Process group

Process and hydraulic design

Communication and collaboration with local design companies, Licensers and

Contractors

Process design for optimization and revamp projects

Service group

Supervising of installation. Inspection of Column producers


Sulzer 175 anniversary

Serpukhov Manufacturing Grand Opening


Distributor test rig


Typical projects

New construction

Revamp of existing columns &

separators. Optimization.

Emergency supply


Example of columns revamp, Tomsk

Revamp objectives:

Capacity maximization

Product quality improvement

Reduction of feed losses

Energy saving for distillation

Increase the workload envelope

Increase reliability


Example. Column revamp. Tomsk.

Scope of service :

Analyses of existing drawings and

drawing review

Training and preassembling

Inspection of attachments removal,

and new attachments welding

Installation of internals

Inspection of installed internals

Consulting for installation , tools

and materials


Tray preassembling on the ground


Support attachments welding and inspection

Laser level


Internals installation

Tray is bolted to support ring


Tray installation with screw expanding rings

New support ring

Existing support ring

New vertical bars

New lattice beam

expanding

ring

Main benefits :

One lattice beam is used for two trays

is useful to increase number of trays

when 2 to 3 and 3 to 4

Allow to minimize welding on the shell


Trays installation


Factory Acceptance

We did it!!! Celebration!

Sulzer Chemtech | 10.09.2014 | слайд 26

Sulzer Chemtech Actual Vacuum Colomn Revamp Shedule. Saratov

0 10 20 30 40 50 60 70

Payment

Comissioning

Internals installation

Transfer assembly

Deinstallation

Transfer manufaturing

Internals manufaturing

Approval

Drawings

Contract signing

Tender

Discussion

Calculation

Objectives

Vacuum Column revamp:

New transfer line

Internals replacement

Sulzer Chemtech | 10.09.2014 | слайд 27

Sulzer Chemtech Analyses of revamp project.

Reengineering , technical solutions and design company selection

should be considered for planning

Innovative Sulzer technologies allow to increase capacity without

column replacement

Local manufacturing allow to save 12 weeks for delivery/!!

Lead time might be reduced by optimization of tender procedure and

time for contract signing

Customer have valued the convenience to have one Supplier for transfer

line, process design and qualified supervision for installation


Emergency Supply. Example.

Day 1. Customer have informed about unscheduled shutdown of Atmospheric

Tower ( ID 5000 mm, 28 off trays? Capacity is more than 400 MT/hour).

Exchange of drawings, booking of manufacturing. Sulzer suggested to order full

set of internals before opening and inspection to minimize unplanned shutdown

time.

Day 3. Manufacturing readiness is 100%. Preliminary Engineering and have

been completed in advance before Contract conclusion and Scope of supply

agreement

Day 4. Column is opened and Customer have started to remove and inspect

internals/ Sulzer have started manufacturing of internals according to defined

schedule

Day 5-8. Dissembling and scope of supply finalizing

Day 9 Warranty letter. Scope of supply defined . Manufacturing is switched into

24 hours mode ( 3 shifts)

Day 11 Contract is signed. Sulzer have started to issue documents

Day 12.Shipping of first batch.

Day 17. Shipping of the rest internals.


Emergency Supply . Customer reference

Sulzer Chemtech LLC provided manufacturing and delivery of column

internals to Kstovo Refinery within 4 days including weekend after order

placement and provided installation supervising in 2 days after delivery. We

would like to highlight the urgent delivery and very qualified help of Sulzer

supervising engineer.


Summary.

Project schedule might be optimized

Lead time is reduced

Qualified service with Russian speaking specialists

Ability to implement complex projects with extended

scope of supply

Competitive price

World class Sulzer service

Волков Станислав | 19.03.2015 ) benefits of sulzer ...’олков...

Documents