Burckhardt Compression TechXchange "Optimizing compressor maintenance through remote support"

Introduction

The host welcomes the audience to the tech exchange webinar and provides some information about the session.

• The webinar is live and will be recorded.

• Microphones are muted, so questions should be asked using the Q&A section on the right side of the screen.

Key Takeaways

The host outlines three key takeaways for the webinar.

• Remote support in an industrial environment

• Where remote support offers high rewards

• How remote support was used to troubleshoot at BISF and during a service intervention at sea

Introduction to Remote Support

James Litchfield, product manager for service solutions at Burkett Compression, introduces remote support as a solution for customers who need expert services without having experts on site.

• Remote support was developed due to travel restrictions caused by COVID-19.

• It offers total flexibility and can be offered globally.

• Immediate support is available with no delay for travel.

• Cost savings can be achieved by eliminating travel and hotel costs.

Relevant Segments for Remote Support

James Litchfield explains where remote support is most relevant.

• Remote locations: vessels in the middle of an ocean or factories in deserts benefit from reduced time and cost associated with offering customer support.

• Complex installations: customers prefer direct contact with OEM without going through local offices or third parties.

• Expertise outsourcing: customers have difficulty finding required expertise, so centralized expert services are beneficial.

What Is Remote Support?

James Litchfield describes what remote support entails.

• A tablet with special encasing that meets ATEX certification requirements can be used in explosive environments zone one.

• Headset is ATEX certified.

Remote Support for Compressor Systems

In this section, the speaker discusses how their company offers hardware as a subscription model to customers and provides expert services at an hourly rate. They explain how the system works in real life and define different use cases.

Hardware Subscription Model

• The company offers hardware as a subscription model to customers.

• Customers can request expert services at an hourly rate without any additional charge.

Real-Life Implementation

• The company supplies tablets and headsets for explosive environments and Hololens for non-explosive environments.

• Customers require a Wi-Fi or mobile connection on-site next to the compressor to connect with the system.

• A tenant is created between the two networks for security purposes.

• Video connectivity is supplied with customers, allowing live instructions on-screen, real-time analysis, and defining next steps with the customer.

Use Cases

Pre-inspections

• Used as a tool to visually check if customers have correct tools on hand or if correct spare parts are on site.

• Quick check of operating condition of compressor before sending an expert on-site.

Health Checks

• Visual health check using tablet through guided assessment of equipment to ascertain compressor condition.

Troubleshooting

• Technical issues with compressors can be resolved remotely using visual communication tools.

• Problems can be identified quickly using troubleshooting techniques.

Service Interventions

• Certain service interventions can be done remotely through expert supervision.

Real-Life Experiences Using Remote Support

In this section, Roger Miller shares his experiences working as a compressor specialist at Woolcott in Switzerland. He discusses two cases where remote support was used to support customers remotely and locally test the system.

Case 1: PSF Petronas in Malaysia

• Customer observed heavy vibration on one of his COS compressor systems but due to the situation in Malaysia, an FSR could not be deployed.

• Remote support was used to deploy a tablet and headset quickly to the customer.

• The system allowed for visual communication with customers, real-time instructions on-screen, and annotations.

Case 2: Local Test of System

• A local test of the system was conducted using remote support.

• The system allowed for visual communication with customers, real-time instructions on-screen, and annotations.

Real Event

• A real event occurred where remote support was used to resolve technical issues with compressors.

• The system allowed for visual communication with customers, real-time instructions on-screen, and annotations.

Introduction of the System and Daily Support

The customer was introduced to the system and received daily support from technical staff.

Introduction of the System

• The customer was introduced to the system and how it worked.

• Technical staff provided step-by-step guidance on work shuttle and work plan.

Daily Support

• Technical support provided 2-3 hours of daily support.

• Only 10-20% of support was online, while the rest involved work plan updates and reports.

• Toolbox talks were given as normal guidance.

• Technical support was available for unforeseen troubles.

Disassembly and Repair of Compressor

The compressor was disassembled, assessed, repaired, and reassembled with expert support.

Disassembly

• The compressor was fully disassembled.

• The crankshaft and cross set were sent to Singapore for further assessment and repair.

• It was recommended that the grout be removed and cylinder support regrown due to broken bolts found in bad condition.

Reassembly

• Expert field service engineer or representative requested for assembly due to complexity beyond dismantling/inspection.

• A bulkhead field service engineer or representative became available recently.

• Compressor is back together after being assembled by experts.

[#](0:13:48 t:828s ) Cost Savings with Remote Intervention

Remote intervention saved costs compared to traditional FSR intervention.

Cost Comparison

• [](0:13:48 t:828s) Remote intervention had 14 working days at 4 hours per day of expert support and rental of headset and iPad.

• [](0:14:07 t:847s) Traditional FSR intervention had travel costs, quarantine costs, permission costs, and 8 man-hours per working day.

• [](0:14:11 t:851s) Roughly a cost saving of 60% for the customer.

Intervention on Vessel

A service intervention was made by the crew on a vessel during a journey.

Service Intervention

• The customer made a service intervention by himself due to inability to deploy an FSR on site.

• Some parts were too complicated for the crew to do themselves.

• A three-day intervention with an FSR was later done online to finish the job.

Challenges

• Compressor could not be stopped for more than 24 hours due to situation.

• Three-day intervention was split into three single-day events.

• Crew had no training on compressors.

[#](0:15:34 t:934s ) Preparation and Communication

Good preparation in advance is key for successful remote interventions.

Pre-information

• [](0:15:34 t:934s) Pre-information sent included work plans, manuals, step-by-step guidance.

• [](0:15:40 t:940s) Internet connection checked in advance with two calls for alignment and briefing.

• [](0:15:47 t946:s ) Test call made before actual call.

Call Process

-[](0;16;20 t980:s ) First call made in morning to ensure everything was working.

-[](0;16;26 t:986s ) Crew did purging during first call.

-[](0;16;30 t:990s ) Tools and permits were available.

-[](0;16;34 t:994s ) Final call made after two-hour stoppage.

-[](0;16;38 t:998s ) Modification of first stage wealth unloader and measurement of first touch cylinder done.

-[](0;16;42 t:1002s) Compressor was started up in the evening.

Intervention on Compressor

The speaker discusses the importance of having a clear scope of work and taking into account the vessel's time zone when planning interventions. They also highlight the advantages of remote support systems.

Importance of Clear Scope and Time Zone Planning

• A clear scope of work is important to ensure everyone knows what is going on during an intervention.

• The vessel's time zone can be challenging as it moves, so interventions must be planned accordingly to avoid missing calls.

Conclusion on Remote Support System

• Wifi mobile connectivity at the compressor is crucial for remote support systems to function.

• Local staff need to be well-trained before using this product to ensure smooth operations.

• Testing hardware and connectivity before planned outages is essential to avoid unexpected surprises.

• Remote support systems offer immediate support, cost and time savings, and reduced downtime for customers.

Conclusion and Feedback

The speakers conclude their presentation by thanking the audience for their participation. They encourage feedback through a short survey and provide information about future webinars.

Feedback Requested

• Audience members are encouraged to provide feedback through a short survey provided in the Q&A section.

• The speakers appreciate opinions from participants as they aim to improve future webinars.

Information About Future Webinars

• More information about OP Remote Support Solutions can be found on their website.

• Interested individuals can register on their website to stay informed about future webinars and activities in this area.

Conclusion

• The speakers thank the audience for joining them today and hope that they found the session informative.

• Recording will be provided on Bookcard Compression Tech Exchange website and social media platforms.

• Participants are encouraged to share the recording with colleagues who may have missed the live session.