Our Services
Troubleshooting Operating Lines, Process Improvements and
Optimizations Services
Operating lines very often run with lower efficiency as
it could be. Always when checking operating lines we find
different types of problems and we provide an action plan
to return back to higher efficiency.
Our services for short or already long time operating
lines provide process optimizing, process automation and
instrumentation optimizing, piping and equipment checks.
The services we offer for once per year and can include
the parts:
- operational troubleshooting for finding the problems
which cause production reducing and/or downgrade of
product qualities
- eliminating fast handled problems but also priority
action plan for long term problems
- preparing future maintenance actions
- optimizing of process sections, equipments and media
consumption
- technological advice as recommendation (valuation and
pre-selection) of higher efficient equipment but also up
to date process sections and up to date process control
strategies
- and also sometimes it will be necessary we take care
about
- correct indication of the measurements at
automation system
- for some measurements like consistency, pH etc
correlation with laboratory
- control function and control parameter optimizing
- pipe guiding and supporting
- possibility for control function upgrades
- necessary operator trainings
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Engineering
For our engineering we use common state-of-the-art
engineering, engineering tools and engineering systems.
Our engineering covers the necessary disciplines for
conception engineering and detail engineering and can
include following services:
- conception of process technological design, efficiency
reports as help for key equipment selection
- conception of process automation design
- project time tables
- selection of process automation system and process
quality control system
- lay out and civil documents according to process needs
and operational needs
- P&ID process flow sheets, mass flow balance data
diagram
- Listing (equipment lists, electric energy consumer
list, instrument lists, valve lists, piping lists, etc)
- Data sheets of process control instruments and control
valves, sizing records
- automation system related documents (IO lists, IO
assignment, data base list, etc)
- process function diagrams (DIN symbols) tags based -
loop based and motor based
- process function diagrams (DIN symbols) for production
control and process parameter control
- process operational concept by monitor displays and
pop ups
- operators functional training documents (process
functions explained in different descriptions)
- assistance for 3D model will be done for: piping, pipe
connections in/out at technological equipments but also
at control instruments and valves, supporting, but also
focusing pipe vibrations and access for operation and
maintenance
- instrument location plan and selection of hook ups
(typical selection for instrument and valve installation
with piping, tubing, cabling, supporting, including
material lists for analog and binary instruments,
control valves and on-off valves, )
- FAT (functional acceptance test) of the automation
system with the automation system suppliers, as
functional test basis the process function diagrams and
the process operational concept will be used, during FAT
also pre adjustments for PID values and process program
time values will be done, and according to customers
standard also certificates of FAT
Engineering done by third parties: following engineering
disciplines can be done by third parties, but also can be
included in our engineering services:
- Process automation and instrumentation, this
engineering can include
- automation architecture diagrams, power supply
lists for UPS/non UPS
- wiring and terminal diagrams, cable lists,
material lists, name plate lists
- documents for local cabinets, terminal boxes
- commissioning reports
- Electrical, this engineering can include
- documents for local panels, terminal boxes
documents, cabinets
- internal wiring and terminal diagrams, cable list,
material and component lists, dimension drawings,
name plate list
- one line diagrams, energy distribution and control
diagram, ProfiBus address list
- detailed motor and el. consumer list, detailed
single drive and sectional drive list
- PDC and MCC specification, one line diagram per
each PDC, MCC, choosing of typical circuit diagrams
for each load, air conditioning data, dimensioning
MCC cables
- commissioning reports
- Plant layout, equipment and piping, this engineering
can include
- location, dimensions, connections and indication
of loads actuating at battery limits,
- piping plans and sections (scales 1:100, 1:50 or
1:25)
- location of all pipes and valves, indication of
supply limits and other indications as pipe
diameter, material, flow medium, insulation etc
according to owner’s standards
- 3D model and Isometric drawings for pipes ≥ DN
50mm
- Location plan for supports, dimension drawing for
standard and special supports
- Calculation records, stress analysis
- Material lists (piping, connections, valves,
structural supports, spring supports, expansion
joints, etc) MTO 60%, MTO 80% and MTO 100%, list for
prefabricated parts
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Line Erection and Installation Assistance Services
Our services for line erection and line installation can
include the parts:
- piping erection check according to P&ID process
flow sheets and 3D model especially for:
- piping situations at equipment connections,
actuating piping loads
- straight pipe situations at process control
instruments and valves
- and when problems detected providing solutions and
checking the modifications
- checking of erection reports, commissioning reports,
motor rotation tests and check-out lists for controls
and electric and according to customers standard also
certificates of SAT
- attention to access for operation and maintenance
- operator training as on site training and class room
training
- on site training will be combined with P&ID
process flow sheets check with the installed plant
(location of pipe connections, control valves, hand
valves and sample valves, etc)
- class room training will be done for explanations
for each P&ID process flow sheet:
- process part shown on the flow sheets, used
equipments, technological functions and process
needs
- automation functions and operator access for
start, stop and continuous operation using the
existing monitor displays
- explanation of pop ups and their needs
- explanation of production optimization
programs
- checking of records only or participation on cold
test: all inputs and outputs from/to the automation
system are tested (also link tests) like local cabinet
functions, local instruments (binary and analog), valves
(on-off and control), MCC connections, connections to
variable speed controlled drives, QCS, pulp quality
measurements, links to others, etc
- documents update to version AS BUILT (flow sheets and
all documents necessary for maintenance and future
operator trainings)
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Line Start up Services
Our services for line start up can include the parts:
- start up support will be done in the different control
rooms, at local control panels but also in the field
like
- function check of safety valves and hand valve
positions
- equipment check
- vibration checks on pipes, supports and equipments
- cavitations checks on pumps
- and when problems detected providing solutions and
checking the modifications
- comparison between indication at instruments with
indication of measurements at automation system
- comparison between indication of opening value at
control valves and on-off valves with indication of
opening indication at automation system
- laboratory correlation of some measurements as
consistency, pH etc
- control functions and control parameters optimizing at
70% of production and at performance test production
- reducing of process alarms by control parameter
optimizing, process optimizing and optimizing of alarm
limits
- control functions upgrade to reach equipment
production limits
- operator training continued
- continue documents update to version AS BUILT (flow
sheets and all documents necessary for maintenance and
future operator trainings)
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