Aftermarket Service + Parts

Partnerships: As Strong as The Foundation You Build

A partnership is defined as a relationship between individuals or groups characterized by mutual cooperation and responsibility for the achievement of a specified goal.

Clients approach us with specific needs and desired outcomes for their equipment.

Dresser-Rand has a long history of working with end users, contractors and even between business units within the company itself. Our engineers recognize that the strength of a partnership can only be judged by how adeptly we are able to achieve a specific client goal. Therefore, we use a foundational approach to providing equipment, systems and controls for each client.

Our foundational approach begins with an initial discussion that focuses on the client’s situation, their specific needs and any underlying conditions that need to be addressed by the equipment or service to be provided. The first discussion with a client is not about what products we can sell them, but rather what problems they are attempting to solve. We want to understand the client in the most comprehensive way, and then develop solutions from that vantage point.

Recip_Tallgrass01In 2012, discussions began with a North American energy provider about a project that initially involved refurbishing 11 Clark engines at one of the client’s gas compression facilities. The rework was intended to bring the Clark engines into regulatory compliance and increase station capacity. During this period, the client was involved with an acquisition which resulted in the sale of the facility to a pipeline company. Although Dresser-Rand has a long standing relationship with the North American energy provider, as a newly formed company, the pipeline company did not have a past relationship with D-R. However, due to the timing of the acquisition, confidence in the solution and focused communications between the companies, the pipeline company chose to continue with Dresser-Rand and quickly negotiated their first Master Services Agreement (MSA) with us.

Dresser-Rand engineers were asked to evaluate doing a revamp versus buying new equipment. The North American energy provider and Dresser-Rand completed a full lifecycle evaluation based on cost of ownership, including initial capital investment and ongoing operating expenses. After completing the evaluation, the pipeline company decided to purchase six new engine / compressor packages as the estimate to revamp the existing engines was greater than 50 percent of the cost of new equipment. Additionally, the corporate support within the pipeline company required to execute a major revamp was very limited.

The project consisted of three phases.

Phase 1 – Design and specify the process piping, connections to the new skids, foundations, building, ventilation, automation and controls, electrical power, and other utilities to support the six new engine / MOS™ compressor packages.

Phase 2 – Procure all parts, package and deliver the Waukesha engines, MOS compressors and Enginuity® iFLEX control systems.

Phase 3 – Construct the supporting facilities designed in phase 1, and install the packages from phase 2.

Start-up and Commissioning Achieved in Record Time
Dresser-Rand was able to shift engineering resources from modifying existing equipment to designing new installations within existing infrastructure, while concurrently facilitating purchasing, project management, resourcing, scheduling, and integration of the new equipment. We believed we could accomplish the task with minimal disruption to existing facility operation, which was a key element in securing the contract. The new packages would require new process piping, structures to house the equipment, as well as ancillary and gas cooling structures.

Additionally, this project was the first site for Dresser-Rand’s MOS compressors to be installed for continuous service. The MOS compressor was determined to be a good fit for the project. Dresser-Rand’s ability to design the installation and support systems, and commission these first MOS units, ensured the compressors would perform when they needed to.

Installing a new engine / compressor design can be difficult and unsettling at the best of times; doing it under a compressed schedule can greatly increase the stresses on the team. Dresser-Rand diligently and steadfastly provided service and support to ensure production would not be affected at the plant. The pipeline company’s plant personnel were also instrumental in making the installation of these new compressors a success, a real team effort.

With engineering and procurement well under way, the focus shifted to installation. During negotiations for installation, the pipeline company determined it had achieved a staffing level sufficient to manage site construction themselves, and would therefore call upon Dresser-Rand’s Gas Engine Technology Center experts to consult on the balance of installation services, including packager inspection and automation control factory acceptance testing, to ensure that each part of the final installed package was executed to the highest quality. After construction was completed, Dresser-Rand and the pipeline company had a smooth and easy start-up and commissioning process. The result: six units fully commissioned and operational in two months.

A new, fully integrated automation and controls system was also designed and installed. The system fully communicates the data to the existing station systems, and allows the operators to visualize unit performance in real time at their stations.

To develop the knowledge and understanding needed by the pipeline company’s staff, training was on-going throughout the various phases of the project. Numerous meetings were held between D-R and the pipeline company’s staff on-site; in the final stages, a complete documentation package was furnished to the pipeline company.

Today, the plant is in regulatory compliance for emissions, and is operating with increased capacity, lower operating expense and processes more gas using fewer packages then it had previously. The project timeline of having six new compressor units commissioned and in operation in less than one year from concept to completion, allowed the pipeline company to maximize return by aggressively pursuing new volume commitments from gas producers.

Working together, Dresser-Rand, the North American energy provider (initially) and the pipeline company (ultimately) were able to create and foster a new successful partnership. Safe installation and construction were considered during the design, and the phasing allowed for the construction contractor to remain safe. No lost time or injury accidents occurred during the life of the project.

In word and in deed, those are the foundations from which we build.

Tags: Emissions Solutions, Enginuity, MOS

other articles from insights issue Summer 2015