Brochure Industrial Services - Brochure

1Buchen ... at the heart of industryINDUSTRIAL SERVICE2FULL SERVICE FOR THE INDUSTRY –SO THAT YOUR PLANT RUNS EFFICIENTLYGrowing competition, increasing costs, more stringent environmental requirements – indus-trial companies are continuously operating in a more complex area of conflict. In order to be successful, they have to generate peak perfor- mance in the most efficient manner. In doing so, functioning infrastructures are essential. Buchen industrial service helps customers efficiently use their plants and machines and ensures that these are always operational. This way, we can make an important contribution to their market success. Our customers can focus on their core business and can become even more successful. Using clean and effective solutions, we retain the balance between cost efficiency and environmental protection. At the core of all our ser- vices are the industrial cleaning processes that we have, in many cases, continuously developed to highly specialised and automated services.Whether industrial heat exchangers, air coolers, tanks, pip-ing systems and devices, vessels or columns: in all areas, the Buchen Group provides all services from a single source – from the initial consulting pertaining to the ad- equate and efficient implementation up to and including the final documentation. Quality, efficiency, and the highest level of security are characteristic performance criteria. Be-yond our standard services, our industrial service is specifi-cally characterised in areas where special challenges must be met. Those include assignments in areas threatened by risk of explosion, nuclear plants, or in working with chemi-cal materials that pose a health risk for both people and the environment. In total, our company employs close to 2.500 people working at 70 locations across Germany, Europe and the Middle East. Therefore, we are always close to our customers in order to react quickly, purpose-fully and individually to all customer requests.Efficient Simple SafeWe make our customers’ business more efficient, simpler and safer. As the first company in our industry, we have been certified in accordance with the RAL quality mark 997 for industrial plant service. Plants and machines maintained and cleaned in accordance with these stand-ards are less sensitive to breakdowns, operate with low emissions and are environmentally friendly, in addition to enjoying a longer lifetime, which lowers operating costs.3SAFETY FIRSTAs a full service provider with a pronounced orientation towards service, we value quality, security, health and environmental protection as the core of our thoughts and actions. At an early stage, we defined and recorded the fun-damentals for workplace safety that, today, have been integrated into a process-oriented management system that leaves nothing to chance.Employees who know what they need to doThose who recognise danger can effectively steer clear of it. For this reason, we are sharpening the risk and environmental skills of our employees through recurring education and ongoing training programmes. Continu-ing education programmes retain our employees’ expert knowledge. Technical knowledge as well as hands-on ability are taught and developed at our certified educa-tional centre, among other places. Avoiding dangers in a targeted fashionIn critical environments as well as for problems with ex-tremely high demands, only employees who have a high degree of experience and who have especially demon-strated their ability to work in an extremely safe way are deployed. On-site we employ low-noise and low-emis-sion technologies. Company-own workshops guarantee the functionality of equipment such as respiratory and chemical protection.Certification confirm the high standardsAll areas within the Buchen Group have been certified for quality, security and environmental standards. In doing so, we follow the internationally recognised SCC standards, the adherence to which is regularly checked by independ-ent auditors. These certifications underline the professional and security-related processing of our services. They con-firm the trust in the Buchen Group and confirm that – in industrial service – it is worthwhile to build a relationship to a partner who sets international standards. Certified, among others, in accordance with: Quality management ISO 9001 Environmental management ISO 14001 Safety management SCC** Waste disposal specialist in accordance with Art. 52 KrW- /AbfG (waste disposal specialist act) German quality mark RAL-997 for industrial plant service4Whether in a refinery, power plant or chemi-cal company: industrial cleaning work is a pre-requisite for ensuring an optimum functional-ity of equipment and component parts and is incurred in almost every industrial segment. Everywhere where efficient and streamlined processes are required to ensure perfect flow-through performance in plants, apparatuses or pipes is required – this is where high-pressure water jet technology is used to clean.Process can be utilised in many different waysCleaning using the high-pressure water jet method is a standard service provided in industrial cleaning and a core competency of the Buchen Group. For over 60 years now, we have been using the high-pressure water jet technology for the efficient and cost-effective removal of residues in process plants.Even persistent stains can be reliably removed using the rational cleaning process, for example residues in vessels and on machines or incrustations in pipes, in order to name just a few. Sometimes automatically, sometimes manuallyDepending on the task at hand and the location, we either clean manually or automatically. The automated high-pressure water jet process is the standard method of operation, because it is superior on so many different levels: it is highly efficient and it is extremely safe since the equipment used can, for the most part, be controlled remotely. In order to attain perfect results, we can also use self-developed special equipment. A typical example of this is the air pre-heated/gas pre-heated cleaning, a computer-controlled system for the fully automated high-pressure water jet cleaning of air and gas pre-heaters in power plants. The manually operated high-pressure water jet cleaning is used in situations where the use of the automated pro- cess is not feasible or not economical.HIGH-PRESSURE WATER JET CLEANING5Equipment in all performance categoriesOur high-pressure pumps are sound-insulated, powered by fuel and therefore work independently of the power grid. Installed in the box body of a truck, the high-pres-sure pumps are mobile and can be used flexibly. Aligned to the case of application, the drive performance varies from approx. 7 to 840 hp; the water pressure from ap-prox. 3.6 psi to 43.5 psi. Ancillary technical equipment, such as tank washer heads with different types of noz-zles, expand the spectrum.Mobile wash stationFor interior and exterior cleaning of heat exchanging bundles, we deploy our mobile wash station on-site, wherever pollutants – as a result of the washing process – can contaminate the ground or the vicinity or where run-off fluids need to be retained. This solution is an envi-ronmentally sound and cost-effective recirculation system that cleans the waste water mechanically and filters it back to the high-pressure pump.Scope of services Consulting, coordination and planning of the most effective cleaning process Use of powerful high-pressure pumps Automated high-pressure water jet tailored to the most diverse cleaning jobs Manual high-pressure water jet cleaning Installation work6TURNAROUND MANAGEMENTManufacturing plants must be in continuous op-eration. However, this is not always possible. From time to time, an inspection, maintenance or reconstruction is necessary that require the temporary shutdown of the plant. Each hour in which a refinery, a chemical plant or a power plant is not operating, costs money. Therefore, it is in the best interest of the plant operator to keep the shutdowns to a minimum and to bun-dle all pending measures. This, of course, turns shutdowns into complex operations that can only be successfully carried out after a detailed planning and organisational period.System as a success factorA core service provided by Buchen is the cleaning, ser-vicing and maintenance work of plants or plant compo-nents during periodical shutdowns. This has made us experts in the field of turnaround management. Using a methodical procedure, we can reduce shutdowns. Speed and dedication to the deadlines are as important a component as are quality, cost efficiency and work-place security.More efficiency through comprehensive solutionsOur service package includes all project phases. This way, the decommissioning is conceptualised, organised and prepared beforehand. We’ll coordinate all neces-sary individual steps and ensure that the involved ser- vice companies complete their work just as efficiently and with the same high quality as we do – even while under immense time pressure and in close quarters.Important is that under consideration of the workplace security, the quality, delivery date and cost efficiency are always met. The final documentation is also a part of the scope of services.Scope of services Advising and planning Compiling and implementing a security concept Set up and retention of on-site infrastructure Coordination of human resources and machines Organisation of required additional work Deadline and cost control Assumption of waste management duties7TANK SERVICEStorage tanks, vessels and columns for crude oil and heavy products must be regularly in-spected and cleaned. If this is not done, than residue will bind the expensive storage goods. In addition, the residues lower the tank volume and thereby also the overall storage capacity. Automated tank cleaning processDepending on the type and size of the tank as well as the consistency of the residue to be removed, we will em-ploy various automated, closed tank cleaning processes through which the negative factors of manual cleaning are largely avoided.Non-man entry systemThese exceptionally effective tank cleaning systems are structured modularly and have been installed in ocean containers for the secure and flexible transport. Since all automated tank cleaning processes of the Buchen Group are closed systems, hydrocarbon emissions – as opposed to standard manual tank cleaning – are signifi-cantly reduced. Short cleaning times and a high security level for employees – since no entry of personnel into the tank is necessary (non-man entry system) – are further advantages of the automated cleaning system. Economic advantages are the high crude oil recovery rates and the related lower waste management costs as well as shortened cleaning times.Mobile combustion chamberThe innovative technology in the area of tank and vessel service includes the mobile combustion chamber for a low-emission waste air treatment. The Buchen Group’s mobile combustion chamber is conceptualized and de-signed for the incineration of industrial gases at tempera-tures over 1000°C in accordance with the TA air regula-tions. Hydrocarbons as well as explosive and dangerous gases are incinerated almost noiselessly without open flames. In case of emergencies, the automatic nitrogen infeed ensures a rapid shutdown. At the Buchen Group’s tank service, safety is our top priority. Scope of services Advising in terms of the selection of the appropri- ate automated tank cleaning system Detailed planning and coordination Transport and set up of a mobile cleaning system Deployment of experienced specialist personnel Waste removal Mobile waste exhaust air handling8POWER PLANT SERVICEThe Buchen Group offers the operators of conventional power plants, thermal waste processing plants as well as industrial incin-eration and steam generation plants across Europe special services related to cleaning, waste management and retrofitting. Individ-ual service packages based on the require-ments of our customers minimise their coor-dination and work-related effort and simplify audits and process steps. Flexibility delivers perfect resultsAligned to the task, our power plant service uses clean-ing processes that have been aligned in different ways to the respective problems, even including those that require special knowledge; these include, for example, boiler cleaning using sandblasting technology, air pre-heat cleaning, air cooler cleaning and blasting technol-ogy. Sandblasting and blasting technology includedDuring sandblasting, the blasting abrasive has been calibrated directly to the soiled area to be cleaned. For the blasting, we create blast waves using exactly dosed blasting loads, for example in the combustion chambers of large industrial boilers or modern fluidised bed boil-ers. In this way, it is possible to remove and break up a large amount of residue within a relatively short pe-riod of time. The effective process can be used in up to 1200°C masses and can already be used in the cooling off period of the boiler during the planned shutdowns. Scope of services Boiler cleaning Air cooler cleaning Chemical cleaning Air pre-heat cleaning High-pressure water cleaning Sandblasting Blasting technology Destudding/studding9MOBILE SLUDGE DEWATERINGAt the core of this service is the preparation of industrial sludge through solid-liquid separa-tion. Products such as caustic solutions, acids or oils are filtered and oil/water/solids de-canted.Advantages that advanceAt the end of the 1960s, FILTRATEC, a Buchen Group company, introduced the mobile sludge dewatering as a service to the German market. Today, this method has be-come an economic alternative to making an investment in an individual sludge dewatering machine or for liquid waste removal. In case of operational failures, the mobile sludge dewatering is often an important component to the retention of the business operations. It can be an im-portant component of a waste management concept and can guarantee economic manufacturing.Flexible, short-term applicable solutionsDepending on the requirements, individual components are developed. For the efficient implementation of the draining requirements technically mature equipment is used. For this, FILTRATEC is – especially for demanding jobs – your competent business partner. Based on your needs, we plan, build and operate mobile and stationary equipment and machines. In this fashion, you have the opportunity to transfer the process-related and operation-al risks of the sludge treatment to FILTRATEC, a measure for more efficiency and better planning ability.Gas-tight mobile decantersIn order to separate the flammable or hazardous ma-terials, FILTRATEC offers nitrogen-heterodyned, mobile, gas-tight three-phase decanters in accordance with ATEX guidelines. With these machines, materials can and should be safely processed. This is the first mobile ma-chine that can process the materials with flashpoints of under 21°C direct at the point of origin. The main area of implementation is the separation of crude oil slack wax, slop residues, residues from tank cleanings, dewatering containing oil as well as sludge containing solvents.Scope of services Individual project engineering Process-technical laboratory analysis Recovery and conveying of sludge Chemical-physical handling Loading/discharge of the separated phases Process monitoring Planning, constructions and operation of plants10REACTOR SERVICECatalytic reactors in the petrochemical indus-try aid the finished products, reduce the envi-ronmental impact and are at the centre of any industrial plant. BUCHEN-ICS, a Buchen Group company, is one of the leading international providers for reactor services.Specialists with a comprehensive portfolioThe reactor service includes all work surrounding cata-lyst-relevant process plants such as hydrocracker, FCC reactors, UOP-CCR reformers etc. This begins with the plant preparation, including detailed and logical plan-ning, preparatory assembly works and the controlled rapid cooling of the reactor through liquid nitrogen flush-ing. The catalyst handling includes the unloading of used catalyst mass, the screening of the material and if pos-sible, re-uses the catalyst, as well as the reloading by means of dense or sock loading processes.The regeneration, passivation or re-use of the catalyst mass are additional specialities in the multifaceted ser- vices offered by BUCHEN-ICS. However, this also in-cludes the most diverse mechanical work, such as opening or closing of reactors, repairs, welding and inspections through to the removal and installation of entire reactor internals. In order to exclude thermal and chemical reac-tions, the work is conducted in a N2 atmosphere.Interface minimisationOur service also includes the turnaround management for catalytic reactors which contains the systematic plan-ning, project planning, and implementation of all work, giving complete attention to the environment, safety, quality, schedules and costs.Experienced personnel and a ‘tried and tested’ technologyFully trained experienced and competent personnel to-gether with a thoroughly developed technology guaran-tees environmentally sound, safe and efficient work. For inspections or other reactor access in a nitrogen atmos-phere, the long term tried and tested CE certified respira-tory equipment “LSS Life Support System” offers patented safety with anti-panic helmet, two independently operat-ing respiratory systems and external secured video sur-veillance.Scope of services Turnaround management Plant preparation Catalyst handling in N2 atmosphere Inspections in N2 atmosphere Maintenance of reactor internals Assembly services11CHEMICAL CLEANING PROCESSIn some industrial plants, materials are used or processed that create strong adhesions. If a certain degree of pollution has been reached, then the equipment can no longer attain the required performance. Chemical cleaning processes in closed systems remove the resi-dues without damaging the material.Chemical etching and cleaning technologyIn order to gently remove welding residues, chemical etching and cleaning technologies are, for example, used prior to the commissioning of new plants. Etching and passivation, de-oiling, degreasing and decalcifica-tion – the cleaning and etching work is completed in the circulation or spray method and is especially geared toward the customer’s requirements.The selection of the chemical and its concentration var-ies depending on the application use. Accompanying analyses regarding the protection of the equipment and apparatuses to be cleaned and the professional process-ing and minimisation of residues round off our offer. System flushing processWith the system flushing, the Buchen Group has devel-oped an economical and environmentally sound alter-native solution for the cleaning of heat exchangers, ves-sels, columns, pipes, crude oil plants and other plant components during ongoing operations and prior to shutdowns.The system flushing cleans the plant and plant compo-nents in the closed circulation under use of a biologi-cally degradable chemical that was developed in order to absorb special oily components such as oil, gas oil, benzene, etc. Complex disassembling, transport and assembly work do not apply. The process is low in emis-sions because of the closeness of the system.12PLATE HEAT EXCHANGER SERVICEPlate heat exchangers (PHE) enjoy widespread use, since they are valued for their low investment costs, space-saving formats and high efficiency. The disadvantage: through its special type of construction, the equipment is susceptible. Even little amounts of residue or small leaks in the system can significantly reduce the performance. The Buchen Group’s plate heat exchanger service restores the performance of all standard brands.In a multi-tiered process, the plate heat exchangers are validated, cleaned and generally overhauled, including the exchange of joints. In doing so, we guarantee quick reaction times and the cleaning and maintenance of large volumes. Our service includes the reassembly, the clean-ing of the plates, the change and, if desired, even the delivery of the joints and wear parts in original equipment quality as well as the assembly and commissioning.COLD CUTTINGAside from precision, cutting work in industrial plants demands an extremely high level of safety. Under these premises, cold cutting is often the first choice. With our Water Abrasive Suspension Cutting technique (WASC) we’ve perfected this technology. The water spray contained in the abrasive means cuts both soft and highly rigid materials in the same exact manner. Steel is cut at strengths of 400 mm, concrete up to a maximum of 500 mm. Despite an enormous cutting power, the WASC process is very gentle on the material. Another alterna-tive cold cutting process works with injection cutting noz-zles. This process is preferred in the removal of chemical plants with a high cutting performance. The control unit of the cutting wagon used is hooked up to an abrasive container that holds the abrasive and provides the cor-rect amount of dosage. 13SURFACE TECHNOLOGYEMERGENCY MANAGEMENTEven the best security concept cannot entirely prevent damages. If an incident occurs, quick and professional action must follow. Our emergency management ensures companies that manufacture, process, transport or store dangerous goods or materials a rapid support in case of emergency. Immediately following the information of the occurrence, we will induce all necessary measures in order to limit and remove the damages. Beyond this, we will document each incident in detail for the claim notification to the insurance company.24-hour emergency management hotline: +49 (0)800 - 0 07 17 70Whether it be ships, containers, floodgates or industry system parts: everywhere where metal areas are subject to the weather, corrosion can occur. The Buchen Group offers corrosion protection as its newest service. This in-cludes all work related to the gently removal of layers of rust as well as the subsequent new coating. Corroding areas are treated with the standard sandblasting process. A less expensive alternative with fewer burdens for the environment is the de-layering with water pressure up to 43.5 psi. For all large and small areas, we use the “Spider-jet” and “Dockmate”, two innovative technologies. Using a remote control, the fully automatic machines can remove the old layers of rust. Cleaning water and residues of rem-nant layers are captured and subsequently separated. The processes reduce processing time and costs, since e.g. the staging is not used. After the complete de-layering, the new layering with all approved colour systems is used.14SEWER SERVICEWhether an industrial company or a local authority: sewer systems are the basis of every functioning water economy. The Buchen Group supports private as well as public or-dering parties with the maintenance of their most important waste water infrastructure.Our offer in the area of sewer service includes the clean-ing, inspection, impermeability analysis and clean-up of pipeline systems, sewer pipes and interceptors. We use methods and highly specialised machines that we‘ve been testing over the course of many years. For example, long-range cleaning up to 400 metres is possible; sealing can be applied using the inliner technology without the need for a foundation trench. We conduct impermeability tests for private households using highly modern canal video and cleaning vehicles – simply and efficiently.Scope of services Comprehensive and competent consulting Cleaning using special equipment Disposal of incidental room goods Sewer inspection with modern TV technology Satellite camera systems Electronic positioning sensors Permeability/house service connection Light fluid interceptor tests (in accordance with DIN EN 858) Development of renovation concepts Sewer and manhole refurbishment Interceptor refurbishment15TECHNOLOGY FOR EVERY REQUIREMENTWhatever the job may call for – the Buchen Group has the right solution for all requirements. In each area, our industrial service works with modern processes and tech-nologies. Sometimes they go back to our own develop-ments, because we utilise our experience in order to fur-ther develop methods, technologies and equipment in a practice-oriented fashion. On the one hand, we intend on making solutions even better, more economical or even more environmentally friendly. On the other hand, we would like to use our know-how to develop our special equipment for use in additional application areas and in order to develop new challenges.Plants and technologiesSince, for the most part, the Buchen Group provides a majority of their industrial services directly on the custom-er‘s premises, most of our high-tech equipment is mobile. In a short period of time it can be brought to the loca-tion and generally functions there self-sufficiently; it only requires electricity and water. In daily operations, this is an advantage, but also for special jobs or in exceptional cases. Therefore, we are in the position to quickly as-sist our customers in case of damages or to provide ad-ditional short-term capacities. The scope of possibilities ranges from mobile waste water cleaning equipment to gas washers, combustion chambers and entire waste air cleaning systems.Equipment and vehiclesOur equipment pool is also diverse. High-pressure pumps up to 43.5 psi are just as much a part of the equipment as mobile wash stations or an air conveyor system that gathers all types of materials over a wide area. The comprehensive logistics include special vehi-cles for almost every purpose. Suction vehicles for vacu-uming, transporting and filling of fluids, combined with high-pressure and suction equipment or flatbed trucks, sweeping machines and hot water equipment. As build-ing blocks of our high-performance network, they help us react flexibly to our customers’ requests as well as being well-equipped to handle all situations.And what can we do for you?16Buchen UmweltService GmbH Emdener Straße 278 D-50735 Cologne Phone: +49 (221) 7177-350 Fax: +49 (221) 7177-276 info@buchen.net www.buchen.net