Global Machinery Consultants can provide you with engineering support for your offshore & pipeline compression engineering / feed assessment.

Some of the services offered are:

• Gas lift compression engineering, troubleshooting and optimisation
• Gas re-injection engineering
• Pipe line gas compression engineering and reduction of compression cost
• Compressor (reciprocating / centrifugal / screw) up-grade / re-staging / re-wheeling
• Compressor driver (turbine, motors & engines) up-grade / re-staging / re-wheeling

Our article, “Optimise gas turbine-driven centrifugal compressors” published in the November 2000 issue of Hydrocarbon Processing has had significant worldwide impact on offshore /onshore gas compression engineering practices. Global Machinery Consultants can assess and identify all opportunities to improve your gas lift / platform throughput (up to 20%) and operating profits

We can assist in compliance with Operations & Maintenance regulatory requirements. We can resolve hazard and risk issues. The experience of our engineers is based on years of field experience

We can assist you in following areas:

• Achieve regulatory compliance for the optimum cost
• Effective use of capital
• Achieve operational & maintenance compliance
• Effective implementation of health, safety and environment initiatives using our risk evaluation process to achieve savings by reducing waste and minimising fugitive emissions

Emissions compliance need not be a business cost and can actually save money. We offer a comprehensive range of risk evaluation tools including fugitive emissions compliance; dispersion calculations and fire and explosions risk minimisation techniques.

Our API 581 based risk management techniques for Oil and Gas operators, LPG suppliers and process plant operators, enable cost-effective and flexible optimisation of plant layout with-in insurance industry guidelines with resultant large savings in project costs.

Use our services for cost effective procurement of rotating equipment for lowest life cycle cost.

We provide rotating equipment engineering, procurement advice and resolution of any maintenance problem aiming their safe, reliable and cost-efficient operation with highest availability. We provide rotating equipment engineering, procurement advice and resolution of any maintenance problem aiming at safe, reliable and cost-effective operation with highest availability. We can add real value to your investigations into poor machinery performance / failures and provide technical assistance in dealing with equipment suppliers.

Every aspect of equipment life is considered when providing you with the required solutions. A comprehensive engineering database, field experience of our individual engineers and contacts with most major manufacturer’s support our services.

Some of the services offered are:

• Technical specification / evaluation and engineering of pumps, centrifugal /reciprocating compressors, steam and gas turbines and auxiliaries to API, client specifications and other international standards
• Collating machinery / technology improvements through contact with user / manufacturers to improve equipment reliability and availability
• Assisting with development of site – specific best practices based on an extensive database of experience from top industry users
• Providing feed / conceptual engineering on rotating equipment selection, specification and upgrades for projects, revamps and studies
• Conducting field performance tests
• Witnessing performance verification tests in Vendor shops on behalf of our clients
• Assisting with development of best practices for the safe and environmentally acceptable operation of equipment

We also provide tailored on-site training for engineers / operators / maintenance technicians covering rotating equipment, optimisation, life extension, reliability and availability improvement.

Our team of specialist machinery, process and metallurgy engineers has outstanding experience in diagnosing machinery component failures. We can assess the root cause of rotating equipment failures to suggest long term corrective actions. Prevention of repeat failures will significantly improve your plant availability and profitability.

You don’t need to wait for the next failure. Our engineers can also audit the history of past failures to remove the source of past problems. For e.g. in the year 1999-2000, for an Australian client, we identified the root cause of recurring gas turbine failure (5 power turbine failures in 2 years) and identified corrective solutions, which were successfully implemented.

We also provide on-site root cause failure analysis training thereby increasing your team competency.

Some of the services offered are:

• Failure diagnosis specialising in rotating machinery, lubrication, tribology, and fuel system related problems
• Training in identifying failure root causes
• Training in the recognition of key failure features & preventative measures

With a proven ability and current knowledge of the latest electrical engineering developments, we can provide an effective solution to complex electrical equipment and system problems. We can provide engineering support to improve performance and cost effectiveness, safety and reliability for a wide range of electrical facilities and technologies.

Some of the services offered are:

• Electrical safety (equipment and procedures) review
• Electrical site audits and system health checks
• Electrical Power system studies, protection and controls
• Feasibility studies and master plan reviews
• Safety and operational studies
• Training: electrical engineering courses, workshops

We will assist you in benchmarking against the industry best practices and latest innovative technologies.

Raise your business margins by utilising our services throughout the business cycle, from planning and development to operation.

Business margins are operating cost dependent, therefore, lower energy consumption and an optimum energy mix is highly desirable. By analysing energy usage at your production facilities, we can assist in minimising energy usage and improving performance to increase your profitability. Using energy more efficiently can bring the additional benefit of lowering green house gas emissions.

Gross margin can be further improved by opportunistic upgrading and in addition, the focus on reducing environmental impact will assist in meeting present and future legislative requirement.

Some of the services offered are:

• On site performance assessment with respect to energy usage, emissions and hydrocarbon losses
• Energy conservation and developmental studies
• Comprehensive reporting including costs, opportunities and potential pay back periods
• Comprehensive report covering performance, proposals, costs, benefits and pay-back times
• Retrofit of dry gas seals on existing compressors with wet seals
• Key equipment operating condition / performance review to either enhance production or minimise losses and energy usage
• On-site performance testing of pumps, compressors, turbines, engines, motors and generators
• Onsite performance review of columns, heat exchangers etc
• Basic design and engineering support
• Project specification and detailed engineering
• Process & plant performance testing and safety audits
• Plant troubleshooting and upgrading
• Operator training

A 5-10% reduction in energy consumption can be achieved. Combined with opportunistic upgrades your operating margin can be improved from 20 to 40%. An energy savings/tracking program can be developed based on a partial risk/reward-sharing contract.

Working with your operations team, we can offer integrated technology solutions and optimised management of your pipeline facilities thereby reducing your operation & maintenance cost.

The key services we offer to our clients are summarised below:

• Pipeline business strategy development
• Definitive operational cost estimation
• Project value and rate of return assessment
• Health, safety and environment audit, assessment of statutory compliance
• Risk assessment – contract, operations and HSE
• Sustained reliable operation

Our experience based tools and techniques for pipeline management are continuously updated and improved to incorporate current, successful operational practices / experience. By comparing your performance against industry benchmarks, we can demonstrate ways to enhance the value of your operations.

Throughout the Oil & Gas industry, we help customers identify substantial cost savings and add value to their operations of pipeline, liquefied / natural gas processing and civil/marine/terminal facilities.

Advanced process control is a recognised field for achieving significant improvement in plant performance.

Higher yields, increased feed, product quality enhancement, and energy savings per ton of production can generate significant profits. Additionally, better process control improves plant integrity, safety and reliability.

Working closely with your operators & with equipment experts, our process control specialists can provide integrated, high performance value-added control solutions.

Some of the services offered are:

• Base lining control objectives (control system audit, design)
• Flawless start-up assistance
• Assess operational dynamics, identify key controllability features & their optimum controls of specific plants (fired heaters, columns, reactors, steam, fuel & utility systems)
• Process safeguarding & instrumented protective functions review & upgrades
• Design / improve / troubleshoot special-purpose control systems
• Compressor & Turbine controls
• Boiler control
• Plant hot & cold section control
• Advanced process control studies
• Feasibility & cost benefits
• Designing cost effective solutions
• Post-implementation review
• Simulation specification
• Dynamic simulation
• Plant information systems definition, functionality and applications
• Training

We can provide the experience and skills in advanced process controls to improve your edge in the global market.

World wide, process plants/operating centres are between 10 to 40 years old with average age 15 – 20 years; the twilight years of design life. Continued profitable operation is largely dependent on the skills of your ageing operating and technical warriors, many of whom are being lost by natural attrition to retirement, leaving a huge skill gap.

High cost of plant replacement is resulting in the operation of existing plants for 35 to 45 years before their shutdown. Combined with high cost of energy, loss of skill is forcing postponement of aged plant upgrades/retro-fits putting further financial pressures on the bottom line of most companies. At Global Machinery Consultants, we are targeting this requirement, bridging the gap of skilled engineers /technicians to assist in plant optimisation /upgrades by providing world-class engineering services.

Plant upgrading is a costly exercise with little returns, if not handled properly. Alternatively, they can also be undertaken with minimal capital layout giving a maximum return on investment. This is largely dependent on the knowledge (been there, done that) of the engineers involved. Our team has a proven track record.

Some of the major successes include:

• Presentation of a billion-dollar project option report that was successfully implemented by the client.
• Successful recommendation using life cycle cost analysis and subsequent engineering of technologically evolving Cryogenic Turbines. 20 years LCC benefit ~ US$140 million. These turbines are now successfully operating providing significant benefits to the client.