Plant inspection
Understand the current condition and make future-proof decisions
There are several good reasons why every operator should have the best possible understanding of the condition of his plant. Firstly, of course for operational safety and so that downtimes can be avoided. Optimal maintenance with careful plant inspection is the basis for maximum plant availability. Investment decisions often entail carefully considering and weighing up benefits, time and security aspects. Inspections give you reliable information about the current condition of your plant and enable you to use the economic and safety-related scope for action responsibly.
We use various methods in our systematic checks for wear and damage to parts. First, our experienced service technicians do a visual check. Then they measure the layer thickness, whereby the thickness of the enamel surface is measured at points using a magnetic induction method and compared to permissible limit values. A high voltage test can also be carried out. This process involves a metallic broom under direct voltage being passed over the surface. If the enameling is damaged, the broom makes contact at the affected point with the metal underneath. The current flows and the damage is quickly found because sparks and a signal noise are emitted.
For critical components, particularly those exposed to high stress, we do a careful appraisal to advise you how quickly action must be taken.
EPCMM
From plant concept, to detail engineering, implementation and maintenance: we do it all.
Planning and implementing modern process engineering systems is above all one thing: highly complex. On top of the basic requirements such as durability, operational safety and economic efficiency, every plant also has the individual challenges of its specific production processes, processed materials, local conditions and much more. The time and cost pressures in traditional plant construction are also increasing constantly. It is no longer enough to reconcile the most diverse requirements; it must be possible to implement well designed solutions, from engineering to construction, quickly and cost effectively.
These challenges demand not only an excellent, interdisciplinary team of experts, but also optimal and temporal interlocking with the least amount of possible interfaces. That’s why there is high demand for comprehensive services in plant construction for the chemical, pharmaceutical and food industries. We offer you this comprehensive service under the name EPCMM (engineering, procurement, construction management to maintenance), and we don’t abandon you after commissioning.
EPCMM stands for...
Engineering
The basis for every project is a well designed plant concept, including stress calculations and feasibility studies. In this phase we work with you particularly closely to methodically determine the specific requirements and develop a customized solution to properly support the horizontal and vertical pipelines, expansion joints, fittings, pumps and insulation in terms of linear expansion.
Procurement
This also involves the procurement of all plant components and materials at good prices, including third-party products such as compensators, pumps etc. We ensure consistently high quality with inspections of incoming raw goods, as well as analyses during production.
Construction
It is only possible to implement the project if the isometrics have been worked out and the system has been designed with precision. If mistakes are made at this point, the best plant concept cannot produce a permanently safe plant. We fulfil this demanding task using decades of experience and cutting edge software.
Assembly, FAT and SAT
At best, optimal preparations result in the smooth and swift dismantling of the existing plant and construction of the new plant, as well as leak tightness test with FAT and commissioning with SAT. To achieve that, full concentration and comprehensive expertise are required to the end. Transport, storage, handling and so on. There are so many things to consider. You can rest assured that we know all the particularities and tricks.
Maintenance
In order to avoid unplanned downtimes and ensure the longest possible life cycle of a plant, the services we offer extend well beyond commissioning. We are happy to take care of an appropriate supply of spare parts, preventive maintenance, as well as all repair and maintenance work for you.
This is made possible by our proven network of partners
In order to manage all this for you, we draw on an experienced network of experts when preparing the offer. Our trusted partners bring all their expertise from the outset and plan your plant in a forward-looking and interdisciplinary way: They assess the conditions for system integration, coordinate material requirements, optimize the use of components, and schedule and coordinate production and assembly work. The profile of properties of technical enamel is considered in the interaction of all components, so that the technical and economic advantages are maximized. If the team encounters a problem, short routes and the ideal interdisciplinary involvement make it easier to quickly develop a practical solution, eg. using a special part.
A reliable contact person - many clear advantages
Düker Enamel Technology GmbH is your sole contractual and contact partner for business and technology. If you want to newly build or renovate your plant as an EPCMM project, you will receive a comprehensive, reliable service with real added value:
- a responsible system provider that is always available for all issues
- safe investment decisions with minimal risk
- cost and performance-oriented, customized system design
- avoidance of errors in planning, implementation or operating throughout every project phase
- high quality across specialisms and trades
- efficient and smooth project handling from planning to maintenance
- reducing strain on your own resources
- uncomplicated warranty protection for the functionality and leakproofness of the plant with quality management according to DIN EN ISO 9001: 2015
Maintenance
Making it easy to act with foresight and invest wisely
The fault-free functionality of the plant is crucial to every production process. Alongside economic success, the safety of staff depends on it to a large extent. If maintenance is neglected, it usually has short and long-term consequences. In the short-term, there can be malfunctions and unplanned operational stoppages. In the long-term, damage and a considerably reduced service life for the whole plant can be expected. So there are good reasons to rely on condition-oriented, preventative maintenance beyond the legal requirements. Your reliable partner for that is Düker Email Technologie.
We work with your own specialist staff to develop a service and maintenance concept, which is tailored specifically to your operational and production processes. In this way planned plant downtimes, eg. for statutory revisions, are used for regular maintenance, so that unnecessary stoppages are avoided. We also give you advice on stocking spare parts based on your needs, in order, where possible, to reduce tied-up resources.
As part of the maintenance, firstly the condition of the plant is checked and assessed using an intensive visual and layer thickness control. If this test reveals increased wear and tear, in many cases we can replace the affected part immediately with standardized components. Wherever possible and sensible, as an alternative we offer a cost-effective and resource-saving re-enameling of the component. By routinely replacing wearing parts, such as ground outlet valves, the cost of repairs over the life of a plant can be kept as low as possible.
Our maintenance service is designed to use the wear reserves of parts optimally, while also substantially reducing the risk of avoidable production stoppages. A balancing act that requires a lot of experience and know-how. Our service technicians have these expertise. For your benefit! Benefits:
- avoiding disruptions and spontaneous malfunctions
- reducing planned downtimes
- reducing costs of repairs and replacement parts
- preventing damage to plants
- extending life cycles
- Maximum operational safety
Training + qualification
The crucial knowledge for your specialists
Whether in engineering, assembly, renovation, maintenance or running operation, each one of your employees is crucial to an efficient, smooth and safe production process. That is why providing your specialist staff with the necessary expertise is an important part of our scope of services. Our training and qualification services, like our other services, are tailored to your needs. Depending on which assembly and maintenance jobs you outsource and which you handle inhouse, we can give you the relevant knowledge.
Training can be carried out at your premises or at our plant in Laufach. It is for your employees alone, so that your team are together. This framework ensures that only the really relevant topics are covered. The topics will be presented in a very comprehensive and practice based way. Experience shows that this type of qualification is the best way of preventing errors in planning, maintenance or operation.
All the training courses share one learning goal: to develop a basic understanding of the technical enamel and its particular profile of properties. Your employees are only able to use the technical and economic benefits of this material to the full if they have this knowledge.
Possible topics for training for your staff:
- assembling pipelines
- assembly and revision of ground outlet valves
- Engineering
- operational safety
- and much more. Ask us about it!
What are the benefits
of Re-Glassing?
Parts with defective glass lining can be made as good as new, and costs are reduced by reusing the steel parts. We assess the damage and initiate the measures for re-glass. This ensures availability again thanks to the replacement part being manufactured as good as new.
We re-glass for example pipeline components, fittings, outlet valves, segments and internals for columns, covers for heat exchangers, manhole covers, and spacer rings for agitator and storage vessels. We advise our customers on reliable, cost-effective and sustainable solutions, because steel/enamel is a very high-quality and very durable combination of materials.
If you have any enquiries or queries about re-emailing feel free to contact Mr. Jochen Wenisch (Tel +49 6093 99666-10 or jochen.wenisch@dueker-emailtechnologie.de).