Aftermarket
The aftermarket team possess a multitude of disciplines covering design, mechanical and chemical engineering coupled with a collective 100+ years of experience in the combustion industry. This wealth of skills and knowledge allow the aftermarket team to offer a full complement of optimized aftermarket solutions covering part supply, site services and engineering support in furtherance of optimal performance, operability and maintenance of your combustion systems.
Parts Supply
With our collective know-how, the Greens Combustion burner team can supply a range of aftermarket parts for virtually any make and model of burner or flare.
Our expertise in combustion is matched by our experience in supply chain and logistics management, allowing us to meet the clients’ requirements and deliver customer satisfaction in every element of our service.
Our parts supply service covers burners for Fired Heaters, Steam Methane Reformers (SMRs), Crackers, Thermal Oxidisers (TO’s), Sulphur Recovery Units (SRUs) and Flares including:
Our expertise in combustion is matched by our experience in supply chain and logistics management, allowing us to meet the clients’ requirements and deliver customer satisfaction in every element of our service.
Our parts supply service covers burners for Fired Heaters, Steam Methane Reformers (SMRs), Crackers, Thermal Oxidisers (TO’s), Sulphur Recovery Units (SRUs) and Flares including:
-Burner Windbox & Damper Assemblies
-Flare Tips, Liquid Seals & Knock Out Drums -Gas Nozzles, Tips & Jets + Oil Atomisers -Complete Gas Gun, Oil Gun & Poker Assemblies -Oil & Water Sprayer Assemblies & Parts -Combustion Air Swirlers & Stabilisers |
-Air Intake Filters & Silencers
-Burner Refractory Tiles & Modules -Burner & Flare Pilot / Ignition Systems & Ancillaries -Flame Detection Systems & Ancillaries -Actuated Assemblies & Components -Fixings, Fittings, Gaskets, Seals & Hoses |
Replacement Parts Our extensive catalogue includes replacement parts for our own and other manufacturers’ burner and flare systems. We guarantee interchangeability between our own and other products, removing the need for timely on-site modification when replacing non-proprietary components. Each order can be supplied with material and test certifications where specified. Reverse-Engineered Parts We can reverse-engineer existing parts and assemblies to ensure long-term supply and support when they are no longer available from the manufacturer. We can take detailed measurements of parts and assemblies during on-site visits or from returned component samples. Once we have measured them we can fully model the parts and assemblies using 3D software and generate production drawings from the model. Engineered Solutions Greens Combustion engineers have a wealth of practical knowledge, meaning we are adept at analysing on-site issues and identifying where engineered solutions can be applied. Our solutions can range from Low NOx burner conversions to meet environmental regulations, atomiser reconfigurations to reduce steam consumptions and bespoke filtration systems to limit particulate ingress. Revamps We are skilled at identifying revamp opportunities of existing burner installations to increase life, efficiency and capacity. Typical burner revamp activities consist of burner refurbishment, tile replacement, re-sizing tips for actual conditions and upgrading instrumentation. A successful burner revamp can result in considerable cost savings in comparison to new burner supply whilst reducing maintenance, noise and emissions and increasing long term support for spare parts. |
Site Services
Greens Combustion specialise in a full range of site services in support of their own and others’ burners, incinerators and flares, from onsite supervision and surveying to the delivery of bespoke training packages. Our engineers have an in-depth knowledge of burner applications, maintenance and operation and each has a wealth of onsite experience.
Installation Supervision
Our site engineers can supervise and manage single or multi-heater burner installations from concept to completion. Each install team is equipped to cover process, mechanical, electrical and project activities with the support of our office team which provides detailed installation plans comprising drawings, method statements and risk assessments. Our day reports and daily timesheets ensure accurate monitoring of the installation project milestones, providing our clients with top level oversight of our activity. Commissioning Supervision Our skilled site team can take a project from installation to commissioning, ably supporting dry-out, start-up, test runs and operation. We provide full documentary support in the form of operating manuals and performance curves, ensuring on-spec operation and effective transfer of knowledge to onsite staff. We strive always to maintain our staff’s certifications so they are fully qualified to deliver support (e.g. the oil & gas safety passport, H2S awareness qualifications, confined space and offshore Bosiet & Mist certification). Pre-Turnaround & Combustion Surveys We can offer a range of surveys covering existing and new installations for our own and other burner models. Our full combustion survey can identify opportunities to optimise burner set-up and often leads to simple changes that result in cost savings through improved fuel efficiencies, longer run times and reduced downtime. Our pre-turnaround surveys can identify problems and recommend solutions for replacing components. These surveys help to ensure requirements are known well in advance of a plant shutdown so provisions can be made for a seamless turnaround. Training We offer basic to advanced level classroom and site- based training courses tailored to our clients’ specific requirements. Our courses are typically delivered to site operators and maintainers and/or heater contractors and vendors. They cover burner design, operation, troubleshooting and maintenance. We have also led and participated in multi-day symposiums delivered in partnership with relevant organisations including fired heater designers, tube and catalyst suppliers and catalyst loaders. These events typically provide a one- stop technical overview of heater-related technology for plant operators. |
Engineering Support
Our unique combination of combustion and burner expertise, dedicated state of the art test facility and partnerships with leaders in inspection and analysis allows us to offer comprehensive engineering support.
Burner Development & Testing Aftermarket focused testing and development provides end users with unique opportunities to trial enhancements or process alterations of their existing burner systems prior to implementing at site. Burner testing of this nature allows end users to assess the merits of a burner design change in advance of committing to the capital expenditure. Click here to go directly to our testing page. Computational Fluid Dynamic (CFD) Studies Access to advanced computing capabilities and knowledge of burner and furnace systems ensures that we are able to execute CFD studies that accurately predict the performance of burners and their furnace environment with regards to flow, turbulence, thermodynamics and combustion. CFD studies are utilised to support burner design validation and to identify potential inefficiencies in existing burner, furnace and combustion air duct systems. GCL’s 3D CAD system gives real time control over burner design changes identified through CFD simulation and allows the generation of detailed modification drawings and implementation plans to overcome identified constraints. Unmanned Aerial Vehicle (UAV) Inspections We can complete innovative online UAV inspections of inaccessible locations within the oil & gas industry i.e. Flare stacks / Tips. Typically a UAV team comprises a CAA qualified pilot, API/CSWIP qualified inspector and purpose modified UAV’s allowing capture of close visual imagery, video & thermal profiling. The visible and thermal imagery allows for clear representation of asset condition allowing an informed decision to be made on planned maintenance and turnarounds. The benefit of online UAV inspection over traditional methods is primarily that production does not cease, working at height is not required and helicopters are not deployed all contributing to a cost saving. Metallurgical Analysis We can conduct metallurgical analysis and testing of burner components to aid failure analysis investigation and to support QA validation of new designs. Through adoption of microscopic examination methods we can understand how specific characteristics of a material has contributed to failure and / or to identify trace contaminants. Further investigation in the form of destructive and non-destructive testing can be applied to validate material selection or failure mechanisms. Each metallurgical study conducted is fully supported with a detailed report of findings complete with preventative engineered solutions for consideration. |