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NEUMAN & ESSER Verwaltungs- und Beteiligungsgesellschaft mbH
Werkstraße w/o no.
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NEUMAN & ESSER Verwaltungs- und Beteiligungsgesellschaft mbH
Werkstraße w/o no.
52531 Übach-Palenberg
Germany
Represented by: Alexander W. Peters, Stefanie Peters
E-mail: info@neuman-esser.de
Telephone: +49 (0)2451 481 01
Fax: +49 (0)2451 481 100

Register entry:
Entry in the Commercial Register:
Register Court: District Court Aachen
Register number: HRB 9573

Value-added-tax I.D.:
Value-added-tax Identity Number in terms of Section 27a Sales Tax Law:
DE811229957

Responsible for the content pursuant to Section 55 Para 2 RStV [Interstate Broadcasting Treaty]:
Martina Frenz, Manager Corporate Communications
(see address above)

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29NEA eNEWS

NEA eNEWS Issue 29

Editorial Issue 29

Challenge Us!

NEUMAN & ESSER is a niche market solution provider, not afraid of taking on difficult engineering projects. NEA welcomes the challenge of satisfying complex customer specifications and developing designs for new processes, with a constant view to optimizing efficiency and costs. The more complicated the specification, the more the staff at NEA relish their engineering skills being put to the test. The reason is simple. NEA’s application teams have amassed a wealth of experience, knowledge of production, and local system design over many decades of successful collaboration, resulting in numerous innovations.

One example is NEA USA’s successful development of the compact design of the “Screwcip” system for the North American oil and gas market. This solution, combining a common driver for the rotary screw and reciprocating compressor, is in particularly high demand on the Enhanced Oil Recovery market. When it comes to compressing carbon dioxide, nothing has proven more cost-efficient; both in the commissioning phase and later in operation.

The MoBIO 800 mobile compressor unit is yet another development designed to address the demands and highly sophisticated specifications of companies such as Ontras. Only the most ingenious design was able to meet their range of often opposing requirements in terms of space, weight and performance, in a single system. And by staying true to NEA’s core values of quality, precision, and reliability, our team of experts found the solution the customer had so eagerly been looking for.

A traditional brewery had an equally interesting request for NEA Mahl- und Sichtsysteme. The challenge was to find a way of grinding sodium bicarbonate to clean flue gas. Unphased by never having worked on any comparable system, NEA’s milling specialists at Übach-Palenberg ran grinding tests at their Test Center and clearly rose to the occasion by designing a NEA Impact Classifier Mill that met all required specifications. The Karlsberg Brewery is very satisfied with the newly-installed low-maintenance ICM 12. It replaces the fault-prone third-party product for the grinding of soda and runs inline without any downtime.

In this issue you can read about how NEA Engineering consistently finds reliable process solutions to meet your needs, no matter where in the world you are. Global spec – German tech! Challenge us.

We hope you enjoy reading this edition and also recommend signing up for NEA eNEWS, which will keep you up-to-date with nuggets of news and even more fascinating facts in between editions.

Alexander und Stefanie Peters
Managing Partners of NEA Holding

Growing Investments in EOR

Innovative Packaging Solutions

Texas has become a major energy powerhouse accounting for nearly 40% of US crude oil output and over 30% of US natural gas. Integrally, the Permian Basin supplies 80% of CO2 for EOR (Enhanced Oil Recovery) – making West Texas an increasingly important link to reduce emissions, boost oil production, and grow the economy. NEUMAN & ESSER USA has grasped this major opportunity in the upstream and midstream markets by introducing advanced methods of compression.

In 2011, NEA USA designed its first “Screwcip” high-speed compressor package for CO2 for EOR for an international oil and gas exploration and production company. The application required handling a suction pressure of 5 psig (0.34 barg) to a final discharge of 2,000 psig (~138 barg). By combining a common driver for the rotary screw and reciprocating compressor, NEA USA reduced the number of stages, compressor throws and cylinders sizes of the reciprocating compressor. This successful installation allowed for a more efficient and cost-effective operation with minimal service work.

More recently in West Texas, this same packaging technique is being installed for one of the largest energy infrastructure companies in North America. Due to the remoteness of the unmanned facility, the customer required cost effective and reliable equipment. A cornerstone of NEA USA is to use its robust API 618 packaging design principles to build customized compressor packages that are genuinely trouble-free. NEA USA worked with the customer to offer several iterations and options of equipment and package design during the initial proposal concept. Subsequently, NEA USA utilized its 3D modeling capability and its typical open-ended design review process with the client to ensure the final as-built total project concept was suitable to meet operational needs.

A dual shaft Caterpillar G3612 TALE engine is used to drive a screw compressor to boost near atmospheric pressure of CO2 into NEA’s reciprocating compressor. In the final product, NEA’s reciprocating compressor utilizes three stages with four throws to produce a discharge pressure of 2,165 psig (150 barg) from a suction of 150 psig (~10 barg). The overall package consists of three separate skids that are integrally connected to supply a volume of 8.56 MMSCFD (9,800 Nm³/h) CO2. The logistics comprised of shipment and delivery to the site and initial installation; allowing the customer to minimize on-site rental crane duration and labor.

NEA’s customized packaging solution reduced the amount of equipment required for the application, thus saving the customer time, money and long-term operating costs. Both NEA USA and NEAC Compressor Service USA offer a unique combined service as an OEM compressor package manufacturer and service provider for the upstream and midstream sectors of the oil and gas industry.

 

More about EOR on Wikipedia

On the Move

Improve Effectiveness with Mobile Solution

Although biogas cannot replace natural gas, it can supplement it very well. It helps to reduce CO2 emission and to diminish dependency on the countries which supply natural gas. According to the German Biomass Research Centre (DBFZ), biogas production in Germany was equivalent to about 20% of natural gas imports from Russia in 2014. The remaining potential would enable the replacement of an additional 10%, taking technical and demographic developments into account up to 55%. Current biogas production on a pan-European basis corresponds to about 6% of the natural gas imports from Russia. According to a recent DBFZ report, there is significantly greater potential here.

Biogas can be stored similarly to natural gas and can supply energy when energy carriers such as wind and sun are unable to provide it, thus compensating fluctuations. This is precisely what is becoming more and more important as the number of wind and solar energy systems used on the grid increases.

It can be used to generate electrical energy, to operate vehicles or for feeding into a gas supply network. Because the biogas demonstrates low pressure following preparation, it must be compressed for feed into the natural gas grid, dependent on the respective grid operation.

Almost 60 NEUMAN & ESSER (NEA) compressors are running in German biogas plants of varying sizes and feed the purified biomethane into the existing natural gas grid. Depending on the grid, the NEA compressors have to increase the gas pressure of 0 to 9 bar(g) to up to 84 bar(g). Local different grid pressures even exist for the same grid operator.

Convincing innovation makes biogas economically viable

24 biogas compressors are in operation for the company Ontras Gastransport. Biogas is an important issue for the transmission grid operator headquartered in Leipzig. Ontras is involved in national and international committees, helping to design the future framework conditions. However, also the large operators are subject to the changes in subsidy policy and looking for opportunities for long-term investment security within the biogas market.

Continuous changes to the market demand the most efficient production concept. Interim processes move into focus. These periods which have to-date remained unused, possess the potential to improve the overall degree of effectiveness decisively. Therefore, Ontras looked for a mobile biomethane compressor solution in order to feed the gas into the gas grid early, even before the stationary compressor system is commissioned.

The mobile biogas compressor is designed to handle the appropriate gas pressures and feed rates for all of the Ontras biogas systems. Also, in case of a failure or malfunction in a stationary system, it should be possible to connect and use the mobile solution in the short-term.

Ontras has had good experience with its long-term partner NEUMAN & ESSER and therefore decided in favor of NEA’s convincing concept. As a result, planning commenced at NEA in Wurzen in 2014.

 

More about ONTRAS

 

MoBIO 800 ready for use within one day

One year later, the turnkey solution stands on the Wurzen factory premises. Ontras’ Project Manager Jens Geier was impressed: “We were amazed to be able to marvel at the MoBIO 800 on the NEA grounds after a mere twelve months. Fully completed and ready to go, including the permission to drive on the road.”

The mobile system consists of two trailers. The split was made due to the requirement to develop one system for all cases of operation within the Ontras gas grid as well as to enable assembly, servicing, cable, escape and rescue routes. As for all NEA compressors, this mobile system is also designed for low maintenance continuous operation.

Two dry running gas-tight NEA reciprocating compressors, driven by a 315 kW mid-mounted engine, are located in the first trailer. The second trailer houses the water coolant and container air-conditioning, steering, controlling as well as the control air generation. Moreover, extensive accessories such as supports, landing gear, lightning protection rods, oil and glycol vessels, concrete weights, load plates and further outdoor assembly parts are housed there during transport. Additionally, the mobile biogas system can be remotely monitored. All safety-relevant aspects such as fire notifications, gas leaks or break-ins can be recorded at the Ontras headquarters in Leipzig, as can the complete technical data.

The second trailer is considerably lighter than the first; the axles and double supports are sufficient to set it up. Its heavy brother is fully supported by existing supports as well as additional extension supports during operation and is therefore independent of the chassis. Flexible connectors between the trailers enable commissioning within one day.

The mobile compressor system achieves a gas production volume of at least 800 Nm³/h for all the different and specified pressure conditions. The suction pressures fluctuate between 1 and 10 bar absolute dependent on biogas generation like amine gas treating or PSA. The final pressures lie within the range from 16 to 85 bar (absolute) – depending on the use location and case as well as the attached gas grid.

Principally, NEA distinguishes between two-stage and three-stage feeding as well as recirculation for the possible applications. Due to the different pressures, the different modes of operation for this mobile system are adapted by efficient, energy-saving regulation (rotational speed and bypass regulation) as well as by disconnecting a reciprocating compressor.

» A large number of ideas flowed in, which had not yet happened in this manner.«

Combined strengths for high-performance application

Even if it sounds so simple, it was an incredible act of strength in reality Axel Korschewski, Plant Engineering Manager at NEUMAN & ESSER in Wurzen explains: “We bundled our experience and resources for MoBIO. Otherwise we couldn’t have handled it. However, we have also recognized what we are capable of. A large number of ideas flowed in, which had not yet happened in this manner. We had to fully take on new paths and establish several new questions that arose when solving the problem. Therefore, complex thoughts which intervened in several areas, were required in order to avoid getting onto the wrong track.”

The greatest challenge was to achieve the necessary rigidity of the trailers while taking the maximum permissible overall trailer weight into account. As Project Manager Philipp Leipner explains: “The couplings have a maximum tolerance of only 0.2 mm in order to operate the system with the accustomed NEA precision and performance efficiency. Therefore, also the base frame is hardly allowed to move – at the most 1 mm over the full length of 9 m. Torsional movements of 5 cm and more are normal for common trailers.“ Consequently, the rigidity of the chassis had to be increased by a factor of more than 50 without losing sight of the weight.

It was agreed in the performance specifications that the mobile compressor system must be appropriate for normal road traffic without a special permit – for a standard truck so that the system is at the use location fast, i.e. dimensions, weight, etc. must be in accordance with the highway code. So the compressor solution had to be light and rigid enough. Additionally, transport should be possible when full (water-glycol mix as well as oil system filling), making it possible for the system to be connected and commissioned as fast as possible.

The initial idea to construct the compressor based on NEA SAPS (Seismic Air Power System) was abandoned fast. The combination of a screw compressor and a reciprocating compressor would have exceeded the maximum permissible weight by at least 10t.

To achieve an optimum result, consider the consequences in advance

The maximum permissible overall weight for a tractor and trailer in Germany is 40t. “It became apparent to us very quickly that we would have to completely rethink the mobile compressor and create an entirely new construction”, as Axel Korschewski describes the outset of the project.

“The first task was to determine the space requirements precisely”, explains Philipp Leipner. “The questions were: Where must the service technicians for servicing work later go, how much space do they need for controlling and how much for servicing lines and connections? Then, we had to take the exchange of valves and, if applicable, of a cylinder into account. As it were, we had to piece a jigsaw together while repeatedly calculating and checking the strengths and torsional forces.” Also, the engineers had to take the environmental guidelines (e.g. Water Resources Law), work protection, fire protection, escape routes and the operator Ontras’ specifications into consideration.

A rigid steel frame was designed within the course of planning, doing justice to the requirements regarding the overall weight. Access is provided to all the wear parts for servicing work. Even some of the roof elements can be removed easily, enabling access to the corresponding points from above and, as necessary, exchange of the cylinders within the shortest of time. The system has various steps and stages, enabling easy access to all connectors and fitting positions.

Operation is guaranteed at outdoor temperatures between -20° and +35°C. “Noise protection and air-conditioning technology are contradictory in-part“, as Korschewski interjects. “Above all against the backdrop, we constantly have to pay attention to the weight. The hinges and door locks alone weigh 300 kg.” The NEA engineers were repeatedly confronted with extreme opposites for which they had to find the ideal solution. In addition to noise, “rigid but light” as well as “compactness with full access” posed the greatest challenges.

Several opportunities for the future

Everybody involved in this project learned a great deal and outgrew themselves. Philipp Leipner summarizes: “The limits lie in the weight and construction space. At the cost of the short development time, we were not yet able to exhaust all options. From the kick-off meeting to delivery, we had a mere eleven months’ time. However, we have already recognized optimization ideas and weight reduction potential here and there.”

The Plant Engineering Manager also sees potential: “We know how it works now. A fully-fledged system which can also be operated permanently exists and is not more expensive than a stationary system. The carry-over effect has transpired as particularly interesting. In principle, we are able to put any compression process desired onto the trailer, providing us with an unlimited application portfolio. For example, this could be a complete functional unit for a chemical process. If a compressor at a chemicals works fails, we can also design this compressor technology in mobile form.”

Several further applications options are conceivable, for example for chemically identical natural gas as a backup system or for feeding into the gas grid, also making these processes flexible. The mobile systems can also recirculate or force off. Although the system in its current status is “overqualified” for this, it is one of the further application options for this system.

Overhaul Under Pressure

NEAC takes a large part

In 1976, Bayer AG ordered the largest GHH compressor constructed to-date which was delivered in 1977 and commissioned at the petrochemicals location in Cologne in 1979.  With ten cylinders, the ethylene compressor achieves a designed pressure of 2,500 bar in the second stage.  The abbreviation PE stands for polyethylene, a thermoplastic synthetic material manufactured by the polymerization of ethylene. LD stands for “low density”; the well-ramified polymer chains have a low density.

More than 230 years ago, the famous “Gute Hoffnung Hütte” (abbreviated as GHH) started its operation in Oberhausen, Germany. Originally conceived as a pure steel mill operation, GHH expanded in the fields of mining and further processing early, becoming the largest machinery and equipment construction company in Europe during the 20th century and was finally merged into today’s MAN Group in 1986.

After MAN withdrew from building reciprocating compressors, NEAC took over servicing for the GHH high pressure reciprocating compressors and NEUMAN & ESSER acquired the full technical know-how for the MAN  Hyper compressors. Since 1992, NEAC Compressor Service offers now spare parts and services for this product. All spare parts are manufactured at the NEUMAN & ESSER machine factory.

Major revision at INEOS in Cologne

After more than 35 years in operation, it was time for a major revision of the GHH compressor. The sister machine which is identical in construction had already been revamped and needed oversize bearings for the crankcase. Following revision of the bearing tunnel, only one bearing size should need to be stocked for both hyper compressors.
The date for the revamp of the GHH machine was set for the planned revision at INEOS in Cologne. As outages of all production units cause extremely high costs and can influence further processes, shut downs take place simultaneously if possible. The processes are planned and clocked down to the last detail so that even major revisions only have minimum downtime to avoid a critical path of that work.

»Working within tightly planned time frames and under pressure is more the rule than an exception.«

Professional time management

“Working within tightly planned time frames and under pressure is more the rule than an exception”, explains Project Manager Christian Michels from NEAC Compressor Service. “That is our specialty, to put it another way.” “Yes, that’s right”, as Product Manager Stefan Damberg agrees. “Time and space are always somewhat tight at our construction sites. Even if we are talking about the largest GHH compressor ever built here, adverse circumstances are part of daily life for us.”

Furthermore, six NEAC technicians worked in two shifts, two specialists for spindling the bearing center line in-situ as well as two employees who checked several components, re-aligned them and finally completed them at the NEA headquarters in Übach-Palenberg, Germany.

The contact person at INEOS in Cologne was Norbert Lütkehaus, maintenance specialist in the PE block: “Precise planning as well as staying in the given time frame has top priority during major revision. The technicians have to report us their progress daily and I check it according to the project schedule. As an OEM of GHH compressors, we placed our confidence in NEAC Compressor Service for the time management because the full revision in only five weeks is a demanding task.”

NEAC successful despite hindrances

The PE-LD system was out of operation for this period for servicing and maintenance. A total of four revisions were made simultaneously; NEAC carried out two of these on the structurally identical GHH compressors: one full revision and maintenance work on the already rebuilt sister machine.

Heavy lift at highest precision

During this period, ten NEAC specialists fully dismantled the compressor, lifted out the crankshaft with a length of 6.5 m and a weight of 17,200 kg and removed the old bearing caps. Stefan Damberg, who is very experienced in 3D laser measurement, measured the extremely long bearing center line precisely using a 3D laser tracker.

This type of laser measurement is the fastest and safest means to determine critical deformations or unevenness down to a hundredth of a millimeter. A prerequisite for in-situ machining of the bearing center line. Special tools were used to spindle the bearing center line over its entire length. This was necessary as the provided time frame could not otherwise have been kept. Finally, the new bearing caps were inserted with the bearings and the machine completed. It runs perfectly again and it no longer looks as old as it is.

It transpired that the NEAC service technicians had even less time than the five weeks planned. They had to temporarily leave the plant twice for safety reasons due to simultaneously conducted servicing work.

Norbert Lütkehaus evaluates the project at INEOS in Cologne as absolutely positive: “NEAC has left a lasting impression. They have a trained team that works hand in hand. That is why they were ready punctually despite delays – without becoming at all hectic – true professionals.”

More about INEOS
»NEAC has left a lasting impression. They have a trained team that works hand in hand.«

Breathing easy in Germany

Flue gas purification at the traditional Karlsberg Brewery

Karlsberg has been brewing beer in the small town of Homburg, Germany since 1878. Almost 140 years later, the little brewery has grown to become the Karlsberg Group, a family of companies employing over 2,000 people across the globe. The range of products has expanded from just beer to now also include mixed beer beverages, mineral waters, lemonades, and fruit juices.

Corporate social responsibility is an intrinsic part of the company’s philosophy, and Karlsberg has been striving to meet its commitments to sustainability through new production processes and innovative technology. In 2011, the brewery had photovoltaic arrays installed on the roof of its Logistics Center in Homburg, with a total output of 270 kilowatts.

To optimize energy management, Karlsberg runs three NEA compressor systems for CO2 recovery. The carbon dioxide released during the production of annually 2.6 million hectoliters of beer and mixed beer beverages is reinjected in a subsequent production process. These compressors, supplied in 1998, have reduced the need for additional CO2 purchases to zero.

In addition, the brewery is able to feed 10,000 MWh of excess heat into the municipal heating system of the city of Homburg, covering the heating demand of 300 single-family homes. A portion of the surplus heat is derived from a lignite coal furnace, a so-called combustion plant. It generates superheated steam which the brewery uses to clean its bottles. As the oven is heated by coal, Karlsberg is highly conscientious in cleaning the flue gas, and this is where the NEUMAN & ESSER Grinding and Classifying Systems comes into play.

Responsible flue gas cleaning

The Saarland company doesn’t rely on conventional lime substrates for this procedure, but instead uses highly efficient sodium hydrogen carbonate (NaHCO3), a salt also known as sodium bicarbonate, or common baking soda.

This is a neutral, non-acidic, and harmless product. When used to clean industrial gases it is ground and subsequently mixed into the flue gases that are to be purified. There, the baking soda reliably binds the pollutants in the flue gas flow, such as acidic components, organic substances, and heavy metals.

To facilitate transport and storage, sodium hydrogen carbonate is commonly produced in granular form, with an average diameter of about 200 μm (0.2 mm). In order to create a larger reactive surface area, the salt is first ground to a higher degree of fineness before being fed directly into the flue duct.

INDUTEC, a member of the NEUMAN & ESSER family

Karlsberg Brewery installed an INDUTEC flue gas cleaning system in 2006. The scope of supply included an impact classifier mill from a thirdparty manufacturer and a bag filter system for dust removal. Last year, NEUMAN & ESSER received an inquiry from Karlsberg to supply a new classifier wheel for their mill.

NEUMAN & ESSER GROUP acquired INDUTEC in 2013, and has since been the exclusive manufacturer of mills and original spare parts (OEM) for the existing population of INDUTEC products. Walter Strerath, former INDUTEC employee, was an important adviser on this project. He remains the prime contact for INDUTEC customers, now as one of the experts in NEUMAN & ESSER’s After Market team.

“I was significantly involved in the flue gas cleaning project back then, so I know the system pretty well“, explained Walter Strerath. “The classifier wheel NEA supplied, replaced the third-party brand to Karlsberg’s full satisfaction.“

“During the replacement project, the brewery’s technicians complained about the excessive number of times they had to replace the grinding discs’ rotor bearing“, added Robert Berdychowski, a member of the After Market Sales department at NEA Mahl- und Sichtsysteme. Even though the technicians were using a reinforced bearing, and had even put in a new shaft, cost-intensive bearing failures occurred repeatedly, leading to long down times.

A Reliable solution for Karlsberg

In order to offer Karlsberg a reliable alternative to their existing mill, NEA carried out grinding tests at their own Test Center in Übach-Palenberg, Germany. The goal was to grind between 10 and 160 kg of sodium hydrogen carbonate per hour, to a degree of fineness d90 ≤ 25 μm. The tests were extremely successful. The NEA impact classifier mill ICM 12 that was subsequently installed achieves the desired degree of fineness and was easily integrated into the existing system to grind inline. The ability to use the existing infrastructure was a prerequisite for Karlsberg.

The impact classifier mill has been running impeccably 24 hours a day since January 2015, aiding the traditional brewery to meticulously clean their flue gas. Although this project was the first time that NEA Mahl- und Sichtsysteme had installed a mill specifically to grind sodium bicarbonate, the grinding experts at NEA once again proved that they can always be relied on to find the optimal solution meeting just about any of their customers’ requirements. 85 years of experience in manufacturing grinding systems, intensive research and development in their Test Centers, and a comprehensive range of products are a strong foundation to achieve full customer satisfaction.

Thomas Regneri of the Energy and Maintenance department at Karlsberg is delighted with the new solution, which puts an end to the frequent bearing replacements: “Finally we have a lowmaintenance mill that runs reliably and doesn’t cause downtime.

»The classifier wheel NEA supplied, replaced the third-party brand to Karlsberg’s full satisfaction«

INDUTEC, a member of the NEUMAN & ESSER family

Karlsberg Brewery installed an INDUTEC flue gas cleaning system in 2006. The scope of supply included an impact classifier mill from a thirdparty manufacturer and a bag filter system for dust removal. Last year, NEUMAN & ESSER received an inquiry from Karlsberg to supply a new classifier wheel for their mill.

NEUMAN & ESSER GROUP acquired INDUTEC in 2013, and has since been the exclusive manufacturer of mills and original spare parts (OEM) for the existing population of INDUTEC products. Walter Strerath, former INDUTEC employee, was an important adviser on this project. He remains the prime contact for INDUTEC customers, now as one of the experts in NEUMAN & ESSER’s After Market team.

“I was significantly involved in the flue gas cleaning project back then, so I know the system pretty well“, explained Walter Strerath. “The classifier wheel NEA supplied, replaced the third-party brand to Karlsberg’s full satisfaction.“

“During the replacement project, the brewery’s technicians complained about the excessive number of times they had to replace the grinding discs’ rotor bearing“, added Robert Berdychowski, a member of the After Market Sales department at NEA Mahl- und Sichtsysteme. Even though the technicians were using a reinforced bearing, and had even put in a new shaft, cost-intensive bearing failures occurred repeatedly, leading to long down times.

A Reliable solution for Karlsberg

In order to offer Karlsberg a reliable alternative to their existing mill, NEA carried out grinding tests at their own Test Center in Übach-Palenberg, Germany. The goal was to grind between 10 and 160 kg of sodium hydrogen carbonate per hour, to a degree of fineness d90 ≤ 25 μm. The tests were extremely successful. The NEA impact classifier mill ICM 12 that was subsequently installed achieves the desired degree of fineness and was easily integrated into the existing system to grind inline. The ability to use the existing infrastructure was a prerequisite for Karlsberg.

The impact classifier mill has been running impeccably 24 hours a day since January 2015, aiding the traditional brewery to meticulously clean their flue gas. Although this project was the first time that NEA Mahl- und Sichtsysteme had installed a mill specifically to grind sodium bicarbonate, the grinding experts at NEA once again proved that they can always be relied on to find the optimal solution meeting just about any of their customers’ requirements. 85 years of experience in manufacturing grinding systems, intensive research and development in their Test Centers, and a comprehensive range of products are a strong foundation to achieve full customer satisfaction.

Thomas Regneri of the Energy and Maintenance department at Karlsberg is delighted with the new solution, which puts an end to the frequent bearing replacements: “Finally we have a low-maintenance mill that runs reliably and doesn’t cause downtime.”

»Finally we have a low-maintenance mill that runs reliably and doesn't cause downtime«

Growing Headquarters

Space for Employees and New Ideas

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    360° view of the planned new building:
    Click on the image and drag the mouse while holding the left mouse button to change your view towards the building.

    It started quite harmlessly. The Managing Directors of the two operative companies NEA Deutschland and NEAC in Germany mentioned, initially incidentally, that the workplace situation in their offices is so tight that currently no further workplaces for apprentices or additional new recruitments could be set up.

    However, for the two Managing Partners Alexander and Stefanie Peters this was already a warning signal. Without further ado, they worked out an ideal solution for the annex together with Dr. Norbert Winands and Oliver Schulte, who supervise investments at the location. The condition: the visual appearance of the entrance area and the generous green areas should not be changed.

    Eye-catching cubes

    As nothing is done by halves at NEUMAN & ESSER, finally not only the decision was taken to build an annex to the existing building, but also to take the building parallel to it into consideration for planning purposes. The result: two almost square cubes of the same size are emerging, each with some 600 m² additional office floor space. The new aluminum panels for cladding the cubes will provide a novel eye-catching accent, consciously setting itself apart from the rear brick facade. The metallic-looking visual aspect not only reflects the company’s own products well, it moreover marks a new construction phase.

    It is decisive that the annexes blend into the existing buildings seamlessly in order to ensure exchange between the employees in this manner and also to seize the opportunity to restructure functional units within the extended areas.

    Beyond requirements

    In addition to the operative companies’ requirements, employees can now also reckon with the realization of their wishes which had not so far been possible due to a lack of space. Thus, a social area for women will arise in the main building because NEA employs more and more female apprentices and employees in the commercial area. The archive designed for 50,000 files will also be extended with an additional storage space of 200 m². A new, more spacious doctor’s room will be furnished for the company doctor’s regular visits, equally a large multifunctional area for training and sports activities which are offered by NEMAN & ESSER after office hours and are received enthusiastically by the workforce.

    Although several of the new spaces arising will initially be spare space, the foundation is laid for establishing further offices in the coming ten years.

    The planning application has been filed, kickoff will be at the beginning of August and it is expected that the work will be completed in April/May 2016. The new road, up to 100 new parking lots, as well as the new orchard should also be ready then. Because without an orchard at the Übach-Palenberg location, NEUMAN & ESSER would be lacking a hallmark.

    Repair Coordination Center

    Global Service Center Network Extended with Saudi Arabia and Shanghai

    “If a Repair Coordination Center (RCC) is founded, this is more than a mere office, it respectively represents the local bundling of infrastructure, resources, competence and certified repair capabilities“, according to Bernd Wagner, NEAC Compressor Service Managing Director in Germany. Each RCC is awarded the certificate following training at the headquarters’ production site in Germany which qualifies it to be capable of carrying out precisely specified repairs to NEA as well as other OEM reciprocating compressors. It goes without saying that this is person-related. Therefore, it is ensured that, in every RCC with the subsidiaries in Brazil, the USA, UAE, India, Thailand, Italy and Germany, the repair standards of the NEA GROUP are adhered to in accordance with the original specifications. In the meantime, they are all certified according to level C and are therefore authorized to carry out complex repairs to driving mechanisms.

    Customer proximity filled with life

    As customer proximity is not just a hollow phrase for the NEA GROUP, it was only logical to extend the global RCC network and now also found RCCs in Saudi Arabia and Shanghai. These are the first two locations where additionally RCCs are built-up outside the regional NEAC company’s headquarters.

    Strategic positioning of Saudi Arabia

    The new RCC in Saudi Arabia was formally opened on Oct. 27, 2014 with good customers and important business partners. The guests included the local partner and sponsor Arabian Hotta Trading Co. who had played a decisive role when founding the RCC. The two heads of this RCC Mohammad Abu Rayan and Mohammad Altartoor are happy to be able to serve their customers promptly with qualitative and “intelligent” services as well as repairs. The Service Center was placed so well strategically that it can both serve the refineries in Al Jubail and those belonging to Saudi Aramco as well as the gas plants at locations such as Ras Tanura to Khafji on the Kuwaiti border. That makes this RCC the first center of its kind which offers specialized OEM services for reciprocating compressors in the entire kingdom.

    Warehouse in Shanghai

    However, in Shanghai the focus is placed on an extensive warehouse which was established. “We have now moved the entire logistics hub from Beijing to Shanghai“, as Kevin Zhang explains. “In this region, one fact is of primary importance: the fast turnaround of spare parts“, smiling happily, because also he knows that the strategic layout of his RCC enables him to fulfill his customers’ wishes.

    Compressor Training for CGG Eidesvik and CGG

    “Servicing and maintenance of reciprocating compressors for maintenance personnel” was the name of the training for four CGG Eidesvik AS employees and three CGG employees who were trained by NEAC in February. The four CGG Eidesvik employees work on the vessels as service technicians, the three CGG employees are engineers at CGG’s headquarters in Paris.”

    The CGG Eidesvik joint venture was founded in 2011. The company for offshore services with special vessels, founded by Kristian Eidesvik in 1996, is domiciled in Bømlo, Norway. CGG is an international geoscience company founded in 1931. The CGG Eidesvik fleet incorporates a total of ten high-tech vessels. The joint venture’s headquarters is in Bergen, Norway.

    Individual company employees had already been trained in advance within the scope of open customer training. However, the current seminar was the first internal company training for CGG Eidesvik and CGG. 18 NEA Seismic Air Power Systems (NEA SAPS) are in operation on the joint venture’s vessels in order to locate oil and gas reserves.

    The customer’s specific requirements in focus

    NEAC Compressor Service holds seminars regularly which are tailored to its customers’ needs. Thus, theory and practice are closely interlinked here.

    The theoretical focus of the customer training with CGG Eidesvik and CGG was placed on the SAPS systems’ control panel. Controlling this system was explained to the participants in detail. The decisive data and functions of the compressor system are collated here. In the practical part of the seminar, within the scope of maintenance, exchanging compressor valves and replacing sealing elements was carried out.

    The feedback from the participants was clearly positive: “I particularly liked the well-balanced proportion of theory and practice. We really learnt a lot”, as one of them expressed.

    Engineers' Meeting 2015

    NEAC Stays Up-2-Date

    Customers across the globe value the technical expertise of NEAC service technicians, not only for their knowledge of compressors, but also of the specialist tools and equipment they use. Modern technologies continue to bring radical change to this area, with ongoing improvements in flexibility and precision. These developments, primarily targeted at the service and maintenance processes, also affect and speed up the communication and information exchange processes.

    The application of these new technologies is treated in depth at the annual NEAC Engineers’ Meeting. Around 20 NEAC specialists from seven sites attended this year’s event, which ran for a full week at the NEAC Training Center at headquarters in Übach-Palenberg.

    Possible errors were simulated and previous repair cases analyzed in detail. Seminars on theoretical and practical subjects ran alongside the KO³ compressor design program on the agenda and the NEAC business strategy for the coming year was presented and discussed. This means, once again, that NEAC engineers across the globe are fully up-2-date.

    Clay Pigeons Shooting and Golf Tournament

    NEA USA Gets Active In Texas, there are only two seasons: “cold & wet” and “hot & humid”. On the occasion, there will be a beautiful blue sky with light winds and temperatures of 80°F. Rain or shine, NEA USA mixes the great outdoors with traditional Texas activities like shooting clay pigeons at the range and competing in golf tournaments. In February, NEA USA sponsored at the Gas Processors Association Sporting Clays Event, which brought in over 200 participants from the Houston area. The high winds didn’t stop the players from destroying the clay pigeons with their guns in good Southern style. NEA USA also sponsored at GPA’s annual NGL Marketers Golf Tournament in April in association with their convention in San Antonio, Texas. More than 120 golfers from around the US took to San Antonio’s beautiful Quarry Golf Club. Both events serve as excellent grounds for meeting new people in the Upstream and Midstream markets while staying active.

    ACHEMA or Expert Conference?

    ACHEMA, the global forum for the chemical engineering and process industries will open its doors in Frankfurt on June 15. NEUMAN & ESSER GROUP was one of the loyal regular exhibitors on this platform from 1956 to 2012. However, they have observed for several years how the international trade fair landscape is developing towards becoming a wider range of symposia, congresses and conferences. They all incorporate a common factor: focus on the operator of a system within his specific area of application. This targeting matches with the NEA GROUP’s objectives: exchange between experts, the opportunity to network and, above all, low scatter loss of contacts.

    The operative NEA GROUP companies such as NEA Deutschland, NEAC Compressor Service, NEA Mahl- und Sichtsysteme as well as STASSKOL have therefore decided against participating in the ACHEMA as exhibitors this year and to make use of platforms with a better customer proximity instead. With this, they remain faithful to the route they have already taken with globally renowned specialist events such as the NEA Compressor Day and the NEA Milling Day. Moreover, they extended their series of events with customer proximity, for example, with “NEAC Training on the Road” – training for customers on selected service topics.

    At the same time, the NEA GROUP supports the Biogas Association, the EFRC, GMRC and KREMEA with its technical know-how. As an active member, it thus contributes to the development of the associated conferences as guiding sector meetings for customers and business partners. That fits in better with NEUMAN & ESSER: an expert conference for niche products, and that with customer proximity.

    Better than Cure

    Series on Health, Part 9

    This year’s Health Days in April, held at NEA’s three German sites, once again offered a day full of exciting activities for staff. At each event, the first item on the keep-fit agenda was a lavish wholesome breakfast that left everyone suitably energized to tackle the main topics on the day’s menu: nutrition, prevention and exercise.

    All program items on offer met with such great interest that they had to be split into several blocks. The series of keynote speeches was no exception, and Leonie Frings-Reinke from BGF institute was only the first to captivate her audience. Her talk “Brainfood”, on energy-supplying foods that help us boost our performance and concentration levels, left many spectators feeling inspired to use the breaks to fill their goody-bags with nutritious “mind candy”. Osteopath Jonny Winands was on next with an eye-opening lecture on “The Spine?!”. He clearly struck a nerve with the audience, describing various back disorders, and how many of these result from bad workplace habits or poor posture while doing exercise. Last but not least, Klaus Hamacher stepped up to the podium to emphasize the importance of preventive health care. The occupational physician enlightened his keen listeners on the first signs of illnesses, many of which often go unnoticed in the hum drum of everyday life, but then end up requiring lengthy recovery periods.

    New experiences with the Blackroll

    Staff at all NEA sites also took up the offer of a personal health check. This included skin screening as well as motion analysis, with individual guidance by physiotherapists on how to improve one’s body posture.

    At Übach-Palenberg, participants personally experienced how painful the immediate effect of bodily exercise can be as they explored the so-called “Blackrolls” method, enchantingly presented by Marina Yakubova from SportFuchs. Minor physical ailments notwithstanding, her course entitled “Muscle training as you don’t know it” left the amateur athletes awe-inspired by the results. Many of them will sign up for the trial course in June, eager to achieve the elasticity they are striving for by completing it.

    Fitness Tests and Noise Golf

    In Wurzen and Stassfurt, the main attractions were the Quick Fitness Test and the “Noise Golf”, a test vehicle in which noise level measurements were arried out. As situations from both workplace and everyday life were under scrutiny, participants were astounded at the amount of noise pollution they are exposed to around the clock.

    The Health Days were enhanced by information stands from two health insurers, Techniker Krankenkasse and AOK Gesundheitskasse, and the trade association Berufsgenossenschaft Holz und Metall (BGHM).

    Once again, this year’s events proved to be a huge success, with a compelling choice of topics that inspired lively participation, and provided much impetus for NEA’s employees to put into practice in both their professional and private lives.

    Sales & Purchase Meeting

    The Managing Directors of the ten international NEA GROUP locations send their representatives to the four-day Global Sales Meeting und Global Purchase Meeting once per year. Traditionally, both events overlap on one day, enabling all the participants to be informed cross-thematically.

    Andreas Hirschter, from Strategic Marketing, opened the Global Sales Meeting in the Training Center at the Übach-Palenberg headquarters on March 2nd. He explained the advantages of the CRM (Customer Relationship Management) system update and cheerfully requested the participants to provide their feedback in the test phase in order to subsequently implement the worldwide users’ individual requirements.

    Dr. Klaus Hoff, Head of Central Division of Technology, and Karl-Heinz Hammes, Head of Applications, presented fascinating new compressor technology developments as well as new areas of use. Customers in the offshore and high-pressure applications areas can reckon with products fitting their specifications. The topic was augmented by discussions concerning all aspects of the development of new drive concepts. The globally bundled competence of the NEA GROUP has created innovative solutions for them. This was demonstrated impressively by the two plant experts Karl-Josef Kremers from NEA Deutschland as well as Todd Sturdevant from NEA USA.

    In addition to new machinery, the topic of revamp and modernization, an area where NEUMAN & ESSER with and around Andreas Hahn has established a competence center, was on the agenda. The customer was the focus of attention on the following day. Additionally, Martina Frenz, Head of Corporate Communications, introduced her newly developed global PR & marketing campaigns. Following this, Brigitte Nierhoff-Schmitz in the insurance area and Karsten Drüke, lawyer and joint organizer of this series of events, presented the novelties of the applicable international economic legislation in-depth.

    The regulations as well as market developments in global procurement were treated on the day the global purchasers were together – an area which requires close collaboration of all parties involved. Finally, Anton Schmidt, Head of Quality & Safety Management for the NEA GROUP introduced the new version of QUAM. This IMS software supports process-orientated organization management and is based on Microsoft SharePoint. This collaboration platform for company- wide cooperation and document management will replace the NEA Intranet used currently in the short-term. In addition to imparting knowledge and the expert discussion, social exchange was not neglected. An important component for mutual understanding and straightforward cooperation above and beyond the geographical borders.

    8th indeland - Triathlon

    Reaching the Finishing Line with Team Spirit and Discipline

    The 8th indeland Triathlon is scheduled to take place on Sunday June 21, 2015. This testing event includes a 500 m swim, 20 km cycle, and 5 km run. Four NEA teams of three are competing for the first time, alive with one of NEA`s core values: team spirit.

    Training for a triathlon requires a great degree of discipline and stamina, with each team member following their own special training plan to prepare for the big day. One of NEA’s champions, Sofia Offermanns from NEAC Compressor Service, goes for regular runs around Carl- Alexander Park in Baesweiler, powering down after her circuit using the “Blackroll” muscle stretching method she discovered at this year’s NEA Health Day.

    Her team-mate and colleague Lena Mäuser, a veteran of the Aachen Company Run, has opted for the 500 m swimming challenge this year. A regular at the gym and pool, Lena is crossing her fingers for a few sunny days so she can immerse herself in the field, swimming lengths in the local lake.

    »We want to represent our team successfully while enjoying this amazing event!«

    Andreas Plum from NEA Deutschland is also highly motivated, “We want to represent our team successfully while enjoying this amazing event. Can you believe we have a fan group already? I’m so excited to be cycling for my team! We even have a winning strategy – my colleague Guido Harsch has been having 19°C baths for weeks, to prepare himself for the lake swim and our runner, Hanno Stoppelkamp, is one of the top achievers in our NEA “No Gear Fitness” program. Now nothing can stand between us and victory!”

    The smell of success is already in the air, with the starting pistol set to be fired on Sunday 13:00 at Blaustein Lake in Eschweiler. We look forward to an exciting triathlon with many fans and colleagues cheering all our NEA teams on. We wish them a strong will and all the best; so…on your marks…get set…and see you all at the finishing line in Aldenhoven!

    »Next year absolutely again!«

    The Company Triathlon was a great success for our teams!

    All four teams have achieved sensational results. The sophisticated types of training like bathing in ice cubes, special bike and run disciplines and the use of Black roll did not fail the desired effect. In some cases this helped even to high-ranking places. Even though it was their first participation in this great sporting event they occupied the top places 1, 4, 5 and 8 of the 15 company groups.

    The triathletes had a lot of fun during the competition and were more than proud. Afterwards they celebrated their win with music and a delicious buffet.

    Georg Flade

    Profile

    ■ Since January 2015: Head of Technical Management at STASSKOL GmbH
    ■ Born on July 3, 1976 in Dresden, Germany, married, two sons, lives with his family in Halle/Saale, Germany

    Education: ■ 1996-2002: Mechanical Engineering degree at the Technical University of Dresden, Germany, specialism in Energy Technology
    ■ 2006: Award of his doctorate (Dr.-Ing). at the Technical University of Dresden, Germany

    Professional Career: ■ 2005: Design Engineer for air conditioning compressors at LG Thermo Technologies GmbH in Annaberg-Buchholz, Germany (Leonhardt Group)
    ■ 2006-2010: Design Engineer for high vacuum technology and cryogenics at Oerlikon Leybold Vacuum Dresden GmbH in Dresden, Germany
    ■ 2010-2011: Design Engineer for valves and regulation at NEUMAN & ESSER GmbH & Co. KG in the Central Division of Engineering
    ■ 2011-2014: Quality Engineering Manager at NEUMAN & ESSER GmbH & Co. KG

    Hobbies: ■ Music (trombonist) and Cycling