Zakum Asset Business Unit: Accomplishment Bulletin
Major Overhaul of Three Elliott Gas Compressors at ZWSC (MZ-293)
Accomplishment Category Production
Background
• The three gas compressors R101-A/B/C are located on GG-2;
the major overhauls were planned and executed based upon
the accumulated running hours between overhauls as per
the OEM procedures and recommendations for Gas
Centrifugal Compressors.
Scope / Actions
• The Contract 144438 was awarded to Elliott who is the
registered OEM for these Gas Compressors; the scope of
work included the major overhaul of the compressors at
site and major overhaul of the spare compressor inner
bundle and rotor at the vendor workshop facility.
Challenges
• Each of the Major overhauls had to be completed within the
contractual time frame and as per the Zakum Integrated
Shutdown Master Plan.
• Initially there was one spare complete inner casing bundle
and rotor in Mussafah Stores this was installed in the first
compressor, the inner bundle and rotor assembly that was
removed from the first compressor was sent to Elliott
workshop facility in Italy for refurbishment and we had to
ensure that it was returned on time to carry out the next
compressor major overhaul.
Actions Completed
• R101-C was the first compressor to be overhauled followed
by R101-A then R-101 B. All three overhauls where
completed within the planned timeframe.
©2014 ADMA-OPCO. All rights reserved. Publication: ZKABU-4/August-2014
Cost X Scheme Execution Completion
Achievement Profile
• With the support of Site, the compressor major overhauls
were safely executed as per the contract and Integrated
Master Shutdown plan without any delays or business
interruption.
Cost Control
• AFE approved for MZ293 = USD 4.0M
• Estimated expenditure till Dec 2014 = USD 3.4M
• Expected Saving = USD 0.6M
This cost saving was achieved by challenging the repair costs
and modification requirements with the OEM during the
compressor refurbishments.
Lessons Learned
• One of the compressor major overhauls was planned to
coincide with the GG-2 Major Plant shutdown, this strategy
is to prevent series of shutdowns.
• However, the commissioning of this compressor was
delayed by several days due to other planned shutdown
activities which resulted in additional standby cost for the
Elliott Field Service Representative.
Appreciation
• ZWSC Maintenance Team
• ZWSC Production Team
• Logistics Division
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 Zakum Asset Business Unit: Accomplishment Bulletin
Major Overhaul of Three Elliott Gas Compressors at ZWSC (MZ-293)
Accomplishment Category Production Cost X Scheme Execution Completion

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©2014 ADMA-OPCO. All rights reserved. Publication: ZKABU-4/August-2014 Page 1 of 1