Areas Where Vacuum Sandblasting is Required

• Areas where vacuum sandblasting is required without disruption to other processes.
• Where environmental contamination cannot be prevented and sealed sandblasting cannot be provided with conventional sandblasting methods.
• Sandblasting of interior components of sensitive equipment.
• Unexpected situations which require fast mobilization.
• Sandblasting in areas where access is difficult or limited.

Application Areas of Dust Free Vacuum Sandblasting 

• Surface preparation for paint or surface cleaning of steel profiles and plates 
• Interior and exterior surface cleaning and de-rusting of process equipment
• Cleaning of surface and interior components of valve assemblies

With its almost 30 years of experience Teknokon provides a whole range of integrated services for industrial storage tanks.
Storage tanks which are needed to store raw materials, intermediate products, auxiliary products or final products in industrial plants are among critical components of the processes in which they are used. 

Storage tanks are also among the equipment with the highest risk for process safety.  Safe storage of hazardous liquid or gasses in line with the relevant processes in many industries is very important not only for the plant where they are stored but also for the general safety of the entire area of the plant.

Safe storage is an integral part of process safety and also an indispensable part of the chain for plant production performance and plant availability. Storage units which frequently fail to function can cause partial or whole disruption in the process where storage units are used in depending on the conditions.
According to another perspective on costs and storage, storage needs to be considered as a form of area rental.  On each day, storage units are not used, there will be no rental income.

In addition to correct design and assembly, regular and correct inspection and maintenance during life time of a storage unit are required in order to ensure a reliable and high performance.
 
Teknokon Servis ve Bakım provides integrated services that cover all life cycles of storage tanks
 

Life Cycle and Technical Activities of Industrial Storage Tanks

Design and Engineering of Storage Tanks and Pressure Vessels

Manufacturing in the Plant and On-Site Assembly

With the challenges in transportation of storage tanks due to their dimensions, there are two options to choose from: tanks are manufactured and assembled in the plant and then transported to the site or components of tanks are manufactured in the plant and assembled on-site.
Teknokon manufactures storage tanks in its plant in Dilovası Kocaeli. Storage units are manufactured and certified according to demands or project requirements and in compliance with the Asme National Board, Din-En Iso 3834-2, Ad 2000–Merkblatt Hp0 And Ped 2014/68/Eu​standards.
 

Inside Cleaning and Removal of Hazardous Materials:

Storage tanks should be cleaned and any remaining hazardous/explosive materials should be removed before technical control and maintenance services. This procedure which is critical for process and employee safety should be carried out by specialized teams and risks should be comprehensively analysed and eliminated.

Supervision and Inspection Services:

Teknokon’s main services for storage tanks are production, assembly and maintenance therefore supervision and inspection services need to be provided by third parties.

Teknokon Servis ve Bakım works with globally reliable business partners to off service integration for storage tanks.

Technical inspections of a storage tank which should start from the first day the storage tank is used should be regularly performed and reported depending on the importance of the storage tank. Reliability of this procedure plays an important role in correct planning and implementing the next process; maintenance activities.  Technical inspections with correct methods and performed by experienced experts ensure that maintenance activities are also as reliable as technical inspections.

Storage Tanks Maintenance and Repair Services:

 
A combination of many factors such as design problems, environmental factors and operational conditions can cause tanks to be subject to more intense processing. Maintenance should be carried out in accordance with the quality criteria specified in the standards in order to ensure reliable and smooth operation for the duration of periodic inspections.
 
Other important factors in performing maintenance activities are correct business planning and efficient resource management. Performing maintenance procedures within planned periods and preventing unplanned delays will contribute to reduce maintenance and operational costs. 
 
Maintenance services provided by Teknokon Servis ve Bakım are listed below:
 

• Replacement of tank bottom plates

• Replacement of shell plating of tank walls

• Revision and repair of tank piping systems

• Revision and repair of tank covers

• Repair of faulty welding areas

• Painting and coating

• Revision and repair of tank nozzles and manholes

• Revision and repair of platforms, walkways, ladders and stairs on tanks

• Raised face flanges
• Ring type joints
• O ring grooves
• Exchanger Body Flanges, cylinder bundle front and back flange surfaces
• Metal to Metal flange surface joints (high precision)
• Manhole connections
• Reactor Flange-Cap connections
• Flange surfaces of equipment used in special processes

Causes of Flange Leakage:

Problems Caused by Tensioning and Torquing

Problems Caused by Misalignment of Flanges

Problems Caused by Improper Gaskets

Problems Caused By Defects on Flange Surfaces  

Problems Caused by Thermal Stress

Problems Caused by Too Much Vibration

Errors in Design

• Disassembling of heat exchangers
• Cleaning
• Visual inspections and NDTs
• Mapping of tube bundles (using advanced non destructive testing techniques)
• Manufacturing and assembling of worn parts
• Heat exchangers retubing
• Hydrostatic tests
• Turning off and torquing of the equipment (Tightness Checks)

• Shell and Tube Type heat exchangers
• Plate heat exchangers
• Air coolers
• Condensers

Planning and Management Models of Maintenance Resources 

1- In-House Maintenance

All maintenance activities are performed by the company itself and under its own responsibility. This includes strategic planning, management tasks and operational activities.

2- Own Teams and Many Contractors

The maintenance activities are performed as required by both the company’s own and external service providers. Strategic planning, management and coordination functions remain within the company.

3- Value Service Maintenance (Teknokon’s Offer)

The maintenance activities are performed as required by external service providers. Strategic planning, specialized services (if necessary/strategic), management and coordination functions remain within the company.
The value service provider, which performs the services with cooperation partners as required, can also provide advice on strategic planning.

4- Full-Service Maintenance

Management and coordination functions as well as the operational implementation of all maintenance functions are outsourced to a single service provider, which, if necessary, provides the services with cooperation partners and can exploit synergies. The full-service provider can also give advice on strategic planning.

Maintenance Outsource Management Models Comparison Tables

What is TMS?

What does TMS offer?

TMS Layers and Content

Each of the 12 sections of TMS consists of unique management concepts developed by Teknokon specialists and each management concept consists of sub elements including theoretical information and on site practices.


TMS has a dynamic structure; the system constantly evolves and grows based on the systematic review and update of data and experience from numerous projects.

What is TMS Maintenance Current State (GAP) Analysis?

                                               

What are the Outputs of TMS Maintenance Gap Analysis?

• Strengths and weaknesses of maintenance organizations are identified.
• Potential improvement areas and subjects are identified
• The level of organizations compared to examples that are up to the world standards are identified using international benchmarking techniques.
• Using the findings obtained with the analysis short, middle and long term development actions and techniques are determined and the development plan determined is implemented with the project management system.

Flash TMS-Gap analysis

Complete TMS Gap Analysis

TMS – TMS- Maturity Model

TMS- TMS- Maintenance Gap Analysis - Implementation Roadmap

Dr. Michel Duval who developed Duval Triangle which is a reliable method to interpret gas dissolved transformer oil analyses is one of the consultants in Laborolec.

Transformer insulating oil provides important data on the current condition and remaining economic life of a transformer. This data helps to prevent potential damages and to determine maintenance and/or replacement frequencies. By analysing transformer oil, you can have information about whether there is any electrical or thermal faults, about abrasion and wear in the transformer and the quality of oil used.

Transformer Insulating Oil Analyses;

(Analysis Type, Related Standard, Sample Amount)

Lubrication oil analyses, when done regularly provides information about the efficiency of equipment lubrication system and the degree of abrasive wear. This approach allows optimization of maintenance and oil change frequencies.

Analyses of Lubrication Oils, Fuels and Other Analyses:

(Analysis Type, Related Standard, Sample Amount)

Fast and reliable repair of malfunctions in piping systems and main equipment is critical. Identifying the causes of these malfunctions is very important in preventing repeating of such malfunctions.

PMI (Positive Material Identification) method allows identification of chemical structure of materials with almost 100% accuracy. With our portable devices we perform analysis without taking samples from systems and equipment.

PMI Areas of Application 

• Inspection of Input Materials
• Inspection of sheet materials in pipes and plates
• Inspection of fillings in weld ring gaskets
• Inspection of material compliance in damaged or malfunctioning systems

Thermal analysis which has become more important among predictive maintenance methods stands out with many of its advantages including its wide areas of use, and its fast and reliable results. Data obtained about the changes in thermal values that are beyond visible for many equipment and many areas of use allows significant improvement in periodic and planned maintenance methods.

Main Areas of Use for Thermography (Thermal Analysis) Method

Mechanical Applications

Rotating Equipment and Motors: Detection of overheating bearings in pumps, compressors, fans, conveyors and turbines

Process Valves: Leak detection

Storage Tanks: Determination of sediment and waste amount, detection of leaks

Boilers and Ovens: Detection of overheated areas

Insulation Faults: Detection of leaks and faults in insulated pipelines and systems; detection of insufficient insulation

Electrical Applications

• Power sources
• Switchyards
• Transformers
• Fuses
• Motor Control Centers (MCC)
• Power distribution boards

Thermography / Thermal Inspection 
The scope and applications of our thermography programs customized and developed by our team of experts in thermography for each plant are as following:

• Inspection of plant assets and identification of the assets that will be thermally inspected
• Determining thermal values at normal operating conditions of the equipment and systems to be inspected by thermography and determining equipment thermal inspection ranges according to the level of importance
• Developing a barcode system for the lines and systems for fast and accurate observation.
• Inspection with high definition and thermally sensitive thermal cameras
• Reporting including expert opinions
• Entering and tracking measured values for equipment and systems in the asset management system
• Long term improvement of periodic maintenance activities based on the thermographic inspection values and trends

Other Services for Combustion Units and Waste Gas Emissions
 

Combustion Efficiency:  Monitoring and correction of combustion dynamics and anomalies; control of solid fuel optimization

Waste Analysis:  Slag formation, pollution and corrosion problems

Reducing Emission Values: Condition monitoring, inspection and reporting, consultancy and solution suggestions.

Air Intake and Filtering Systems: Consultancy for equipment selection and problems
 

Measurement of Process Parameters: Air - fuel ratios

Computational Fluid Dynamics (CFD): Modelling of combustion chambers and air intake units.

Root Cause Analyses: Finding root causes of problems.

Support and Consultancy About Combustion and Emission Equipment
 

SCR deNOX Catalyser: Catalyser tests, spare parts planning

Air Filters: Maintenance, planning and suggestions

Combustion Chambers:  Determining remaining economic life

Teknokon Service & Maintenance  through its collaboration with Laborolec, provides turnkey chemical cleaning services for boilers and boiler systems. In addition to complete set of solutions, consultancy services for chemical cleaning processes are also provided.

Chemical Cleaning Services 

• Metallurgical inspections of the systems which will be chemically cleaned to select the right chemical cleaning method and develop cleaning procedures before chemical cleaning
• Technical control on the field during chemical cleaning
• Material inspection and measurement of cleaning efficiency after chemical cleaning

Technical consultancy services offered with the collaboration of Teknokon Service & Maintenance and Laborolec, cover all components of a power plant.

The company provides a wide range of technical consultancy services starting from the design stage of power plants to control of design parameters, engineering in changing operating conditions, re-design requirements throughout the life cycle of the power plants.

Main technical consultancy services are listed below:

• Retroactive installation
• Engineering and design services to increase or decrease capacity
• Design and engineering consultancy

​
When your critical equipment does not operate at required parameters or when same malfunctions /faults recur and cannot be solved, root causes for the problems need to be found and the factors leading to these root causes should be eliminated.

Teknokon Service & Maintenance, through its collaboration with Laborolec offers root cause analysis for all faults and flaws that can occur in all important systems of power plants.

Experienced Based Standard Methodology and Multidisciplinary Expertise 

We efficiently analyse root causes of flaws and faults with a comprehensive perspective based on our standard methodology and multidisciplinary expertise.

Comprehensive laboratory services of Laborolec include all advanced identification tools required for comprehensive root cause analysis.

Through the collaboration between Laborolec and Teknokon Service & Maintenance, we assess and determine remaining economic lives of steam production and heat recovery boilers which are critical for your plant independent of the manufacturer and model.

Key components and elements of a boiler are inspected separately to analyze the current condition of the boiler.  Furthermore, key components of the boiler are used to estimate remaining economic life and critical data such as actions required to operate the boiler with optimum values and long term experience plans is provided.

We provide services based on our vast knowledge and expertise for the entire life cycles of heat recovery steam generators and boilers which play a major role in energy production and recovery.

With the collaboration we have with Laborolec which is an R&D and consultancy company with an experience of over 50 years in power plants, we provide services including downtime inspection which should be done before and during an downtime, maintenance planning services and downtime services.

Our Turnkey Services for HRSG and Boilers

• Mid and Long Term Maintenance and Inspection Plans
• Inspection Services
• Downtime Planning and Management
• Purchasing Management
• Manpower for Downrime
• Scaffolding Services

​Equipment should be regularly calibrated to ensure that a plant operates at required operating parameters and systems are controlled and checked correctly. We provide on-site or off-site calibration services starting from the planning stage.

Maintenance of rotating process equipment which is critical for all industries is a comprehensive process that requires experience. Teknokon Servis ve Bakım provides a wide range of services including installation, predictive maintenance, periodic proactive maintenance and root cause analysis for malfunction and faults for all brands and models.

Equipment to Which We Provide Our Services

• Pumps
• Gas Turbines
• Steam Turbines
• Generators
• Fans
• Turbo Compressors
• Gearboxes and Reducers

Our Rotating Equipment Services
We, through our experienced maintenance experts, customize our rotating equipment services according to your requirements and work strategies. Depending on the request, we provide all maintenance of rotating equipment in all stages or provide expertise and labour support to your company’s maintenance teams.
 

• Installation and commissioning
• Periodic and routine maintenance
• Precision equipment adjustments
• On-site balancing services
• Damage and malfunction root cause analyses
• Vibration analyses
• Oil analyses
• Boroscope Services

We enter in our asset management program all important data such as all maintenance performed on your rotating equipment, damages and malfunctions on your equipment, spare part requirements, periodic maintenance times to manage all your maintenance processes with an updated and long term approach.

​
For scaffolding services, Teknokon Service & Maintenance leverages from the sources and experience of Teknopur which is a Teknokon group company. With our comprehensive stock of scaffolds and experienced scaffolding teams we provide services in a wide range of areas:

• Plant downtime scaffolding services
• Long term scaffolding services
• Emergency scaffolding services

Our Turnkey Scaffolding services covers all process stages.

• Supply and rental of scaffold materials
• Identifying the need for scaffold materials and consultancy after on-site inspection
• Developing projects to erect scaffolds; static calculations for scaffolds
• Skilled labour to erect and dismantle scaffolds

For equipment production and maintenance, Teknokon Service & Maintenance  leverages from the sources and experience of Teknokon Makina A.Ş. which is a Teknokon group company.  We manufacture a wide range of equipment in our process equipment factory with 10,000 m2 indoors area in Dilovası, Kocaeli, Turkey.

• Pressurized tanks
• Storage tanks and silos
• Reactors and mixer tanks
• Tubular heat exchangers
• Special purpose process equipment
• Modular skids
• Piping parts

We manage many of the processes in equipment manufacturing successfully with our team of experts and the advanced technology we use in Teknokon Service & Maintenance .

• Mechanical design of equipment
• Materials supply, purchasing management
• Manufacturing of equipment
• Project Management
• Transportation

Certifications

• ASME -S, ASME-U, ASME-R
• PED 97-23
• AD 2000
• Merkblatt HP O
• EN ISO 3834-2

​
With its 28 years of experience and knowledge, Teknokon provides services at high safety and quality standards for projects planned for industrial plants.

Our contracted services for industrial plants

• Projects to increase plant capacity
• Revision projects
• Projects for plant relocations

Our Turnkey solutions

• Detail project works (construction, steel structures, buildings, foundations, equipment, pipelines)
• Purchasing management
• Construction and infrastructure work
• Heavy equipment lifting and installation
• Piping
• Insulation work
• Electrical works and instrumentation
• Commissioning

With our team of experts and organized service structure of Teknokon Servis & Bakım, we shorten shutdown and complete all activities related with shutdown according to the planned schedule with maximum efficiency without compromising on quality.

Our Services For Plant Shutdown Process

• Planning
• Spare Parts Management
• Design and detailed engineering
• Inspection services
• Manpower supply
• Valve Maintenance services (mobile valve maintenance container)
• Scaffolding services

Our Mobile Maintenance Workshop

We provide support for your shutdown operations with our fully equipped mobile maintenance workshop placed in a large ISO container, which carries out an independent task in each shutdown process. There are valve maintenance equipment, a modern valve testing device (400 bars capacity), overhead crane, a turning machine, a shot chamber, workbenches, production etc. equipment in our mobile workshop. Our expert team works closely with the management units of our customers and provides support in all stages of the shutdown process starting from the planning stage. We assume the responsibility of the entire plant or part of the systems and departments during an shutdown depending on our customer’s strategy.

Multidisciplinary Structure and Management from a Single Center

We provide all work and activities necessary during an shutdown from a single center at the highest Teknokon quality and without using external sources, such as mechanical design, detailed engineering, process equipment manufacturing, turnkey scaffolding services, insulation, customized welding which have been developed over 25 years by Teknokon Grup companies. Thus we can guarantee the quality of the services we provide and we also provide a dynamic and easily manageable structure whereby all services are supplied to customers from one center.

​Industrial cleaning plays a major role in the hygiene, life cycles of equipment and systems which are all very important for the products produced with these systems and equipment and for the plant assets.

Teknokon Service & Maintenance provides a wide range of services, from routine cleaning to specialise industrial cleaning that requires expertise.

Our Industrial Cleaning Operations

• Removal of grease and hydrocarbons
• Hydro jet cleaning
• Dry ice cleaning (cleaning with the cryogenic method)
• Chemical cleaning with acids

Our mobile teams visit our customers’ facilities with fully equipped service vehicles and provide periodic and routine maintenance on equipment according to their maintenance schedule.

Thus we take over routine and time-consuming maintenance work from our customers’ own teams and allow our customers to increase efficiency in their human resources structure and focus human resources on projects about improvement of their organizations.

To develop and plan periodic maintenance processes of equipment and systems in a plant,  we combine operational experience of the plant and experience of Teknokon Service & Maintenance experts to determine optimum methods.

We plan, manage and provide reporting for all identified maintenance processes using our asset and maintenance management program (IBM Maximo™) .

Regular maintenance and inspection of valves which are one of the key components of industrial plants is critical to ensure process safety and system reliability. Teknokon Servis ve Bakım provides advanced services which includes maintenance and inspection of industrial valves of all brands and types.
 

Our Mobile Valve Maintenance Workshop

We mobilize and activate our mobile valve workshop equipped with all devices and tools necessary for the maintenance and testing of all types and brands of valves at your plant and perform fast and reliable on-site maintenance of your valves.

Our Comprehensive Valve Maintenance Service

• Valve malfunction inspections (using ultrasonic or thermal analysis methods)
• Installation of valves using systems
• Valve Maintenance
• Spare Parts Management; stock keeping, spare parts supply, spare parts production
• Valve pressure tests (Hydraulic and Pneumatic Valve Pressure Tests)
• Re-certification of valves
• Sandblasting and painting of exterior surfaces of valves
• Re-installation of valves in the systems
• Control of commissioned valves while they are still operating
• Quality management and reporting

Manual and Automatic Valve Maintenance 

Maintenance of all valves with all types and brands of connection, bodies and bearings

Body type: Gate valves, Globe valves, Butterfly valves

Connection Type: Welded valves, threaded valves, flange valves

Bearing Type: Flat bearing, conical bearing

Process Type: Steam valves, water line valves, oil products and natural gas valves, pneumatic valves, cryogenic valves etc.

Safety Valve Maintenance

Maintenance of all types and brands of safety valves

• Valve sealing maintenance
• Calibration of safety valves, pressure regulations

Valve Pressure Tests

We perform fast and reliable tests on a wide variety of valves with our high capacity valve testing device. We provide the following tests and analysis with our valve test device on all types and brands of valves:

• Hydrostatic testing up to 400 bar hydrostatics and valve body and bearing testing (at any size) up to 200 bar
• Certification in accordance with the standards DIN, API and ASME

Reporting

Maintenance reports are provided for each valve involved maintenance process in accordance with the standards ASME, DIN and API depending on the area of use of the valve. Our reports include pre- and post-maintenance images of the valve, work done during maintenance and comments on the condition of the valve.