India, October 19, 2026: John Crane has enabled a major refinery in Bavaria, Germany, to restart operations on schedule by completing the refurbishment of two critical Type 28XP dry gas seals in just six weeks, compared to the typical 16–18 week turnaround. The expedited project helped the refinery avoid at least €1 million in production losses for each week of delay averted, according to the company.
The seals are integral to a compressor essential for the refinery unit’s operation. John Crane stated that its estimate of €1 million in weekly production at risk is conservative, referencing McKinsey & Company research that places reliability-related lost-profit opportunities for a mid-sized refinery at US$20 million to US$50 million annually.
Global coordination accelerates schedule
With the shutdown confirmed at short notice, the refinery required both tandem Type 28XP non-contacting dry gas seals to be inspected, repaired, dynamically tested, and returned within a six-week window. John Crane mobilised its global service and supply network, with its dry gas seal service centre in Japan prioritising the work, metal components produced in the Czech Republic, and specialist suppliers expediting delivery of seal faces.
Teams in Germany and Japan conducted weekly progress reviews with the refinery, tracking each stage and addressing schedule risks as they arose. Both seals were returned within the shutdown period, enabling the refinery to resume production as planned.
Significant reduction in lead time
The accelerated response reduced the standard refurbishment lead time by 10 to 12 weeks. Christian Naldini, Vice President, Europe at John Crane, said, “With at least €1 million in production at risk for every week of delay, there was no room for the refurbishment to overrun. By mobilising our teams and supply network across Germany, Japan and the Czech Republic, we completed in six weeks work that would typically take 16 to 18 weeks.”
The project was delivered through John Crane Performance Plus service solutions, designed to improve rotating-equipment reliability and address critical maintenance demands.
Industry context and implications
The example comes as the International Energy Agency forecasts that India’s oil demand will rise by about 1 million barrels per day between 2024 and 2030, the highest projected increase for any country. John Crane highlighted the case as an example of how efficient shutdown planning and maintenance execution can help refineries minimise downtime and protect production.
John Crane is a global provider of flow control technologies and operates as part of Smiths Group plc.
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