Gas Compressor Challenges: Inappropriate Materials and Designs
A global chemicals company operating two vertical process gas compressors faced significant challenges including high leakages, reduced gas flow, temperature issues, and a short wear lifetime of parts. These problems led to frequent compressor shutdowns and wasteful energy consumption. A system integrity analysis by Burckhardt Compression identified inappropriate materials and designs as the root cause of all problems.
The two compressors were operated in parallel without any standby compressors as a backup. The company was experiencing unexpected compressor shutdowns, decreasing output, high maintenance costs, challenging dry-running applications, high leakages, reduced gas flow, and temperature issues. Burckhardt's team of experts conducted a complete compressor system integrity analysis on-site, which showed that the cylinder liner was damaged due to inappropriate piston ring material.
The solution included upgrading the piston/packing rings to Persisto 850, a material that has been specially developed for sealing applications in dry-running reciprocating compressors. The piston rod was repaired, applying proper coating material and roughness, and all other components were refurbished at Burckhardt Compression's local service center.
As a result of the solution provided by Burckhardt Compression, energy savings were achieved by avoiding internal losses, and emissions were reduced. Internal leakage was eliminated and nominal gas flow was restored. There was a substantial increase in wear parts' lifetime and a reduction in maintenance costs. Burkhardt Compression also had a local expert team on hand for immediate support.
The customer said, "We were struggling with the short lifetimes of the piston rod seals and packing rings. Burckhardt Compression's solution with the right selection of material helped us to increase compressor availability significantly. Thanks to their analysis, we now better understand the component failure modes. Our second compressor, which was plagued by the same issues, is now being revamped by Burckhardt Compression too."
Burckhardt Compression's customized solution was able to optimize the chemical company's energy efficiency, reduce emissions, and increase its profitability.
Claudia Pröger is the Global Marketing Manager at Burckhardt Compression.
Burckhardt Compression is a market leader for reciprocating compressor systems and the only manufacturer and service provider that covers a full range of reciprocating compressor technologies and services. Its customized compressor systems are used in the gas gathering & processing, gas transport & storage, refinery, chemical, petrochemical as well as in the industrial gas & hydrogen mobility & energy sectors. For further information please visit www.burckhardtcompression.com.
