The two vertical process gas compressors had a range of issues, 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.
The two compressors were operated in parallel without any standby compressors as a back-up.
The analysis showed that the cylinder liner was damaged due to inappropriate piston ring material.
Burckhardt Compression’s solution included upgrading the piston/packing rings to Persisto 850, a material that has been 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 centre.
The solution achieved energy savings by avoiding internal losses, and reduced emissions. 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 team on hand for 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.”