EXPLORATION • DRILLING • FIELD SERVICES
MAINTENANCE R
COMPRESSOR
eciprocating gas compressors are used in many applications and their operators demand excellent
reliability. Unscheduled downtime can have significant financial costs for the business and operators should therefore employ a proactive maintenance regime. At the same time, sustainability is an increasingly pressing issue. To that end, fugitive emissions
from gas compressors represent a significant issue for operators. While leaks will not necessarily result in immediate problems or incur unplanned downtime, they might, and so should be addressed at the earliest opportunity.
CURRENT PRACTICE Although gas leakage will not cause an immediate halt to the process, it tends to worsen over time and can cause other issues, such as a rise in operating temperature. The key to the most effective
solution is to look at the complete sealing system holistically. During the compression process,
the majority of leakage occurs at the piston rod packing, and this should be the primary concern for the operator. Tackling this issue and implementing a proactive maintenance program will not only ensure compliance with local environmental legislation, but deliver a more reliable compressor that costs less to run. The integrity of these seals is
determined by several factors including the ring design, material and the surface finish of the piston rod. For reciprocating compressors, increased wear rates and therefore seal leakage can be identified using measurement of gas leakage flow, or by identifying a change in the leaking gas temperature.
MODELLING THE SOLUTIONS Currently, it is very difficult to obtain accurate data on gas leakage and to precisely predict the improvements
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www.engineerlive.com Careful inspection of compressor components is essential for identifying leaks
that might be achieved by replacement parts based on modelling alone. But it is possible to demonstrate reduced leakage and improved reliability using real-world examples, and this is where Burckhardt Compression is leading the field. In one situation, a dry-running
compressor working with 90% hydrogen and 10% methane exhibited a very high leakage rate. Burckhardt Compression suggested a proprietary solution that included a set of multi- piece rings made from Persisto 850, which had been developed by the manufacturer’s in-house team of experts. This enabled the packing to significantly reduce gas leakage and achieve a minimum lifetime of 8,000 hours. Typically, when looking for
technical support, the first port of call is the OEM and responses can vary depending on the age of the compressor and the ability of the manufacturer to deliver local support. Burckhardt Compression not only has decades of experience in working with compressors alongside numerous OEMs but can also provide in-person assistance and live, one-to-one support using advanced equipment.
DATA IS KING As with any key equipment, process data from compressors is essential to establishing important operating characteristics. However, the amount of information available fluctuates wildly, depending on the operator. The solution for situations where a
minimal amount of data is available, is to temporarily install additional sensors and data recording equipment as part of the performance analysis to enable the current operating conditions to be established.
FUTURE CONSIDERATIONS As national governments increase their focus on sustainability, operators may soon be required to provide evidence of the measures they are implementing to reduce emissions. As discussed, data is essential, and the ability to highlight improvements and demonstrate increased efficiency will be what provides them with a competitive advantage.
For further information please visit:
www.burckhardtcompression.com
Tips on how to reduce compressor system downtime
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