Burckhardt Compression Holding Ag · SIX:BCHN
Burckhardt Compression — Technical Presentation (April 2021)
21 slides from Burckhardt Compression's technical presentation, Apr 15, 2021
Slide 1: Operation and Mechanical Reliability of Hyper Compressors on LDPE Plants
OPERATION AND MECHANICAL RELIABILITY OF HYPER COMPRESSORS ON LDPE PLANTS Winterthur, April 15th 2021 Heinz Meier / Bob Armstrong / Joaquin Flores - ECI Group Manchester, UK Baton Rouge, USA © Burckhardt Compression: Do not copy or distribute without permission.
Slide 2: Motivation: Reliability on LDPE Plant
Motivation: Reliability on LDPE Plant Key features ensuring proper reliability Operations (ECI Group) Design & Maintenance (BCAG) Typical hours of operation Mechanical design What can go wrong and Mechanical reliability reduce the hours ? Proper installation – Operating conditions Lu
Slide 3: Operational Reliability: Typical Hours of Operation
Operational Reliability Typical hours of operation of Hyper components in homopolymer operation Packing or piston rings 16,000 – 24,000 Valves – 16,000 – 24,000 Plungers – 16,000 – 24,000 Main cross-heads – 60,000 – 80,000 Crankpin bearings – 60,000 – 80,000 Main bearings – 60,000 – 80
Slide 4: Operating Process Conditions
Operational Reliability What can go wrong and reduce the hours of operations? 1. Operating process conditions Recommended maximum temperatures 1st stage discharge 2nd stage discharge Homopolymer < 90 C < 85 C Low EVA’s < 85 C < 80 C High EVA’s < 80 C < 75 C High reactive co- < 75 C < 70 C monomers
Slide 5: Presence of Liquids
Operational Reliability What can go wrong and reduce the hours of operations? 2. Presence of liquids Reciprocating compressors are sensitive to any liquid (including droplets). Liquids are incompressible – Small liquid amounts may break valve components – Droplets can also form on cylinder walls
Slide 6: Lubrication
Operational Reliability What can go wrong and reduce the hours of operations? 3. Lubrication Follow OEM recommendations for your compressor Ensure they fully understand the chemical matter and composition of your gas stream. – HP Copolymers requires higher flows and added antioxidant package T
Slide 7: Cylinder Lubricant Functions and Types
Operational Reliability What can go wrong and reduce the hours of operations? Primary functions – Lubricate – Gas-tight seal – Source of Antioxidants to prevent from polymerization – Cool – Right lubrication viscosity Type of cylinder lube oil – Polyalkylene Glycol (PAG) – only for Homopolymer u
Slide 8: Packing Seal Leak Gas Lubricant
Operational Reliability What can go wrong and reduce the hours of operations? Packing seal leak gas lubricant – Packing leak gas flow should be monitored, preferably from each cylinder. High leak gas flow will «wash out» the lubrication oil resulting loss of lubrication and plunger failure. © Burc
Slide 9: Plungers
Operational Reliability What can go wrong and reduce the hours of operations? 4. Plungers A major HP PE operational risk is failure of a plunger, resulting in catastrophic releases of ethylene Plungers are currently made of Tungsten Carbide to improve reliability due to wear (~ 90% TC in ~ 10 %
Slide 10: Compressor Monitoring
Operational Reliability What can go wrong and reduce the hours of operations? 5. Compressor monitoring Do frequent field inspections. Check visually and be alert for unusual vibrations or noise. Always believe vibration and run out sensors. – Safety critical – Frame vibration – protect machine f
Slide 11: Design Versus the Bad Actors on Your Compressor
Design Versus the Bad Actors on Your Compressor Cylinder Valve HP-packing LP-packing Cylinder lubricant © Burckhardt Compression: Do not copy or distribute without permission. Reliability of Hyper Compressor April 15, 2021 Page 11
Slide 12: Mechanical Reliability
Mechanical Reliability © Burckhardt Compression: Do not copy or distribute without permission. Reliability of Hyper Compressor April 15, 2021 Page 12
Slide 13: Mechanical Reliability
Mechanical Reliability Variation in design and material Storage and preparation of packing & plunger © Burckhardt Compression: Do not copy or distribute without permission. Reliability of Hyper Compressor April 15, 2021 Page 13
Slide 14: Advanced Part Treatment in Service Shops
Advanced Part Treatment in Service Shops Surface treatment Material selection Design © Burckhardt Compression: Do not copy or distribute without permission. Reliability of Hyper Compressor April 15, 2021 Page 14
Slide 15: Background Data: Bad Influencers of Your Compressor
Background Data: What Are the Bad Influencers of Your Compressor Sealing system Gas composition Lubricant Temperature © Burckhardt Compression: Do not copy or distribute without permission. Reliability of Hyper Compressor April 15, 2021 Page 15
Slide 16: Advanced High Pressure Cylinder Monitoring
Advanced High Pressure Cylinder Monitoring © Burckhardt Compression: Do not copy or distribute without permission. Reliability of Hyper Compressor April 15, 2021 Page 16
Slide 17: Advanced High Pressure Cylinder Monitoring
Advanced High Pressure Cylinder Monitoring © Burckhardt Compression: Do not copy or distribute without permission. Reliability of Hyper Compressor April 15, 2021 Page 17
Slide 18: Cylinder Lubricant: A Life-Time Factor
Cylinder Lubricant: A Life-Time Factor Flow-control to individual lube- point Inlet with adapter Support Flowmeter Fixation of support Collector © Burckhardt Compression: Do not copy or distribute without permission. Reliability of Hyper Compressor April 15, 2021 Page 18
Slide 19: Discipline
Discipline Start up and pressure increase Quality of lubricant Pipe-alignment Grade-change Homopolymer vs EVA © Burckhardt Compression: Do not copy or distribute without permission. Reliability of Hyper Compressor April 15, 2021 Page 19
Slide 20: Summary
Summary 1. Compressor reliability is one of the top reasons for loss of online time. 2. Best performance requires attention to many details from design through daily operations. 3. Monitoring and control systems must be understood & have appropriate responses. 4. Process changes can require a change
Slide 21: © Burckhardt Compression: Do not copy or distribute without permission. Reliability of Hyper Compressor
© Burckhardt Compression: Do not copy or distribute without permission. Reliability of Hyper Compressor April 15, 2021 Page 21
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