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A Second Life for Reciprocating Compressors Compressor Upgrade and Revamp Index

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A Second Life for Reciprocating Compressors Compressor Upgrade and Revamp Index A second life for reciprocating compressors Compressor upgrade and revamp Index HOERBIGER upgrade and revamp dated compressors in ways that are tailored to the existing and future requirements in your industry. This increases the efficiency, reliability and environmental soundness of your compression system. Simply select the application most appropriate for your industry and we will provide more information to allow you to see the benefit of our services for yourself. Nr Industry Gas Compressor Country Short Description 1 Refinery N2 Nuovo Pignone Germany Manufacture cylinder and install reconditioned compressor 2 Refinery H2 Dresser-Rand Germany Increase capacity and install HydroCOM and RecipCOM 3 Refinery H2 Borsig Hungary Increase capacity 4 Chemical Plant Air Halberg Germany Engineer and manufacture crankcase 5 Refinery Natural gas Borsig UAE Engineer and manufacture crankcase and cylinder 6 Refinery CO2 Nuovo Pignone UK Old cylinder cracked: new cylinder designed / manufactured / installed 7 Chemical Plant H2, N2, Dujardin & France Engineer and manufacture piston and rod CO, CH4 Clark 8 Chemical Plant C2H4 Nuovo Pignone France Upgrade control to HydroCOM 9 Technical Gases N2 Burckhardt Switzer- Solve bearing problems: new crosshead Plant land 10 Natural Gas Plant Natural gas Borsig Germany Convert to new operating/process conditions 11 Refinery H2, CH4 Worthington Italy Install reconditioned compressor 12 Refinery H2 MB Halberstadt Germany Cylinder corrosion problems: new cylinder designed / manufactured / installed 13 Natural Gas Plant C3H8 KOHO Russia Convert to new operating / process conditions 14 Technical Gases O2 Linde Norway Install reconditioned compressor Plant 15 Chemical Plant C2H4 Ingersoll Rand Serbia Reliability and troubleshooting project, pulsation / vibration reduction 16 Refinery H2 MB Halberstadt Germany Extend lifetime of compressor by full overhaul and service, including foundation 17 Natural Gas Plant Natural gas RUMO Romania Reduce emissions 18 Chemical Plant Propylene Linde Norway Upgrade compressor control to HydroCOM 19 Refinery H2 Dresser-Rand UK Convert compressor for new process conditions with in- creased capacity 20 Chemical Plant CO2, NH3 Atlas Copco France Upgrade crosshead guide and overhaul compressor Crepelle 21 Natural Gas Plant Natural gas Ingersoll Rand Hungary Convert compressor from engine to electric drive 22 Natural Gas Plant Natural gas MB Halberstadt Hungary Convert compressor for new process conditions and upgrade to HydroCOM control 23 Technical Gases H2 LMF Germany Upgrade capacity control system Plant 24 Technical Gases H2 Dresser-Rand USA Convert compressor for new process conditions Plant 25 Chemical Plant H2 MB Halberstadt Russia Repair heavy crankcase damage Upgrade and Revamp - 1 Manufacture cylinder and install reconditioned compressor A refinery wanted to rebuild a poorly-running compressor using parts from another manufacturer. Compressor manufacturer: BORSIG / NUOVO PIGNONE Type BX 40/ 2HB-2 Gas N2 Power 275 kW (374 hp) Suction pressure 1.5 bar (22 psi) Speed 600 rpm Discharge pressure 6.5 bar (94 psi) Lubrication yes Customer requirements Replace NP frame with 205 mm stroke by a Borsig frame with 200 mm stroke Nuovo Pignone cylinder Adapt existing NP cylinders to the Borsig frame Check and adapt throughput from compressor Increase efficiency through optimisation of the gas flow Solution applied Upgrade to HOERBIGER CP valves and new liner with full-size valve ports Design modified pistons for the new stroke length, with improved flow geometry and clearance Redesign piston rods with new diameter, combined with new Superbolt Adaption of cylinder and drive crosshead connection adapted to original Borsig crosshead Deliver re-engineered cylinder liners Install HOERBIGER cylinder rings, pressure packing and oil wiper packing Assemble and install all new parts on site New electric motor, coupling, flywheel and guard to suit Borsig frame Project management and documentation Results CP profiled plate valve Compressor has run safely since 2008 with the Borsig frame Energy consumption reduced by 10% for the same flow Pressure peaks have been reduced Borsig compressor rebuild with reconditioned cylinder Project Execution by: HOERBIGER Service GmbH Walsrode, Germany Upgrade and Revamp - 2 Increase capacity and install HydroCOM and RecipCOM A refinery in Germany required more hydrogen for the desulphurisation process. Compressor manufacturer: DRESSER-RAND Type BDCB 12 Gas H2 mix Power 1,080 kW (1468 hp) Suction pressure 22 bar (319 psi) Speed 371 rpm Discharge pressure 47 bar (681 psi) Lubrication no Customer requirements One of the three hydrogen compressors Increase the throughput of the three single-stage compressors by 9.1–9.8 t/h to meet an increased need for hydrogen for desulfurization Solution applied Compressor audit and simulation Evaluation of possible capacity increase Capacity increase achieved by combining slightly bigger cylinder diameter with reduced clearance volume Pulsation calculation Pulsation calculation New HOERBIGER valves and piston rings Installation of HydroCOM system for continuous control Change pistons from a single-piece to a two-piece design Documentation and CE marking Results Economical investment compared to six new cylinders Capacity increased by 8% Fast and accurate control has improved operability of the hydrogenation process New dummy valves for reduced and extended the catalyst lifetime clearance New FEA-optimised pistons Project Execution by: HOERBIGER Service GmbH Walsrode, Germany Upgrade and Revamp - 3 Increase capacity A Hungarian refinery needed to increase both the quantity and pressure of the hydrogen supplied to its oil and wax hydro- finishing unit. Compressor manufacturer: BORSIG Type PK 3-4 Gas H2 Power 160 kW (218 hp) Suction pressure 25 bar (363 psi) Speed 590 rpm Discharge pressure 45 bar (653 psi) Lubrication yes Facts in Brief New process requirements in the lube oil and wax hydro-finishing unit required Installation drawing substantial compressor modifications: Capacity increase from 4,500 Nm3/h to 6,000 Nm3/h Discharge pressure increase from 40 bar to 45 bar Customer requirements Cost-effective solution to meet a budget cap Compressor modification conforming to API 618 Reduction of vibration level Solution applied Capacity increased by enlarging cylinder and piston diameter Pulsation calculation New coating on cylinder running surface New electric motor, coupling, gearbox, other compressor parts and auxiliary equipment New pulsation dampers Assembly and commissioning Calculation of the capacity and the required power Preparation of a risk analysis including recommendations for safe and reliable operation Verification of rod load and strength for higher pressures Check of pulsation level at new higher capacity and design new pulsation Compressor upgraded damper Preparation of documentation Results Hydrogen capacity and pressure meet new requirements Vibration level reduced Compressor operating successfully since 2008 Project Execution by: HOERBIGER Service Hungaria Kft. Dunakeszi, Hungaria Upgrade and Revamp - 4 Engineer and manufacture crankcase A chemical plant in Germany used a 30-year-old three-stage compressor to provide air for the oxidation of cyclohexane. Repeated cracking of the frame affected production availability. Compressor manufacturer: HALBERG Type 4C 2.8/8 11/200 Gas air Power 1.000 kW (1360 hp) Suction pressure 11/34 bar (160/493 psi) Speed 485 rpm Discharge pressure 34/82 bar (493/1190 psi) Lubrication yes Facts in Brief Manufacturer delivered in 1976 and 2nd version in 1978. Original compressor with I-beam Repairs over the years included welding of cracks and, in 2008, realignment by cylinder support and additional steel a third party using epoxy grout structure A similar crack in 2010 was repaired by the end user High vibration levels were reduced by adding massive external supports between the cylinders of stages 3 and 4 Customer requirements A new reliable crankcase with reduced vibration Solution applied Peak-hold vibration spectra Vibration measurement Compressor, fracture and foundation force analysis Used FEM to engineer new crankcase with high safety margin, better fixing to foundation and reduced vibration Fabricated new crankcase Installed rebuilt compressor on new foundation with A-type cylinder supports HOERBIGER rings, packing cases and oil wiper Commissioned compressor and checked vibration Results 3D designed and FEA optimised welded Compressor is running well with new HOERBIGER frame frame Reduced gas emission thanks to HOERBIGER BCD packing Stronger design means improved durability Improved frame and better attachment to foundation reduced vibration New strengthened crankcase and A-type cylinder supports Project Execution by: HOERBIGER BENELUX BV Heerlen, Netherlands Upgrade and Revamp - 5 Engineer and manufacture crankcase and cylinder A 700kW compressor used for natural gas suffered a catastrophic failure. The crankshaft, connecting rod and housing of the compressor were among the parts that were severely damaged. Compressor manufacturer: BORSIG Type BX28-20/2S2 Gas NG Power 700 kW (952 hp) Suction pressure 1.8 bar (26 psi) Speed 375 rpm Discharge pressure 8.8 bar (128 psi) Lubrication yes Facts in Brief Cleaning the crankcase Failure of lubrication caused major damage to this natural gas compressor. The crankcase assembly, second-stage distance piece, liner and piston rod were all wrecked. The operating company
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