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COMPRESSOR COMPONENTS
HIGHEST AVAILABILITY OF YOUR EQUIPMENT
2 HYPER/SECONDARY COMPRESSOR COMPONENTS HYPER/SECONDARY COMPRESSOR COMPONENTS 3
TRUSTED SOLUTIONS
FROM THE LEADER IN HYPER TECHNOLOGY
SUPERIOR SOLUTIONS With decades of experience and our broad in-house The individual components being replaced or repaired
FOR EVERY PROCESS TECHNOLOGY MARKET APPLICATIONS expertise in Hyper/Secondary Compressor components need to be perfectly matched and their interaction with
we are ideally suited to provide integrated solutions other components, process parameters, the environment
Burckhardt Compression’s high pressure reciprocating LDPE is used in a wide range of products including: designed to maximize the safety, reliability and avail- of the parts and auxiliary equipment must also be taken
compressors are designed to operate in autoclave, –– Packaging film and bags for foodstuff and sanitary ability of your equipment. Comprehensive know-how into consideration to find the optimal solution.
in tubular or multiple technology plants. Those plants articles and experience are crucial to design and implement
produce a wide range of homo-polymers or Ethylene –– Agricultural film perfect solutions for replacing Hyper Compressor In close collaboration with our customers, we define the
Vinyl Acetate (EVA) copolymers. –– Surface protection film and lamination film components. necessary scope in order to meet the requirements
–– Shrink and stretch hood film placed on the performance of the entire LDPE produc-
Our compressor components are suitable for customers –– Bags tion line.
who expect outstanding performance, process flexibility –– Bottles and tubes
and product quality. They can be built to order for any –– Sheet
retrofit project with the objective of enhancing the –– Healthcare applications
product capability and reliability of compressors of all –– Extrusion coating
types and brands. –– Lids, caps and closures
–– Wire & cable
Ethylene and its co-products and derivatives are vital
for many segments of the economy, including the OUR OFFERING OUR IN-HOUSE
production of consumer products, packaging, housing, EXPERTISE
automotive components and other durable and non-
durable goods.
HIGH-PRESSURE PARTS
MANUFACTURING
REPAIR OF DAMAGED UPGRADE/OPTIMIZATION/
COMPONENTS MODIFICATION HIGH-PRECISION
MANUFACTURING
FULL QUALITY
ASSURANCE
RETROFIT/REVERSE RECONDITIONING OF
ENGINEERING WORN PARTS TRIBOLOGY
EXPERTISE
MATERIAL ANALYSIS
KNOW-HOW
1:1 REPLACEMNET REPLACE PARTS
OF PARTS OF INEXISTENT OEM LUBRICATION
TECHNOLOGY
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CRANKSHAFT CYLINDER
MOVING FRAME LUBRICATION UNIT
ELASTIC
CONNECTING BEARINGS ROD
ROD COUPLING
DISTANCE PIECE
PLUNGER
PLUNGER
COUPLING
OIL SEALING
SYSTEMS
HIGH
ELASTIC ROD PRESSURE
WITH AUXILIARY CRANKCASE PACKINGS
GUIDE CYLINDER
LOW
PRESSURE CENTRAL
PACKINGS VALVE
COMPONENTS IN DETAIL
CUSTOMIZED FOR BEST PERFORMANCE
REDURA® HYPER
CRANKCASE BEARINGS CRANKSHAFT CONNECTING ROD MOVING FRAME CROSSHEAD TO PLUNGER DISTANCE PIECE CENTRAL VALVE CYLINDER CYLINDER LUBRICATION PUMP CONNECTION TECHNOLOGIES
SEALING SYSTEMS
•4 –12 cranks / 2x8 cranks • High precision bearings • Stroke up to 450 mm • Lubrication bore connection for bearing • Massive construction for smooth power •E lastic rod coupling: •S ingle or combined distance piece • High pressure packing • Combined suction/discharge multi-poppet • Burckhardt Hypropack™ cartridge system • In-house engineered design with hundreds • Safe and reliable connection of the
•M ax. 3’500 kN rod load • Hydrodynamic radial and axial thrust • Diameter up to 900 mm lubrication oil feed is integrated transmission – Prevents fretting • F or precise guidance of the plunger – Heterogeneous design based on decades valve for compact design for fast exchange and service of references different parts is crucial especially
•H orizontal opposed bearing • Rigid against torsion and bending • Hydraulic tensioning connection to provide • Bottom guidance for easy access •E lastic rod with auxiliary guide: •P revents ethylene from entering the crank of experience • Optimized flow for best performance and • Hydraulic tightening ensures even • One or more pumps for one lubrica- for the dependable operation of Hyper
•C ast steel frame or welded steel • Any required bearing (main-/crosshead • Compact design optimal tensioning to crankshaft and • Two shoe slide design –E liminates undesired plunger movement gear – Highest sealing efficiency longest lifetime distribution of forces tion point for most effective lubricant Compressors.
construction frame) crosshead frame bearing avoids bearing –P recise plunger alignment •D ouble compartment design • Low pressure packing • Flow optimized for optimal design • Oil cooled design disrtibution • Appropriate connection technology for the
• Robust design aspects are focused for • Single/two part design fretting –L ong guiding bush •V ented interspace for extra safety – Avoids flow of ethylene into distance • FE Analysis • Extra-long cylinder tie bolts and elastic • Multiple adjustment possibilities for each different connecting points:
reliable performance • Anti-twist protection • Massive construction for (low vibration • Plunger coupling: •N o explosion relief valve required piece • Improved single poppet design design is a safety feature in case of exces- lubrication situation • Hydraulic tightening device for highest
DESIGN
DESIGN
• Upgrade with vibration and temperature level) smooth power transmission – Straightforward design to avoid tractive • Increased safety – Provides extra safety sive pressure inside cylinder • Easily adjustable forces on the connection
monitoring • 3-piece design for easy bearing forces for less adjustment work and easy – Includes plunger cooling • Rupture disk provides extra safety in case • Quick measuring of feed rate • Burckhardt Hypropull™ integrated
replacement access – N2 purge option of leakage of high pressure cups hydraulic cylinder design
• Robust design • Plunger: • Oil sealing systems
– upto 160 mm diameter (other dimensions – Separate seal on crank gear and
upon request) distance piece side
–H ighest demand on surface finish and – Self-centering design
tolerances – Prevents mixing of crank gear and
cooling/flushing oil
• In-house manufacturing capabilities • Tri-metal galvanic layers for increased • High precision manufacturing for optimal • Materials: cast steel •M
aterials: cast steel other upon request • Elastic rod auxiliary guide •M
aterials: cast iron • Persisto® material for sealing elements • Full metal execution withstands wear and • Material selection according to process & • Also available for other applications • High precision manufacturing for optimal
•S tate-of-the-art laser measurement wear protection compressor performance – Remachining of bush inner diameter and •S
tate-of-the-art laser measurement • High pressure packing cups: provides longest durability pressure (e.g. reactor etc) compressor performance
MANUFACTURING &
MANUFACTURING &
guarantees highest quality standards • Large diameters for low specific load • Materials: forged steel/cast iron etc. use of oversize guide rings on auxiliary guarantees highest quality standards – Specific material selection • Specific high pressure manufacturing • Even force distribution by hydraulic
MATERIALS
MATERIALS
•V arious materials (e.g. grey cast iron, • Interchangeable shells for connecting rod • Bearing surfaces are ground and polished guide for re-use of original parts •S
ituation/requirement analysis, compre- – Special materials with enormous methods to achieve superior durability and tightening.
steel) “big end” and crosshead pin bearings. • Situation/requirement analysis, compre- • Plunger: hensive engineering services for reliable mechanical and chemical resistance resistance: • Fulfills high HSE standards
•S ituation/requirement analysis, compre- hensive engineering services for reliable –S olid tungsten carbide or tungsten solutions: revamp projects/replacement/ – Multi-ring design with the inner cup • Autofrettage treatment
hensive engineering services for reliable solutions: revamp projects/replacement/ carbide plated, depending on pressure repair/fast track repair etc. shrunk into the outer ring • Shot peening
solutions: revamp projects/replacement/ repair/fast track repair etc. – Deep rolling/roller burnishing, shot • Deep rolling/roller burnishing
repair/fast track repair etc. peening and autofrettage treatment • Reusable valve seat
•S
eparate inspection covers for easy access • Improved bearing shell version for high • Customized engineering • Integrated bearing temperature • Easily removable from top • Proven procedure for elastic rod recon- • Improved oil wiper and sealing ring design • Poppets: specific material selection and • Improved cylinder tie rod coating against
ADDED
ADDED
VALUE
VALUE
•O
ptimised material selection load compressors to increase bearing measurement ditioning overall and in fretted coupling to minimize oil leakage coating for maximum lifetime corrosion of threads
lifetime areas • For any brand of Hyper compressor • For any brand of Hyper compressor
OUR IN-HOUSE HIGH-PRESSURE PARTS HIGH-PRECISION FULL QUALITY TRIBOLOGY MATERIAL ANALYSIS LUBRICATION
EXPERTISE MANUFACTURING MANUFACTURING ASSURANCE EXPERTISE KNOW-HOW TECHNOLOGY
12 HYPER/SECONDARY COMPRESSOR COMPONENTS HYPER/SECONDARY COMPRESSOR COMPONENTS 13
To maximize reliability and availability of your Hyper Our offering also includes repair work for basically any
Compressor equipment, well serviced Hyper Compressor Hyper/secondary compressor component of any type or
components are crucial. model.
We provide outstanding reconditioning service for all Our repair service stands for high quality and rapid
major components of any Hyper Compressor brand and turnaround in close cooperation with our customers.
design. –– Situation analysis
–– High pressure packing –– Evaluation (e.g. dye penetration etc.)
–– Low pressure packing –– Engineering for repair procedures
–– Oil sealing system –– Processes like laser cladding, nitrate hardening etc.
–– Central valves
–– High pressure lubrication unit UPGRADES/MODERNIZATIONS
–– Auxiliary guide
–– Plunger We are constantly striving to optimally support our
–– Check valves customers regarding the requirements on LDPE plants
for Hyper/Secondary Compressor systems as well as
CUSTOMIZED SERVICES for primary compressors; we not only focus on compres-
sor components but also on solutions supporting the
–– Requirements and situation analysis entire system and our customers’ processes.
–– Thorough examination
–– Complete disassembly This has led us for example to the development of a cup
–– Inspection of individual parts lifter tool for fast and easy assembly and disassembly
–– Recording the condition of the main parts of high pressure packings. Or to innovative high pressure
–– OEM engineering evaluation if required cylinder lubrication pipe insulation for quick installation
–– Thorough cleaning (glass bead blasting and/or and best insulation values and absolutely stable tempera-
ultrasonic cleaning if necessary) tures of the pipes and the lubricants.
–– Repair and re-machining
–– Lapping and grinding of all sealing surfaces
–– Dimensional checking
–– Replacement of worn and damaged parts with new
Burckhardt Compression quality parts
–– Careful reassembly
–– Quality inspection including required testing
–– Corrosion protection and adequate packing
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MONITORING THE CRUCIAL PARTS INDIVIDUAL SOLUTIONS FOR YOUR REQUIREMENTS MORE THAN 25 YEARS OF EXPERIENCE PROGNOST®-NT is an automated machinery diagnostic
system incorporating SIL 2-certified and online condition
Preventing accidental breakdowns is vital. They can have Depending on your needs we can provide the best Monitoring of machines in LDPE (Low Density monitoring. It has been developed specifically for recipro-
serious consequences, such as risks for plant safety solution for safety monitoring and supervision including Polyethylene) service demands a highly adaptable and cating machinery but is also used for different kinds
and the environment, production loss, expensive conse- installation engineering. A combination of individual reliable technology. of rotating equipment. It detects pending failures at an
quential damages, etc. sensors and measuring systems is possible: early stage and identifies the affected components.
–– Spring loaded or radar pulse sensors for cross head PROGNOST®-NT is the leading system for monitoring Operation-critical damages are avoided and maintenance
Main measurements points for monitoring are: bearing temperature Booster/Primary and Secondary Compressors in LDPE work can be performed efficiently.
–– Crankshaft trigger for the crankshaft position –– Proximity sensors for plunger vibrations plants. PROGNOST monitors hundreds of machines
–– Vibration acceleration on intermediate crosshead and –– Elongation measuring ring for cylinder pressure in the LDPE industry at all major production companies.
cylinder –– Resistance temperature sensors (PT100) for various
–– Vibration velocity on crank gear measuring points Burckhardt Compression recommends PROGNOST
–– Temperature on: plunger/crankshaft bearing/inter- Systems – the technological leader in safety
mediate crosshead/crosshead guide plate/crosshead To meet most stringent requirements on safety monitor- protection and online monitoring with more than
bearing/crankshaft journal ing and supervision an online system is recommended. 25 years of experience.
–– Indirect measurement of the cylinder pressure by
strain gauge technology
–– Measurement of the plunger vibrations
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UNEQUALED CAPABILITIES
FOR YOUR HYPER EQUIPMENT
INCL. CERTIFICATION
– Feasibility studies – 3D Modelling
– Finite Element Analysis (FEA) Studies – Computer Fluid Dynamics (CFD) Analysis
ENGINEERING
– On-site, and/or in-house measurements – Reverse engineering/Retrofit
of components – Material selection and sizing
– Recalculation and dimensioning – Load optimization
– Engineering for repair procedures – Thermodynamics
MANUFACTURING
REGARDING SPECIFICATIONS AND
INTERACTION WITH CUSTOMER
FIELD ACTIVITIES
– Extensive service network with our specialized – Dismantling/Reassembly of parts
field service engineers/troubleshooters – Large parts stock
– Spare parts framework agreements – Burckhardt e-Shop™ spare parts identification
– Worldwide distribution and service center and ordering system
network
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IN-HOUSE MANUFACTURED
HIGH PRESSURE COMPONENTS
FOR LONGEST LIFETIME
AND HIGHEST AVAILABILITY