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HYPER/SECONDARY

COMPRESSOR COMPONENTS
HIGHEST AVAILABILITY OF YOUR EQUIPMENT
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TRUSTED SOLUTIONS
FROM THE LEADER IN HYPER TECHNOLOGY

BURCKHARDT COMPRESSION –– Service friendly parts design


–– In-house manufacturing of high pressure parts
Burckhardt Compression is the recognized market leader –– Professional installation
in Hyper Compressors and the only manufacturer that –– Skilled start-up assistance and adjustment for perfect
offers the complete range of reciprocating compressor running conditions
technologies, Process Gas Compressors API 618, Hyper
Compressors, Laby® Labyrinth Piston Compressors and MAXIMIZE YOUR PLANT AVAILABILITY
Standard High Pressure Compressors.
All our activities are aimed to maximize your plant
As the pioneer in Hyper Compressor technology since availability. Our close cooperation with customers and
1951, our long standing know-how and unrivalled Hyper specialists allows us to satisfy market require-
­expertise are the basis for innovative solutions for any ments in the constant quest for sustainable solutions.
Hyper/Secondary Compressor. Our dedication to Hyper Compressor technology and our
focus on evolving market needs are what motivate us
LEADING HYPER COMPRESSOR TECHNOLOGY to organize the highly regarded Burckhardt Compression
LDPE Symposium on a regular basis. The exchange
With our proven track record and experience we provide of information and ideas with internationally renowned
best in class component and service solutions. We are experts inspires us to continuously improve our solu-
able to support you at every stage of the Hyper Compres- tions to meet the requirements of compressor users.
sor’s lifecycle, including:
–– Requirements evaluation Our dedicated Hyper Compressor specialists are the
–– Situation analysis experts when it comes to comprehensive high pressure
–– Consulting services application know-how and experience. We are ready
–– Engineering services to provide full support for Hyper/Secondary Compressors
–– Capacity change/modernization as well as Booster/Primary Compressors of any brand
and any type.

OUR GLOBAL SERVICE CENTER NETWORK


SUPPORTS YOU IN EVERY ASPECT OF YOUR
HYPER COMPRESSOR SYSTEMS LIFECYCLE.
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HIGH PRESSURE PROCESS TECHNOLOGY A PERFECT FIT


FOR HIGHEST SAFETY AND AVAILABILITY HYPER COMPONENTS AND SERVICES FOR ANY BRAND

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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HYPER COMPRESSOR OVERVIEW


INTEGRATED SOLUTIONS

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
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REDURA® OIL SEALING SYSTEMS REDURA® LOW PRESSURE


ELABORATE COMBINATIONS FOR HIGHEST SEALING SEALING SYSTEMS
EFFICIENCY FOR BEST PERFORMANCE

REDURA® INCORPORATING THE PATENTED The subsequent combination of Redura® sealing


RAZOR BLADE™ TECHNOLOGY ­elements depends on the process parameters and gas
compositions. It consists of a selection of:
The Redura® Low Pressure Sealing System provides Redura RS 300 sealing elements
additional safety; it avoids the flow of ethylene into the –– Well established 3/6 piece sealing element. Radial
distance piece. Its general design consists of an indi- tangential cut with bridge element, for outstanding
vidually optimized combination of different ring types. sealing efficiency
Redura RS 900 sealing elements
First the new oil wiper element LW 410 removes most –– Axially pre-loaded sealing ring pair with double 3-piece
of the lubricating oil and process matter coming from sealing ring. Extremely reliable with maximum sealing
the high pressure cylinder side. Thanks to its superior, efficiency for low pressure differences.
patented Razor Blade™ technology it provides precise
and optimal oil removal and lowest surface pressure, The integrated plunger seals with a self-centering design
increasing the lifetime of the ring and the plunger. ensure that the cooling and flushing medium is kept in
place. Thanks to its superior design the consumption of
oil for cooling and flushing is absolutely minimized.

Tailor-made solutions backed by decades of experience


DUAL OIL SEALING SYSTEM FOR MINIMAL LEAKAGE ADVANCED TRIBOLOGICAL IN-HOUSE RESEARCH in design and material selection ensure that you will
FOR LONGEST OPERATING TIMES receive the perfect solution for your Hyper Compressor.
Separate seals on crank gear and distance piece side
provide highest sealing efficiency. The tried and tested Depending on the parameters, the housing and the
heterogeneously designed Redura® Oil Sealing Systems mounting place of your Hyper Compressor, a specifically
consist of 3 main elements, each with its own specific optimized solution can be designed based on your
function. requirements. Advanced tribological in-house research
provides excellent materials for longest operating
First the pre-wiper element LW 100, which prevents times.
most of oil from ever entering the oil wiper housing.
The pre-wiper element is followed by a series of rings
with optimally designed edges to remove all but a fine
film of oil from the elastic rod. A final sealing element
seals any oil mist that may have been created within
the housing. The oil sealing system of the distance
piece side is equipped with an additional sealing
element and a pressure ring. This prevents carry-over
of ethylene into the crank case.
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REDURA® HIGH PRESSURE CENTRAL VALVES


SEALING SYSTEMS FOR IMPROVED LIFETIME AND INCREASED RELIABILITY
DECADES OF EXPERIENCE FOR PERFECT SOLUTIONS

STATE-OF-THE-ART SOLUTIONS FOR ANY REDURA® FOR LONGEST MTBO


HYPER COMPRESSOR
The sealing system is based on a heterogeneous design
Redura® High Pressure Sealing technology from which includes at least two different high pressure
­Burckhardt Compression is based on decades of experi- sealing element designs.
ence with continuous incorporation of state-of-the-art Redura® RB 100H pressure breaker
solutions and the latest quality standards for highest –– High performance pressure breaker to withstand
safety and longest MTBO. the dynamic pressure component and protect the
­subsequent sealing elements
The Burckhardt Hypropack™ cartridge system allows for Redura® RG 900H guide ring
extremely fast exchange and service, therefore highest –– Robust guide ring provides reliable plunger guidance
possible availability of the compressor. The preassembled and high durability
unit includes: base ring, high pressure cups, cups for Redura® RS 300H sealing element
guide bush and pressure breaker, sealing rings, shrunk –– 3/6 piece classic sealing element for outstanding
liner and head core. sealing efficiency
Redura® RS 310H sealing element
The packing cups consist of a multi-ring design with –– Very robust 3/3 piece sealing element for extended
the inner cup shrunk into the outer ring in order to provide lifetime
highest resistance against deformation. ABSOLUTE PRECISION FOR MAXIMUM SAFETY SUPERIOR TECHNOLOGIES FOR CENTRAL VALVES
Customized designs ensure the optimal solution for your
Hyper Compressor. The central valves have to operate with absolute reliabil- Our customized processes for best individual
ity at the highest pressure levels, up to 3’500 bara. performance:
They must be engineered, designed, manufactured and –– FE Analysis
installed with absolute precision and care. –– In stationary fluid dynamics simulation
–– Rigorous material selection
Minuscule imperfections on parts exposed to these –– Application of special high pressure manufacturing
extreme pressure levels can lead to major damage. technologies such as: Autofrettage, shot peening or
deep rolling/roller burnishing at the essential locations
Our tried-and-tested multi-poppet design results in –– Meticulous assembly and installation executed by
lower poppet weight and therefore substantially dedicated Hyper Compressor specialists
lower kinetic energy. This leads to significantly longer –– Uncompromising quality assurance throughout all the
lifetime of poppet and valve seat. process steps

Our comprehensive Hyper Compressor component


know-how and experience allow us to carefully evaluate
the possibilities to adapt our superior design to any
other Hyper Compressor brand and type, or improve the
existing single poppet design based on your requirements.
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COMPONENTS RECONDITIONING AND


REPAIR SERVICES
MAXIMIZE RELIABILITY AND AVAILABILITY

RECONDITIONING COMPONENT REPAIR

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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SAFETY MONITORING/SUPERVISION ONLINE CONDITION MONITORING


MINIMIZE RISK – REDUCE COST AND DIAGNOSTICS
WE RECOMMEND PROGNOST®

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

REQUIREMENTS & SITUATION ANALYSIS


– Process Compressor condition change – Worn out parts
– Improved design to replacement parts with – Precarious or unsafe operating conditions
excessive wear – Troublesome parts

OF REQUIRED GUIDELINES AND STANDARDS


– Damaged parts/failure – Maintenance and spare parts logistic scheduling

INCORPORATING FULL ­DOCUMENTATION


EVALUATION
– Root cause analysis/failure analysis – Non-destructive testing (NDT)
– Risk/Condition and Material analysis – Stock recommendations

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

– Highest quality assurance – Fast track production upon request


– Reproduction (1:1 replacement incl. integration – OEM guarantee
of latest quality standards) – Specific in-house manufacturing
– In-house precision manufacturing of parts (e.g. Autofrettage)
SCOPE OF WORK

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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“WE TRUST OUR PARTNER BURCKHARDT


COMPRESSION, THE LEADER IN HYPER
TECHNOLOGY AND WE ARE ABSOLUTELY
SATISFIED WITH THE RELIABILITY AND
AVAILABILITY OF OUR EQUIPMENT AND
THE SERVICE PROVIDED.”
Guan Xinchun, Plant Maintenance Manager Nanjing, BASF-YPC Company Limited
LEADING HYPER/SECOND- COMPRESSOR COMPONENTS SERVICES
ARY COMPRESSOR TECH- BEST PERFORMANCE THE FULL RANGE
NOLOGY SINCE DECADES AND LONGEST LIFETIME

Compressor valves Burckhardt Valve Service


Redura® rings & packings Spare parts logistics
Capacity control systems Field service
COMPREHENSIVE SOLUTIONS Capital parts Technical support
FOR YOUR LDPE PLANT
Labyrinth piston compressor Revamps & upgrades
components Component repair
Hyper/secondary compressor Condition monitoring &
components diagnostics
SUPERIOR PARTS DESIGN Training
FOR PRESSURES
UP TO 3’500 BARA

IN-HOUSE MANUFACTURED
HIGH PRESSURE COMPONENTS
FOR LONGEST LIFETIME
AND HIGHEST AVAILABILITY

23.23.14.40 – 05/2016 – Printed in Switzerland on FSC certified paper

Burckhardt Compression AG Your local contact


CH–8404 Winterthur
Switzerland
Tel.: +41 52 262 55 00
Fax: +41 52 262 00 51
24-hour emergency tel.: +41 52 262 53 53
aftersales@burckhardtcompression.com
www.burckhardtcompression.com

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