Best practices for process compressor maintenance and reliability

Process compressors are essential in many industrial settings. When they fail or even function below optimum levels, the knock-on impact to production and profit can be huge.

Maintaining your process compressor to ensure productivity, reliability, longevity, and safety should be a priority. And the best part is… It’s actually really easy! In fact, the effort and cost of maintaining your equipment is tiny compared to the consequences of mechanical failure.

Today, we’re looking at simple steps you can take to maintain your process compressor and keep it running smoothly.

Issues to look out for

Different types of process compressors may have specific telltale signs that something’s wrong, but the following are examples that are worth looking into, whatever make and model you own:

• If your monitoring instruments give readings outside normal margins or any alarms sound, this is an obvious sign that something is wrong. Keeping an eye on temperatures, pressures, vibration and discharge gas composition is important to catching problems early.
• Overheating is a clear indication that something’s wrong. It could be internal friction caused by e.g. fouling; dirty and ineffective filters; or a problem with the cooling system.
• Reduced output pressure/flow could indicate problems with valves or rotors.
• Increased pressure could indicate fouling, valve malfunction, compromised seals or simply the wrong settings.
• Excessive vibration is a sign of imbalance, misalignment or worn parts. It can be caused by fouling.
• Unusual noises e.g. knocking, rattling or high-pitched sounds can indicate bearing wear or internal damage.
• Oil leaks should prompt you to check for seal failures/wear.
• Excessive power consumption tells you the system in working inefficiently and action is needed.

Preventative maintenance

While knowing the warning signs of various problems is useful, it’s far better to avoid issues through preventative maintenance. Simple, effective and cost-saving measures are key to getting the most out of your equipment. Implement a daily, weekly, monthly and annual maintenance schedule with detailed logs and accountability. Here’s an example of what you might include:

Daily

• Check oil levels
• Inspect for leaks
• Monitor vibration and noise
• Check pressure and temperature readings

Weekly

• Weekly on-line process compressor washing (or even daily in cases of rapid build-up) keeps foulants from accumulating and impacting production/causing irreversible damage.

Monthly

• Clean/replace filters
• Test safety devices, including pressure relief valves and alarms

Every six months

• Analyse oil samples for contaminants
• Calibrate sensors
• Inspect valves and seals

Yearly

• Conduct a full vibration analysis
• Consider thermal imaging to check for hot spots
• Inspect internal components
• When your process compressor is shut down for maintenance, consider off-line washing

How regular washing optimises process compressor performance in industrial settings

Process compressors become fouled through normal use. Contaminants enter the system via the process gas itself, lubricants/grease, polymeric compounds, production chemicals and more. The high temperatures and pressures exacerbate the issue, and once fouling is present, it increases friction, impacts production, and can damage equipment.

On-line cleaning can be carried out during normal use without impacting efficiency and is the best way to maintain the cleanliness of your process compressor. Off-line soak washing is also an option for less frequent cleans.

Find out more

Hopefully our guide to best practices when it comes to process compressor maintenance has given you some good ideas for getting the most out of your equipment. For more information, this blog goes into greater detail about fouling and process compressor washing.

Backed by over 40 years’ experience, our range of specialist equipment and chemicals are chosen at sites around the worldIf you’re interested in prolonging the life and increasing the efficiency of your process compressor we’d be delighted to discuss how we can help. Please get in touch to find out more.