Maximize Hyper Compressor Uptime Applying an Industry Proven Monitoring Approach

The high pressure (Hyper) Compressor is one of the most critical assets within a LDPE production line. Failures starting off with simple valve leakage may lead into interstage pressure variation, load increasing and loss of load reversal and finally a main bearing failure resulting into multiple days’ downtime. This paper describes some of the challenges and a proven effectively method for monitoring Hyper compressors and its individual components. Using a series of short real-life case studies, it will be illustrated how a state-of-the-art monitoring technology helps to detect impending failures at an early stage to eliminate consequential damages and avoids to be caught off-guard. One case study describes the early indication of a developing valve failure; another provides understanding how a packing failure is detected reliably. The third case study covers aspects of a safety relevant damage resulting into an automatic compressor shutdown, which otherwise would have likely resulted into significant and costly production loss. The session will be concluded with hands-on guidance on recommended Safety Protection analysis.