On-site machining of a hyper crankcase at an LDPE plant

The high market demand for LDPE required Transformadora de Etileno A.I.E. (TDE), a manufacturer of low-density polyethylene in Tarragona, Spain, to run its production lines with the highest possible performance.

After 180'000 hours in operation, TDE detected hard fretting damages on the contact surfaces between hyper compressor crankcase and distance pieces.

Before machining it was possible to see the movement between crankcase and distance pieces, mainly on the 2^nd stage, and a quite high oil leakage between both surfaces. Now all is much more stable and static.

Alberto Munarriz, Mechanical Maintenance Manager TDE

Our solution

• General overhaul with two Burckhardt Compression Supervisors on-site on double shift
• Crankcase machining on-site (including prior levelling check) instead of dismantling the entire compressor and transporting the crankcase to a workshop
• Machining of distance pieces and other internal parts carried out in a local workshop
• This was the first time such a repair is done on-site on an F-type hyper compressor worldwide
• Machining controlled by a dedicated Field Service Representative from Burckhardt Compression

Customer benefits

• Smoother and safer operation of the compressor with a significant reduction of movement and vibrations on distance pieces and cylinders during operation
• Minimized oil leakage between crankcase and distance piece
• Easier alignment of distance pieces and cylinders after overhaul
• Extended lifetime of plunger, packing and elastic rod
• Zero safety incidents due to highest safety standards

• Petrochemical and chemical
• Hyper compressors
• Success Stories
• Capital parts for compressors
• Preventive maintenance
• Corrective actions