Reviving high-pressure air compressors – a sustainable turnaround

In a remarkable demonstration of sustainability and engineering excellence, Burckhardt Compression India successfully restored two non-operational, high-pressure air compressor units from the Material Organisation in Vizag, transforming them into fully operational systems. This initiative not only extended the equipment’s lifespan - bringing them back to a like-new condition - but also reinforced our commitment to circular economy principles and reducing carbon footprint.

Originally installed onboard a ship, the compressors were decommissioned based on the customer’s lifecycle estimation guidelines. The customer initially requested an inspection and certification for disposal. However, during our visual assessment, we found that while some components were irreparably damaged due to the harsh marine environment, the core integrity of the compressors remained intact.

Following technical discussions, the customer agreed to our proposal to restore the units. This collaborative decision led to the successful revival of the compressors, showcasing the value of sustainable refurbishment over replacement. 

We were impressed by the transformation of what was once considered non-operational into fully functional, high-performing compressors. The Factory Acceptance Test at 400 barg exceeded our expectations, and the professionalism of the Burckhardt Compression India team was commendable.

Customer Representative, Material Organisation, Visakhapatnam
 

Thorough project planning
Our teams meticulously inspected the equipment and created a project plan that responded to every need and stayed within the given timeline.

Comprehensive service scope
In order to bring the compressor systems back into an operational status, they needed a complete revamp. We offered a full service scope that covered all needed repair and refurbishment actions.

Re-using parts
Not all parts had to be disposed of. We examined thoroughly which parts could be salvaged and repaired them to reduce the environmental impact.

New parts, where necessary
Despite all efforts, some components needed replacing including components for motors and panels.

Full working condition restored
Finally, we assembled the compressors and systems, conducted a full-load test at 400 barg to validate all operational parameters, and the customer witnessed a Factory Acceptance Test.

Working day and night
With a very tight schedule, we could complete the project on time by working in 24 hours in shifts.