www.hpmag.co.uk HYDRAULICS & PNEUMATICS June 2025 39 environment ensures that the recommendations provided are not only technically sound but also practical and implementable within the customer’s operational framework. By engaging all relevant stakeholders, the assessment team can develop solutions that address the root causes of any issues, leading to sustained improvements in performance and reliability. Three: Careful documentation renewal Diligently reviewing technical and operational documentation is a crucial step in ensuring that the compressor is operating within design specifications and that the design is adequate to the realworld conditions it’s working in. The types of documentation reviewed include the compressor manual, component information, piping and instrumentation diagrams (P&IDs), and process flow diagrams (PFDs). On top of this, the team will also need to review the compressor’s maintenance history, as well as all the operational records, trends and data available from its monitoring systems. The compressor manual provides input on original specifications and intended operation, while schematics and process diagrams provide an understanding about compressor interfaces. This is essential for understanding the overall system configuration, its operating mode and any potential impacts from the process – such as contaminants in the gas, fluctuating operating parameters, or changing demand for compressed gas. Meanwhile, the maintenance history and operational records give a view of the compressor’s past performance, detailing any repairs, upgrades, or recurring issues. By having an accurate and up-to-date picture of the compressor’s history and current state, the assessment team can identify patterns and recurring issues. These “bad actors” can include components, operating modes, process conditions, and operating or maintenance practices that are limiting the compressor’s reliability or efficiency. This information forms the basis for diagnosing the root causes of any performance problems and developing effective solutions that allow it to operate more efficiently and sustainably. Importantly, collecting up-to-date documentation also ensures that all stakeholders have access to the same information, facilitating better communication and coordination during the assessment process. It also makes it easier to plan any future maintenance and operational strategies, as it provides a clear record of past issues and interventions and gives a solid foundation for making informed decisions. How operators can make the most of an assessment If operators are going to generate the maximum possible value from their assessment, they should recognize that the process is a two-way street and allocate sufficient time and effort to the process. Effective preparation, active participation, and a diligent follow-up can help operators to maximize the benefits of a compressor assessment. Preparing for the assessment Before the assessment begins, it is essential to ensure that all relevant documentation is as up to date as possible and accessible. This includes design manuals, schematics, process diagrams, and maintenance records. These documents provide the assessment specialists with the background needed to understand the compressor’s design and operational history. Additionally, operators should make sure that when the assessment specialists arrive, they can provide a clear understanding of their operational goals and challenges. This involves outlining specific performance targets, known issues, and any unique operational constraints. During the assessment Active involvement during the assessment is vital to its success. Operators should participate in technical meetings, sharing insights and observations from day-to-day operations. This firsthand information can provide valuable context and highlight potential issues that may not be evident from data alone. Operators should also be prepared to answer questions and provide additional information as needed. Case study An excellent example of the benefits of a well-managed compressor assessment can be seen in a recent project. A leading agricultural technology company encountered significant issues with several newly acquired compressors during the warranty period. These challenges impacted on their operational efficiency and reliability, but the OEM was unable to address the issues. This prompted them to seek assistance from Burckhardt Compression for a comprehensive assessment and solution. Based on the findings from the assessment, Burckhardt Compression’s engineering experts implemented several targeted modifications. The cylinder groups, piston rods, and liners were modified to address the identified issues, and improvements in the compressor’s tribology – the areas where two parts move over one another – were also made, significantly enhancing seal longevity and reducing operating temperatures. These changes eliminated the root causes of the problems and optimized the compressors’ performance. The solutions implemented by Burckhardt Compression resulted in several tangible benefits for the company. The reliability and efficiency of the compressors were significantly enhanced, leading to more consistent and dependable operation. Maintenance costs were lowered due to improved component longevity and a reduced need for repairs. Overall, the performance of the compressors improved, and their lifespan was extended, providing the company with a robust and efficient solution to their initial problems. This success highlights the importance of not just engineering excellence, but also a thorough and methodical assessment process in identifying and addressing complex compressor issues. By using precise measurements, technical collaboration, and comprehensive documentation review, Burckhardt Compression was able to deliver a tailored solution that met the company’s needs and restored the performance of their critical equipment.
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