22 | Plant & Works Engineering www.pwemag.co.uk June/July 2025 Process, Controls & Plant Focus on: Compressed Air the customer’s operational goals. By understanding the needs of the customer and the specific conditions under which the compressor operates, the assessment team can then tailor their recommendations to deliver the most value. Ideally, these meetings will provide a detailed understanding of the customer’s expectations and a collaborative approach to problem-solving. This collaborative 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 real-world 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. Supporting the assessment specialists in conducting measurements is crucial. This involves ensuring that measurements are made when the compressor is operating under typical—and in some cases problematic or challenging—conditions. Additionally, technical staff should be available to assist with the measurement process and address any immediate queries the assessment specialists may have. Post assessment After the assessment, reviewing and discussing the report with the experts is crucial. This discussion helps clarify findings, ensures that all recommendations are understood, and provides an opportunity to ask questions about the proposed solutions. Implementing the recommended actions promptly is also a key part in addressing any identified issues and improving compressor performance. As such, the customer should develop an action plan that prioritizes tasks based on urgency and impact. It’s also vital that they monitor the effect of these changes to ensure that the desired improvements are achieved. This involves tracking key performance indicators (KPIs) and conducting follow-up assessments as needed. It’s also important to maintain open lines of communication with the compressor assessment specialists for further support; to ensure that any additional issues are addressed swiftly; and that the improvements are sustained over time. This article was contributed by Burckhardt Compression. For further information please visit: http://www.burckhardtcompression.com Data collection is the foundation of any high-quality compressor assessment.
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