Restoring reliability in a critical propylene compressor

An Indian oil company with a large fleet of reciprocating compressors was facing reliability issues with a Laby compressor in a propylene application. Due to gaps in the maintenance strategy, the lubrication system developed some issues, which was causing the compressor to perform below its full potential. Faced with frequent unplanned maintenance a permanent solution was needed that would improve reliability and minimise disruption to operations.

With the compressor supporting a critical, single-line process, maintenance opportunities were limited and downtime carried significant financial consequences. Burckhardt Compression needed to find a solution for high oil consumption, accelerated wear of rod packing and oil scraper rings that were impacting plant reliability.

Following a comprehensive technical assessment, Burckhardt Compression engineers identified the root causes affecting the performance of the key asset. Drawing on extensive expertise in reciprocating compressor technology and propylene applications, the team recommended a specially engineered piston rod packing system designed to meet the unique sealing requirements of propylene compression. The upgraded design significantly improved sealing performance while reducing component wear and lube oil consumption.

To support the implementation, Burckhardt Compression developed a detailed plan aligned with the customer’s operational priorities. A streamlined 24/7 work schedule ensured the project progressed continuously while keeping downtime to an absolute minimum. In parallel, application-specific spare parts were supplied in advance, eliminating procurement delays and ensuring every component was available when required.

The rod packing modification was completed on schedule through close coordination between engineering and field service teams. The compressor was successfully returned to operation without disruption to surrounding plant activities, demonstrating the effectiveness of both the technical solution and the project execution.

The results were validated over a six-month operating period. Lube oil exchange intervals were extended from four oil changes per year to just one, while oil carryover into the process gas was eliminated, ensuring cleaner operation. The service life of critical wear components, including rod packing and oil scraper rings, increased in line with the customer’s maintenance strategy. Most importantly, the compressor achieved significantly higher reliability and operational stability, reducing maintenance requirements and improving overall plant performance.