Compressors used to fill tube trailers naturally have to start and stop frequently. This poses a challenge for reliable operation. In addition, all scheduled downtimes of the compressors must be coordinated with those of other plant components in order to keep operational interruptions to a minimum. A practical example from Burckhardt Compression and Infraserv Höchst demonstrates how this can be achieved. The compressors, delivered in 2001, still achieve excellent availability today and a mean time between overhauls (MTBO) of between 8,000 and 9,000 hours.
Few solutions available 25 years ago Twenty-five years ago, supplying high-pressure hydrogen still involved enormous difficulties. To handle the smallest molecules in the world and, at the same time, ensure that compressors remained tight at 230 bar gauge pressure (bar (g)), only a few technical solutions were available. Today, similar plants are specified for up to 550 bar (g), thanks in part to the industry solutions from Burckhardt Compression.
For the two type 2CS hydrogen compressors in the Infraserv application, frequent start-stop cycles were to be expected as part of normal operation. This usually has a negative impact on maintenance intervals. The operating costs of the new trailer filling station were naturally to be kept as low as possible and the compressors were to be available to the maximum extent. The target of 8,000 to 9,000 MTBO was set in coordination with the maintenance requirements of other plant components. Burckhardt Compression could also have achieved an MTBO of 12,000 hours if required.
Proprietary materials and components Such service life and efficiency require a combination of design expertise and carefully selected materials. Drawing on decades of experience, Burckhardt Compression has developed its own materials, such as Persisto rings and Redura sealing systems, key components for dry-running high-pressure compressors.
The plant operates with many compressors for various gases, distributed across the entire site. These include numerous Laby compressors (oil-free piston compressors with labyrinth sealing), which are maintained on site by Burckhardt Compression technicians.
Strong presence and communication Another important aspect of the cooperation with Infraserv is communication. Burckhardt Compression appointed a central contact person to ensure an effective exchange of information. This enabled the efficient handling of all aspects of compressor management, from initial commissioning and training through to scheduled maintenance and troubleshooting.
Burckhardt Compression’s presence in Germany covers four locations. They offer customers competent support, available around the clock, which helps keep total cost of ownership (TCO) as low as possible.
Optimizing productivity for the future Steffen Enghard, mechanical operations engineering at Infraserv Höchst, said, “In recent years, we have experienced nearly continuous trouble-free operation, hardly any unplanned maintenance work, hardly any unexpected failures. This has enabled us to ensure optimal productivity for our company. The continuous support from Burckhardt Compression has been invaluable and has ensured that our systems function flawlessly. The filling process of the hydrogen trailers is a central element of our facilities, and high availability is essential.”
For Infraserv Höchst, the combination of technical solutions and on-site support was the decisive factor for the long-standing business relationship. And with the hydrogen ramp-up, Burckhardt Compression is also expanding its network of experts for 24/7 support. Last year, six new service centers were added worldwide.
