Failure analysis of refinery hydrogen reciprocating compressors

Abstract

Hydrogen compressors perform specific functions in the technical system of crude oil processing. The authors characterize consequences of wear margin loss of the compressor, present design solutions of hydrogen piston compressor and divide its construction into functional units. The compressor fault analysis is based on post repair documentation of compressors maintained according to their service life, and making use of technical diagnostics applied to 21 compressors, covering the last 20 years. The analysis distinguishes the loss of compressor wear margin due to loss of functional unit wear margin and due to damage to a compressor component. Faults typical of hydrogen compressor elements have been described. Besides, the authors estimate fault risks for selected elements and risks of wear margin loss of selected functional units. Statistical data are given in tables and bar charts. The analysis outcome indicates the need to implement methods and tools for diagnosing the cylinder unit, comprising several functional units.