HYPER COMPRESSORS
FOR LDPE PRODUCTION –
CUSTOMERS’ CHOICE SINCE 1951
2 HYPER COMPRESSORS
YOUR PROCESS KNOW-HOW
AND OUR TECHNICAL EXPERIENCE
A SOUND FOUNDATION FOR
A BENEFICIAL PARTNERSHIP
Hyper Compressor
Booster/primary compressor
C 2H 4
C 2H 4 C 2H 4
C 2H 4 C 2H 4 C 2H 4
Fresh ethylene gas
Storage
HYPER COMPRESSORS 3
Reactor
Separators
Extruder
– Cable & wire
– Foils
– Shopping bags
– Waste bags
– Hoses
PE pellets – Special bottles
– Many more
4 HYPER COMPRESSORS
TECHNOLOGY AT ITS BEST
SAFETY AND RELIABILITY
KEY COMPRESSOR COMPONENTS –
FOR BEST PERFORMANCE AND LONGEST LIFETIME
CENTRAL VALVES HIGH-PRESSURE LOW-PRESSURE OIL SEALS BEARINGS
– Combined suction/ PACKINGS PACKINGS – Separate seals on – Large diameters for
discharge multi-poppet – Applied technology – Provides extra safety crankgear and low specific load
valve for based on decades of – Avoids flow of ethylene distance piece side – Expected lifetime
compact design experience into the distance piece – Self-centering design > 15 years
– In full metal execution – Extremely high sealing – Tri-metal galvanic
to withstand wear efficiency and lifetime layers for increased
for long durability – Different materials and wear protection
– Autofrettage treated designs for various
to withstand copolymer applications
high pressures
– Optimized flow for
best performance
and long lifetime
HIGH-PRESSURE
PACKING CUPS
– Special design to
withstand fretting
– Surface treated
to avoid fissures
RUGGED DESIGN –
FOR DURABILITY
INSTRUMENTATION CRANKSHAFT CRANKGEAR LARGE CROSS SECTIONS OF
(NOT ILLUSTRATED) – With camshaft design – Three types to minimize COOLING/FLUSHING PIPING
– Latest technology – Without webs cylinders in operation – Extra safety in case of a
implemented – Without bores – Robust design with low plunger failure
– For safe-guarding – Rigid against torsion specific loads
(protective circuits) and and bending – Welded construction for K-type
condition monitoring – Cast construction for H-types
and F-types
– Separate oil tank, no oil sump
HYPER COMPRESSORS 5
IN-HOUSE DESIGNED AND MANUFACTURED MAIN PARTS –
FOR RELIABILITY
CROSSHEAD FRAMES ELASTIC ROD AUXILIARY GUIDES PLUNGER COUPLINGS BURCKHARDT
– Bottom guidance for COUPLINGS – With elastic rod – Simple taper design to HYPROPACKTM –
easy service access – Low tolerance – To eliminate undesired avoid tractive forces CARTRIDGE SYSTEM
– Massive construction connection for plunger movement – For less adjustment – Pre-assembled module
for low vibration level excellent guidance – For exact plunger work and easy access including base cup,
of the auxiliary alignment high pressure cups,
guide and plunger cups for the guide ring
and the throttle ring,
shrunk liner (cylinder)
and head core
(valve seat)
– For fast exchange
and service
DISTANCE PIECES SAFETY DEVICES CYLINDER TIE BOLTS
– To prevent ethylene from – Rupture disk provides extra – Extra long and elastic design
entering the crankgear safety in case of leakage of – Allow safe gas decomposition
– For increased safety high pressure cups
– Double-compartment design
– No explosion relief valve
required
– Vented interspace for extra
safety
6 HYPER COMPRESSORS
TECHNICAL DATA
PERFECT FIT FOR ALL PLANT SIZES
PERFORMANCE RANGE
H4 H6 H8 F4 F6 F8 F10 K6 K8 K10 K12 K14
bara / psia
3’400 /
49’300
3’000 /
43’500
Discharge pressure
2’600 /
37’700
2’200 /
31’900
0 50 / 110 100 / 220 150 / 330 200 / 440 250 / 551 300 / 661
Hyper Compressor mass flow (t/h) / (lbs/h in 1’000)
TECHNICAL DATA AND DIMENSIONS
Type No. of Rated Power Width Height Length Max. Pressure Plant Capacity
Cylinders kW / hp mm / in mm / in mm / in bara / psia (kt/a) / (mn lbs/a)1)
H 4 4’600 / 6’200 2’820 / 111 33 / 73
6 6’500 / 8’700 8’430 / 332 1’590 / 63 3’500 / 137 3’500 / 50’760 59 / 130
8 8’000 / 10’700 4’180 / 165 66 / 146
F 4 8’600 / 11’500 3’350 / 132 69 / 152
6 12’900 / 17’300 4’250 / 167 128 / 282
9’750 / 384 1’950 / 77 3’500 / 50’760
8 17’000 / 22’800 5’150 / 202 137 / 300
10 20’000 / 26’850 6’050 / 238 206 / 450
K 6 18’900 / 25’350 5’000 / 197 210 / 463
8 25’200 / 33’800 6’100 / 240 226 / 498
10 31’500 / 42’250 11’300 / 445 2’110 / 83 7’200 / 283 3’500 / 50’760 332 / 732
12 35’000 / 46’950 8’300 / 327 400 / 882
14 38’000 / 51’000 9’400 / 370 452 / 9962)
1)
Reference values based on the following assumption: suction pressure 270 bara (3’900 psia), discharge pressure 3’100 bara
(5’000 psia), suction temperature 40 °C (104 °F), pure ethylene, 200 rpm, 8’000 operating hrs/a, reactor conversion rate 31%.
2)
Machine configurations for larger plant capacities upon specific request.
HYPER COMPRESSORS 7
Length
Height
Width
The nominal speed of Burckhardt Compression Hyper
Compressors is 200 rpm in order to minimize the overall
wear of the machine.
Burckhardt Compression also offers the corresponding
booster/primary compressors. Our Process Gas Compressors
are designed according to API 618 specifications and repre-
sent highest quality and reliability.
8 HYPER COMPRESSORS
HYPER COMPONENTS FROM YOUR OEM
BEST QUALITY FOR HIGHEST SYSTEM AVAILABILITY
CUSTOMIZATION FROM THE HYPER COMPRESSOR MANUFACTURER
High pressure packing High pressure packing Effective stress on valve
radial deformation static load
– Hyper Compressors are taylor-made – customization – Instationary fluid dynamics simulations
is the only way to find the best individual component – Extensive research resources
characteristics for your Hyper Compressor – Broad experience with more than 220 realized projects
– Pulsation and vibration studies including c ompressor with different gas compositions, processes, additives and
model with integrated cylinder stretch forces and pipings environmental conditions
with supporting structures models of the interstage heat
exchangers, preheater and reactor
PLUNGERS
– High demands on surface finish
and tolerances
– Specifications and quality assurance
by Burckhardt Compression
– Design and material selection
based on d ecades of experience
– 1st stage: tungsten carbide plated
(depending on pressure and
customer preference)
– 2nd stage: solid tungsten carbide
(depending on pressure)
– Unique one-touch connection
without alignment Component with highest mechanical stress
HYPER COMPRESSORS 9
HIGH-PRESSURE PACKINGS LOW-PRESSURE PACKINGS
– Applied technology based on decades of experience – Provides extra safety
– Extremely high sealing efficiency and lifetime – Avoids flow of ethylene into the distance piece
– Pressure breakers with advanced design and improved – Meets environmental requirements
functionality – Advanced tribological in-house research provides
– Experience with special design and material selection up-to-date materials for longest o perating time
for various copolymer applications
CENTRAL VALVES HIGH-PRESSURE CYLINDER LUBRICATION PUMPS
– Customized sizing for optimized efficiency – In-house engineered design with hundreds of references
– FEM optimized flow and multi-poppet design – One pump for one lubrication point for most effective
for best performance and long lifetime lubricant distribution
– Autofrettage treated to withstand high pressures – Multiple adjustment possibilities for each lubrication
situation
10 HYPER COMPRESSORS
EASE OF MAINTENANCE
SMART FEATURES
FOR SHORTEST DOWNTIME
DESIGNED FOR LOWEST MAINTENANCE BURCKHARDT HYPROPACKTM – CARTRIDGE SYSTEM
– Design with lowest number of cylinders in the market – Pre-assembled unit including base cup, high pressure
– Resulting in minimized number of wear parts cups, cups for the guide ring and the throttle ring,
– Low speed to reduce wear shrunk liner (cylinder) and head core (valve seat)
– Advanced lubrication system for all main bearings – For fast exchange and service
and the entire cylinder assembly – Special tools included
– Easy and quick access to all wear parts
BURCKHARDT HYPROPULLTM –
CROSSHEAD FRAME INTEGRATED HYDRAULIC CYLINDER
– Bottom guidance for easy access to the entire crankcase – Pre-tensioning of the center bolt
– Easy access to crankgear, crosshead, frame, auxiliary – For quick disassembly of the cylinder
guide, elastic rod coupling and oil seals of distance piece – No torsional stress to the cylinder
– Crosshead shoes can be removed without disassembling – Scope of supply includes hydraulic pump
neither the distance piece nor the cylinders
HYPER COMPRESSORS 11
EASY ACCESS TO THE CRANKGEAR
World’s most powerful single frame Hyper Compressor K12
14 HYPER COMPRESSORS
LEADING COMPRESSOR TECHNOLOGY
FOR LOWEST LIFE CYCLE COSTS
Our Hyper Compressors are the result of the broad experience gained by Burckhardt Compression over many
decades. The second to none design has been accomplished in close collaboration with our customers throughout
the world. Based on their needs, Burckhardt Compression provides a robust and reliable compressor of Swiss
engineering. Certified Swiss manufacturing, quality management and committed workforce ensure a constant high
quality level.
INITIAL COSTS OPERATING COSTS MAINTENANCE COSTS LOWEST LIFE CYCLE
The lowest number of The high quality of our Unpredicted downtimes COSTS
cylinders in operation compressors results in are the main cost factor The over-all result of our
results in a reduction of a long MTBO and in low of a Hyper Compressor. continuous development
parts and complexity. consumption of: We are the only one that are compressors with
Together with latest can provide: lowest life cycle costs.
advanced machining – Energy
technology, highly effi- – Lubricants – Unique maintenance
cient manufacturing oriented design
processes and global features
sourcing, we are able to – Guaranteed lowest
offer compressors at very downtime
competitive prices.
Plant: Nanjing long lifetime of the packings and valves.
Country: China We appreciate the good aftersales service
and the periodical visits of Burckhardt
“Our company BYC is located in China and Compression. In case of any issues they
is a joint venture between BASF and provide strong and prompt technical
SINOPEC. We purchased two booster/ support.
primary compressors and two Hyper
Compressors from Burckhardt Compres- We are happy to have Burckhardt
sion. The compressors are in operation Compression as a partner.”
since May 2005. Up to now, we are satis-
fied with the project management and Guan Xinchun
the good quality of the compressors that Plant Maintenance Manager Nanjing
represent high reliability – especially a BASF-YPC Company Limited
SWISS DESIGN
HYPER COMPRESSORS 15
MANUFACTURING
WITH STATE-OF-THE-ART MACHINING TECHNOLOGY
Cutting-edge 3D CNC Measurement Machine for quality inspection Dörries Scharmann, Heavyspeed CNC Milling Machine
Centric table load: 40’000 kg, spindle stroke: 1’000 mm
Okuma MacTurn550, CNC Multitasking Center. Okuma MacTurn350, Multitasking Dörries Scharmann, CNC Boring Mill
One of the 10 machining centers Center. Fully automatic parts feeding 4 tables, spindle stroke: 600 mm
16 HYPER COMPRESSORS
BURCKHARDT COMPRESSION
THE HYPER PIONEER WITH THOROUGH
IN-HOUSE EXPERTISE ...
HYPER COMPRESSORS 17
... FROM PRE-SALES TO FIELD OPTIMIZATION BOTH
FOR EPC C ONTRACTORS AND PLANT OPERATORS
COMPRESSOR DESIGN
Pre-sales support
Engineering analysis
Feasibility study
Selection and sizing
RESEARCH & Pulsation and vibration studies
DEVELOPMENT COMPRE 3D CAD
SS O Compressor valves
Finite element analysis RD
ES Rings and packings
Research and testing NT IG N
of lubricants P ME
Mechatronics LO
VE
DE
&
CH
EAR
RES
PL ANT
ENGINEERIN
G
PLANT ENGINEERING
SE
Contracting
RV
SERVICES Customer and standard
IC
ES
Engineering services specifications
Optimization Lubrication skid
Spare parts logistics Cooling water skid
Trouble shooting
ING Cooling/flushing skid
Revamps TUR
MANUFAC Instrument and control,
Field service motors
Valve service MANUFACTURING PLC programming
Component repair CAM in-house machining
Technical support Purchasing
Monitoring Assembly
and diagnostics Quality assurance
Training
18 HYPER COMPRESSORS
SERVICES
THE FULL RANGE
BURCKHARDT VALVE – Analysis of valve condition – Complete quality inspection
SERVICE – Tracking of valve history – State-of-the-art leak test
FAST VALVE SERVICE WITH – OEM valve engineering – Root cause analysis
EXTENSIVE GUARANTEE – Valve cleaning and overhauls – Corrosion protection
SPARE PARTS LOGISTICS – Original spare parts with OEM – 12 month guarantee
OEM GUARANTEE AND BEST guarantee – Save time and money: use the
LIFE CYCLE COSTS – Spare parts frame agreements Burckhardt e-ShopTM – the easy
– Stock recommendations spare parts identification and
– Express service for emergencies ordering system
– Over 16’000 parts on stock
FIELD SERVICE – On-site assembly and installation – Start-up support
ONSHORE AND OFFSHORE: BENEFIT – Erection/commissioning – Service contracts/preventive
FROM OUR SKILLED RECIP EXPERTS – High safety standards – SCC and maintenance
HUET certified – Plant overhaul/revision
– Turn-key installations – 12 month guarantee
TECHNICAL SUPPORT – Performance analysis for optimized – Emergency availability 24/7
PROFESSIONAL SUPPORT FROM and efficient compressor operation – On-site failure analysis
OUR WELL TRAINED AND – Start-up support – Online diagnostic support
EXPERIENCED SPECIALISTS – Troubleshooting – Consulting
– Root cause analysis
COMPONENT REPAIR – Condition analysis – Incorporation of the latest
SAVE MONEY AND GET – Recommendations concerning technology where possible
“AS NEW” GUARANTEE which parts can be repaired or – 12 month guarantee
need to be replaced – Repair of crossheads, piston rods,
cylinder liners, bearings, pistons
ENGINEERING SERVICES – State-of-the-art pulsation and – Reverse engineering and reengi-
SOPHISTICATED IN-HOUSE SIZING vibration analysis neering for own as well as for
AND ANALYSIS TOOLS – Finite element analysis other brand compressor systems
– Unique analysis models for – Dynamic analysis for any compres-
high pressure application sor parts
HYPER COMPRESSORS 19
REVAMPS – Modernizing – Operation mode studies
REJUVENATE OR TUNE – Upgrades/retrofits for own as well as for other
YOUR COMPRESSOR – Relocation of machines brand compressor systems
– Debottlenecking – Conversion from lubricated to
– Turn-key installations non-lubricated conversions
MONITORING AND – Support for system evaluation – Broad experience through
DIAGNOSTICS – Comprehensive customized service compressor installations in
EXTEND MEAN TIME from diagnostic service to predic- various processes
BETWEEN OVERHAUL tive maintenance
– Full-service agreements for Burckhardt Compression
maximum availability recommends
– Online diagnostic services
COMPRESSOR – Theoretical and practical training – Standard trainings, customer
TECHNOLOGY TRAINING from our compressor experts specific programs on request
HAVE YOUR OWN – Training center with full-size
COMPRESSOR SPECIALISTS equipment (Laby®, Process Gas and
Hyper Compressor)
SERVICE CENTERS Full range of services and top 24 hours emergency:
WORLDWIDE performing components through +41 52 262 53 53
global organization and local service
centers.
20 HYPER COMPRESSORS
HYPER COMPRESSOR TRAINING
HAVE YOUR OWN HYPER SPECIALISTS
THE BURCKHARDT COMPRESSION TRAINING CENTER
Our Training Center features the complete range of WHAT WE CAN OFFER YOU IN OUR TRAINING
Hyper Compressor service parts and components. It is – 1–5 days intensive training including
the right place to train your staff for the demanding compressor specific information
activities of a Hyper Compressor service without the – Theoretical advice and practical training
stress of getting back into LDPE production. – Full size equipment
– Qualified supervision
For more detailed information about training, – Full documentation
please contact: – Training of all operations until perfect
Tel: +41 52 262 57 39 – In a professional environment
training@[Link]
[Link]/training We also offer customized trainings on-site.
HYPER COMPRESSORS 21
22 HYPER COMPRESSORS
MONITORING AND DIAGNOSTICS
CRYSTAL CLEAR INFORMATION
FOR ADVANCED OPERATION
Online condition monitoring and diagnostics of compres-
sors in LDPE service demand a highly adaptable and
reliable technology. PROGNOST®-NT is the leading
diagnostic system of booster/primary and secondary
compressors worldwide.
It has been chosen as the No.1 OEM and retrofit solution.
More than 60 compressors in LDPE service are equipped
with PROGNOST®-NT today.
TECHNOLOGY HIGHLIGHTS
– Reliable and super-fast machinery protection functions
using an intelligent shutdown logic.
– The Early Failure Detection module identifies mechanical
defects in early stages. Clear text messages with accurate
information about component damages (including location
and probability) are supporting the maintenance decision.
– Continuous Wear Monitoring avoids unplanned machine
stops and allows full component utilization.
– PROGNOST® Efficiency Optimization is based on dynamic
p-V analyses and automatically informs about sealing
problems even within Hyper Compressor cylinders.
– Integration of PROGNOST®-NT into existing DCS enables
an automatic, operating condition based threshold moni-
toring to avoid false alarms.
[Link]
HYPER COMPRESSORS 23
– Frame vibration – Accleration and – Strain gauge rings
– DCS (distributed vibration sensors for high pressure p-V
control system) values diagrams
e.g. temperature, line
pressure
– Horizontal and vertical
plunger vibration
RECIPROCATING COMPRESSORS COMPRESSOR COMPONENTS SERVICES
LEADING TECHNOLOGY FOR BEST PERFORMANCE THE FULL RANGE
LOWEST LIFE CYCLE COSTS AND LONGEST LIFETIME
Laby® Compressor valves Burckhardt Valve Service
Compressors
Contactless Redura® rings & packings Spare parts logistics
and oil-free
Capacity control systems Field service
Laby®-GI Capital parts Technical support
Compressors
Fully balanced
Labyrinth piston compressor Revamps & upgrades
components Component repair
Hyper/secondary compressor Condition monitoring &
Process Gas components diagnostics
Compressors
API 618 – lowest life Training
cycle costs
Hyper Compressors
Safe and reliable
up to 3’500 bara /
51’000 psia
Standard
High Pressure
Compressors
Compact package for
demanding applications
[Link] – 11/2017 – Printed in Switzerland on FSC certified paper
Burckhardt Compression AG Your local contact
CH–8404 Winterthur
Switzerland
Tel.: +41 52 262 55 00
Fax: +41 52 262 00 51
24-hour emergency tel.: +41 52 262 53 53
info@[Link]
[Link]