We will present bottlenecks eliminating case study on how to remove bottlenecks. Here, you see two trends of different vibration parameters for piston compressors. The upper trend shows deterioration of the valves. As you can see, on average, the compressor faces valve issues weekly.
Incorporating the real-time diagnostic COMPACS® system made it simpler to compare different parameters and figure out the root causes and bottlenecks. When the reliability team compared valve deterioration trends with hydraulic shock trends, they confirmed the correlation. After each hydraulic shock, valves quickly deteriorated. Further investigation revealed that there was no filter between the compressors, and dirty gas was causing hydraulic shocks and valve deterioration, thus causing poor compressor reliability.
They kept two standby piston compressors to keep the facility continuously running. The compressor was repaired once a week until a gas filter was installed. Since the filter was installed, the issue was no longer a bottleneck for the unit. Thus, in this bottleneck’s eliminating case, the piston compressor’s reliability increased significantly by utilizing the advantages of the real-time equipment monitoring system. Honestly, the reliability team tried to convince management to fund the solution for about a year.
Eliminating Equipment Bottlenecks
This bottlenecks eliminating case study underscores the importance of timely maintenance and proactive machinery monitoring. By utilizing the COMPACS® system, the team could foresee potential failures and take corrective actions before they escalate into major issues. The real-time data provided a clear picture of the operational health of the compressors, enabling more informed decisions that enhanced the overall efficiency and reliability of the equipment.
Furthermore, the case study highlights the long-term benefits of investing in advanced monitoring technologies. Although it took significant effort to secure funding, the resulting improvements in compressor performance and maintenance cost reduction demonstrated such investment value. The bottlenecks eliminating approach solved the immediate problem and set a precedent for addressing similar issues in other parts of the facility, ensuring sustained operational excellence.
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