At an industrial gas facility, hydrogen is supplied to a refinery's hydrocracker via a critical dry-running compressor. This essential equipment experienced failures in key components with unclear root causes. To determine the source of the failure, a temporary PROGNOST®-NT condition monitoring system was deployed under the existing service agreement. By providing real-time insights to our expert technical team, it enabled early detection of potential issues, rapid diagnostics and root cause analysis.
Together with a sealing element upgrade over the past few years the mean time between failures (MTBF) was doubled, exceeding all expectations. Encouraged by the outstanding results, the customer decided to integrate a permanent PROGNOST®-NT monitoring system at their sister hydrogen plant. To support an optimized maintenance strategy, our experts will conduct regular data assessments. The system also includes a SIL3 emergency shutdown function, providing safety for personnel and robust asset protection.
What our customer says
- MTBF consistently below 8'000 hours in a critical hydrogen application
- Failures across multiple compressor components with unclear root causes
- A monitoring tool was required to verify the correct functionality of the stepless flow control system
| Manufacturer | Burckhardt Compression |
| Type | Process Gas Compressor 4B2C |
| Power | 4'000 kW / 5'360 hp |
| Speed | 333 rpm |
| Gas | Hydrogen |
| Suction pressure | 24 bara / 348 psia |
| Discharge pressure | 120 bara / 1'740 psia |
| Lubrication | dry-running |
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PROGNOST®-NT monitoring system
The PROGNOST®-NT 360° digital condition monitoring solution was temporarily deployed to enable real-time monitoring of the dry-running compressor and to identify the primary source of the failures. - Expert support and root cause analysis
Our OEM expert team and machine diagnostic specialists delivered actionable recommendations based on monitoring data. This enabled the customer to quickly identify and resolve issues - even remotely and during off-hours. - Predictive maintenance
By leveraging data-driven insights, maintenance activities were strategically scheduled in advance, effectively preventing unplanned shutdowns and ensuring continuous, reliable operation. - Early failure detection
The monitoring system identified issues at the earliest stage to mitigate the impact of critical failures, safeguarding personnel, the environment, and valuable assets. - Design and material improvements
Sealing elements were upgraded through the integration of the latest Redura® designs and the use of proprietary Persisto® 850 material. These enhancements effectively addressed nown failure points, improving overall system reliability.
- Significant increase of compressor availability
- MTBF doubled from under 8'000 to over 16'000 hours
- Minimized operating costs
- Full control and transparency over compressor health for both the customer and our technical support team
- Customized, long-term maintenance strategy with transparent pricing, ensuring budget clarity
- Success Stories
- PROGNOST-NT - condition monitoring