Compressor replacement parts and valve refurbishment at a coal liquefaction plant
In a 2010 replacement-parts project for an imported hydrogen compressor at a large coal-to-liquids plant in Inner Mongolia, RONDER completed measurement, manufacture and delivery within half a month of notification, compared with the two-month wait for newly ordered imported parts. The replacement parts were installed in November 2010.
The operator runs a million-tonne-scale direct coal liquefaction production line. RONDER manufactured piston rings, rider bands and piston rod pressure packing in China for its imported hydrogen compressors, and refurbished valves already in service. Customer reports issued in 2012 and 2020 document the parts and valve use on three compressor models.
Figure 1. Replacement-part supply and valve refurbishment for the 1SZL500 compressor, summarized from the customer’s service report.
Replacement parts delivered in about two weeks
The customer’s 2012 service report records that, during maintenance in 2010, newly ordered imported parts would take two months to arrive. RONDER’s locally manufactured replacement parts arrived within half a month and were installed in November that year.
The equipment was a 1SZL500 compressor manufactured by NEUMAN & ESSER in Germany for the plant’s direct coal liquefaction center. This diaphragm-type hydrogen compressor served the membrane-separation process and was one of the center’s key machines. Its normal operating conditions were:
| Parameter | Value |
|---|---|
| Gas | Hydrogen |
| Speed | 333 r/min |
| Motor power | 2,800 kW |
| Suction pressure | 9.781 MPa |
| Discharge pressure | 20.388 MPa |
HOERBIGER supplied the original piston rings, rider bands, piston rod pressure packing and valves. During maintenance in October 2010, the customer found that the piston rings, rider bands and packing were severely worn and could no longer be used. The spare parts in stock were insufficient for one complete compressor set, and newly ordered imported parts would take two months to arrive.
The customer commissioned RONDER to manufacture replacement parts in China. RONDER measured the existing parts and manufactured replacements. These arrived in about two weeks and were installed in November 2010. From notification through measurement, manufacture and delivery, RONDER supplied the replacement parts within half a month, compared with the two-month imported-part lead time. The customer report records that their service life was no shorter than that of the imported products.
Refurbishing valves with replacement plates and springs
In April 2011, the customer again commissioned RONDER, this time to refurbish the existing compressor valves for reuse and reduce costs. RONDER replaced valve plates, springs and other key components before reinstalling the valves.
The 2012 service report also records RONDER’s piston rings, rider bands, packing and PEEK valve plates, with service life comparable to that of the imported products on this compressor. The report also notes that locally manufactured spares shortened delivery time and reduced costs.
Valve replacement records for models from three international OEMs
On 18 August 2020, the customer’s mechanical and power department issued a statement on reciprocating compressor valve use. It confirmed that the customer had worked with RONDER since 2010 to develop and manufacture replacement parts in China for imported reciprocating compressors, and listed the principal compressor models below.
| Process | Equipment | Model | Discharge pressure, MPa (gauge) | Number of compressors | Compressor manufacturer |
|---|---|---|---|---|---|
| Hydrogenation and stabilization | Hydrogen compressor | Thomasen C45-3 | 14.8 | 3 | Thomassen |
| Coal liquefaction | Hydrogen compressor | 6 BDC-OF18H3-3 | 19.6 | 4 | Dresser-Rand |
| Coal liquefaction | Membrane separation compressor | 1SZL500 | 20.38 | 3 | NEUMAN & ESSER |
Figure 2. Compressor applications listed in the customer’s statement dated 18 August 2020.
The customer’s mechanical and power department stated in 2020 that RONDER’s reciprocating compressor valves had been used to replace imported valves.
Enquiries about replacement parts or valve refurbishment
To discuss compressor replacement parts or valve refurbishment, send the following information to sales@ronder-valve.com:
- Compressor manufacturer and model, and the parts to be replaced or refurbished;
- Gas, suction and discharge pressures and temperatures, and operating speed;
- Parts service history, inspection photographs, and drawings or dimensions that can be shared;
- Planned maintenance dates and spare-parts requirements.
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