Better safe than sorry: The importance of preventive maintenance in marine compressors

Tasks like preventive maintenance and equipment inspections may not always be the most exciting things to appear on the job list, but if a ship’s compressors are to run reliably, it’s vital that engineers treat it as more than just another item to tick off.

Properly tackling issues before they cause problems is a vital part of ensuring the long-term reliability and efficiency of equipment, particularly for process-critical machinery like the reciprocating compressors used on multi-million-dollar marine gas transport vessels.

The necessity of routine maintenance

Reciprocating compressors are an essential element of marine gas transport. This is due to their ability to efficiently compress and manage a variety of gases under high pressure, which is crucial for loading, offloading, and maintaining them during transport.

The compressors’ robust design ensures they can operate reliably under the demanding conditions of marine environments. However, this reliability depends on meticulous, planned maintenance. Skipping the recommended procedures outlined in the operator’s manual might seem harmless, but such oversights can lead to significant issues, affecting not just the compressor's performance but potentially jeopardizing the entire vessel's operation.

Every compressor is unique, designed for specific applications with materials and components chosen for optimal performance. This uniqueness is mirrored in the maintenance guidelines, which contain essential, model-specific instructions and precautions. Regular inspections and adherence to the manufacturer’s guidelines ensure the longevity and reliability of these machines.

It’s particularly crucial for components like lubrication and coolant systems, where correct specifications and regular checks are fundamental for efficient operation and extended service life.

The importance of correct maintenance: A case study

A clear example of the importance of regular, careful maintenance came in recent incident involving a new LNG vessel.

Burckhardt Compression delivered two boil-off gas (BOG) compressors, specifically designed for the vessel based on its detailed requirements. After less than one year in service, however, the ship reported coolant in the compressor oil system and requested Burckhardt Compression attend to investigate and provide technical support.

When our engineers came on board to carry out this inspection, they found that the coolant galleries around the cylinders were more corroded than they expected. Further investigation showed that the maintenance team had failed to install the specified mixture of glycol during the commissioning process. As a result, some corrosion was found in the cooling jacket of the cylinders as well as in the pipework to the compressor.

While this was not an immediate problem, the corrosion could have caused serious damage if left unchecked. Fortunately, our engineers were able to quickly install new coolant with the correct mixture of glycol and draw up a plan to replace the damaged parts during the vessel’s first dry-dock maintenance period.

The continuous support loop

As unfortunate as it was, the incident aboard the LNG vessel serves as a stark reminder of the importance of following maintenance protocols to avoid unnecessary damage and costs. Continuous support and preventative maintenance, underpinned by comprehensive inspections and careful planning, is indispensable for the longevity and reliability of crucial maritime equipment – saving time, resources, and ensuring uninterrupted operations.

It's a cliché, but prevention is indeed better than the cure – especially in the context of maintaining complex and vital equipment, such as reciprocating compressors on marine vessels. Following recommended procedures not only maintains operational efficiency but also safeguards against unforeseen failures, ensuring the vessel’s smooth sailing and operational integrity.

Written by Paul Dance , Fleet Manager Marine Service Solutions at Burckhardt Compression.