Case Study: Enhancing Reliability of a Hydraulically-Driven Hyper Compressor

By Mirko Graf from Innospec Leuna GmbH

Download the case study Presentation_PIC_CMS-on-Hyper_Mirko-Graf_Final

Client Overview

Innospec Leuna GmbH, part of the global specialty chemicals company Innospec Inc., operates a plant in Leuna, Germany, producing EVA-based products such as FLEXAREN® and VISCOWAX®. The plant includes a hydraulically-driven Hyper Compressor commissioned in 1968, used in the EVA tubular reactor process.

Challenge

The Hyper Compressor at Innospec Leuna is a critical asset operating under extreme conditions:

  • Discharge pressure up to 2,350 bar
  • Hydraulic load transmission across 6 cylinders in 2 stages

Due to its age and complexity, early detection of mechanical issues was essential to avoid costly downtime and ensure safe operation. However, standard sensor arrangements were not feasible due to the unique hydraulic design and internal cylinder bolt configuration.

Solution: PROGNOST®-NT Condition Monitoring System

Innospec partnered with PROGNOST Systems to implement a customized condition monitoring solution tailored to the hydraulic Hyper Compressor. The system integrated:

  • Resistance Strain Gauges for valve activity monitoring
  • Rod Drop Sensors for piston ring damage detection
  • Vibration Sensors on bearings and hydraulic control units
  • Pressure Transmitters and Mass Flow Meters for hydraulic system diagnostics

Implementation Highlights

  1. Resistance Strain Gauges

  • Standard installation on exposed cylinder bolts was not possible.
  • Custom solution: Modified cylinder bolts and distance bushes were tested but yielded weak signals.
  • Breakthrough: A reliable signal was achieved by placing strain gauges on an unexpected location on the cylinder housing.

  1. Rod Drop Sensors

  • Initial placement led to sensor damage due to hydraulic override failures.
  • Improved design: Sensor adaptors were integrated into the safety packing gland lid, enhancing durability and reliability.

  1. Vibration Sensors

  • Enabled early detection of bearing lubrication issues and material fractures.
  • Identified hydraulic control unit failures such as broken pistons and inner leakages.

  1. Pressure Transmitters

  • Detected discrepancies between oil pumps, allowing for predictive maintenance and avoiding unplanned shutdowns.

Results

  • Increased reliability and extended operational life of the Hyper Compressor
  • Early fault detection enabled scheduled maintenance, reducing downtime
  • Customized sensor integration demonstrated PROGNOST’s flexibility and engineering expertise

Conclusion

This case study showcases how PROGNOST Systems delivered a tailored condition monitoring solution for a legacy Hyper Compressor, overcoming installation challenges and significantly improving asset reliability. The collaboration with Innospec Leuna highlights the value of adaptive sensor technology and predictive diagnostics in high-pressure, high-risk environments.