Critical compressor overhaul successfully completed in nine-day maintenance marathon
Wilrijk, Belgium, March 2014: Atlas Copco’s ZH compressor plays a critical role at the Solvay hydrogen peroxide factory in Póvoa de Santa Iria, Portugal. When the 80 000-hour unit needed an overhaul that would require it to be out of service for three weeks, Atlas Copco and Solvay technicians developed a plan to complete the maintenance project in nine days of intense work.
Solvay purchased the ZH oil-free centrifugal compressor 10 years ago. Equipped to save energy and guarantee reliability, Atlas Copco’s ZH compressors are ideal for customer processes with a fluctuating or constant air demand. These innovative compressors provide reliable operation in the most demanding environments. For optimum product quality, air is 100% certified oil-free according to ISO 8573-1 Class 0 (2010).
Overhauling within nine days
“Thanks to Atlas Copco’s flexibility and cooperation, and their awareness of the impact this compressor’s absence would have on us, we managed to put together a work plan that allowed us to overhaul the compressor in record time,” says Ramiro Dionísio, head of the project at Solvay.
No room for error
On the first day of work, shortly after the rotors were removed, an international carrier was waiting at the gates to take them to Germany for balancing. “Nobody does this balancing work in Portugal, so the parts have to go directly to the manufacturer,” says Ramiro Dionísio. Twenty-four hours later, the rotors arrived in Germany, and in three days the work was completed and the rotors returned to Solvay.
A team of two Atlas Copco technicians and two Solvay employees then reassembled the equipment. “The entire overhaul was completed in nine days. The tenth day was spent monitoring the machine as it went back into production,” Ramiro Dionísio says.
Solvay’s ZH compressor, which works approximately 8600 hours per year, has supplied compressed air very reliably, robustly and safely, and the final evaluation of the work done on the compressor was very positive. “Let’s hope it lasts at least another 80 000 hours,” said Ramiro Dionísio.
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Atlas Copco’s Compressor Technique business area provides industrial compressors, vacuum solutions, gas and process compressors and expanders, air and gas treatment equipment and air management systems. The business area has a global service network and innovates for sustainable productivity in the manufacturing, oil and gas, and process industries. Principal product development and manufacturing units are located in Belgium, Germany, the United States, China and India.