2K160
Burckhardt Compression 2K160 — Marine cargo compressors for LNG vessels, BOG handling.
Inspector Detail
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Common issues
- Increasing labyrinth piston/cylinder radial clearance over time, reducing volumetric efficiency
- Rod packing leakage, particularly with cryogenic BOG service where seal materials can be affected by low temperature
- Suction/discharge valve wear or breakage causing reduced capacity and abnormal stage temperatures
- Crosshead or crankshaft bearing wear
- Cylinder liner wear increasing blow-by
- Vibration from valve or piston rod issues
- Instrumentation/safety trip faults (high discharge temperature, low suction pressure, vibration) - critical given BOG duty
- Rod packing cooling/venting system issues affecting seal life at low temperature
Inspection checklist
- Monitor and trend suction/discharge pressure and temperature per stage against design values
- Check rod packing vent/leak-off for excessive gas leakage
- Vibration monitoring on crosshead and cylinder
- Inspect valves at scheduled intervals for plate condition, spring integrity and seat wear
- Check crankcase oil level, condition and analysis (crankcase lubrication is separate from the oil-free cylinder section)
- Inspect the piston rod for wear, scoring or coating damage, particularly at the packing contact area
- Check labyrinth piston/cylinder radial clearance at overhaul against the maker's tolerance
- Test high/low pressure and temperature trip functions
- Check foundation/mounting for looseness and listen for abnormal knocking
Service intervals
| Valve inspection/overhaul | per maker manual, commonly every 4000-8000 running hours depending on gas composition and duty - confirm against Burckhardt's schedule for this model |
| Crankcase oil change/analysis | per maker manual, commonly every 2000-4000 hours or per oil condition |
| Rod packing inspection/renewal | condition-based on leak-off rate; checked at each running period and renewed per maker guidance |
| Major overhaul (piston, liner, bearings) | per the maker's published time-between-overhaul - confirm against current Burckhardt documentation |
| Vibration/trip system function test | per class and maker schedule, typically at each survey and after any trip event |
Typical wear limits
| Labyrinth piston/cylinder radial clearance | maker-specified and comparatively tight for a labyrinth design; increases reduce volumetric efficiency - confirm exact limits against Burckhardt's own tolerance table rather than a generic reciprocating-compressor figure |
| Rod packing leak-off rate | condition-based - a rising trend against the maker's baseline indicates packing wear, no single universal number applies |
Ranges are typical for this design class. Always confirm against the manufacturer documentation for your serial number.
Critical spares
- Suction/discharge valve assemblies per stage
- Rod packing set, cryogenic-rated for BOG service
- Labyrinth piston set / rider components as applicable
- Crosshead and crankshaft bearings
- Gasket and O-ring sets rated for the service temperature
Safety
- Handles flammable boil-off gas - gas detection, ventilation and hazardous-area electrical requirements apply in the compressor room
- Cryogenic-cold upstream piping can cause cold burns
- Oil-free design means no lubricant belongs in the gas path - do not introduce oil during maintenance; this is a process/safety requirement, not just a mechanical preference
- High-pressure gas at discharge - depressurize and purge before opening
- Rotating crankshaft/crosshead - lock out before internal access
Class survey
Cargo compressors on LNG carriers are essential cargo machinery under class and IGC Code survey scope. Class will expect evidence of gas detection and ESD system testing, safety valve/trip function tests, and overhaul records for valves and rod packing. Given the oil-free labyrinth design, surveyors may also check that no lubricant contamination has been introduced into the gas path during maintenance.
Components & Design
Component data being added…
Technical Data
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Common failures & inspection points
Inspect for labyrinth piston clearances, measure wear on throttling points, verify no metal-to-metal contact in sealing zones, check for gas leakage at rod gland, perform dye penetrant testing on piston rods for micro-cracks. Critical for cryogenic operation at -160°C.
Verify material certifications for all cylinders and pistons (austenitic stainless steel or equivalent for -160°C service), test impact strength at cryogenic temperatures, inspect for frost cracking or thermal stress fractures, verify welding procedures per ASME BPV Code Section VIII for cryogenic service, check thermal cycling history for material degradation.
Check water inlet/outlet connections for scaling or blockage, verify cooling water chemistry (inhibitor concentration, pH, hardness), inspect internal cooling passages using boroscope if applicable, measure differential pressure across coolers, test for corrosion product accumulation, ensure cathodic protection if applicable for marine environment.
Verify anti-vibration mount condition and load distribution using dial indicators, check bolt torque on skid feet to foundation (re-torque after 100 operating hours), measure vibration levels at crankshaft bearing housings and compressor frame (ISO 10816 compliance for marine), inspect for foundation cracking or erosion in marine environments, verify piping strain relief to prevent resonance.
Perform gas sample analysis (GC-TCD) for hydrocarbon carryover from labyrinth oil-free design, measure valve pop pressures and re-seating reliability, inspect valve seats under magnification for erosion patterns or debris embedding, verify no lubrication cross-contamination in gas discharge lines, check for particulate generation in multi-stage systems, perform pressure drop testing across valve assemblies.
Type-general inspection and maintenance points for this equipment category — not model-specific.
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