The Situation
The customer, a plastic injection moulding company, approached HAYLEY DEXIS reporting cold-start performance issues with their reciprocating compressors. The customer also wanted to reduce oil consumption and prolong valve life, as the oil and valves were currently being replaced every 1500 hours. In operation were four Compare Reavell H Series 5236 compressors; two running 24/7, one running on-demand, and one spare.
The Solution
The HAYLEY DEXIS team worked quickly to identify an appropriate solution. To extend oil life beyond 1500 hours, HAYLEY DEXIS recommended a trial of the synthetic compressor lubricant, Shell Corena S4 P 100. The lubricant is produced specifically for high-pressure reciprocating compressors running at high temperatures. With a synthetic ester base fluid and high-performance additive system, Shell Corena S4 P 100 can achieve 2500 hours of oil life. A trial was run onsite to 1000 hours, with condition-monitoring every 250 and 500 hours thereafter. Key components were photographed before and after the trial, to document the extension to component life.
"THE CUSTOMER WAS ABLE TO EXTEND OIL LIFE FROM 1500 TO 2500 HOURS."
The Result
By using Shell Corena S4 P 100, the customer was able to extend oil life from 1500 to 2500 hours. This meant that consumption levels were reduced significantly. With improved cold-start performance, the customer was able to switch off the oil heaters that were previously used during cold starts. The amount of valve refurbishments needed was also reduced from 11 to 7 per year, representing an annual cost saving of over £5000.