Common process compressor failures and how to prevent them
08.27.25
are essential to smooth and productive industrial operations. Should your process compressor fail, from lost revenue to expensive repairs/replacements and labour for necessary works.
Today we’re looking at the common causes of process compressor failures and how to prevent them, saving you avoidable expenses and the stress of equipment breakdown.
Common causes of process compressor failure
In , process compressor failures are extremely disruptive due to the highly demanding operating conditions. Failure can be caused by:
Contamination and fouling
in the gas itself cause corrosion, erosion and fouling. Lubricants can also be responsible for fouling.
Wear and tear
Over time, the process compressor becomes worn e.g. high pressure and corrosive gases deform valves and corrode surfaces; seals degrade due to extreme temperature changes and chemical corrosion; bearings may fail due to insufficient lubrication and/or misalignment. The latter results in vibration and eventually rotor damage.
Overheating
Thermal stress is caused by overloading, ineffective heat dissipation or blocked coolers.
Electrical failures
Like lots of equipment, process compressors are vulnerable to power surges or cuts, especially at offshore sites. It’s also essential that sensors are working correctly and give accurate readings as any issues may result in sub-optimal operating conditions or delayed shutdowns due to unreported problems.
Human error
Many process compressor failures are entirely preventable and due to human error:
- Improper maintenance e.g. skipping inspections or not cleaning often enough can mean issues are missed and preventable fouling left unchecked.
- Not following proper practise regarding startup/shutdown can lead to thermal shock.
How to prevent process compressor failure
Fortunately, there are simple steps you can take to avoid process compressor failure. While some measures come with minor financial outlay, the savings in real terms are huge.
How we help prevent failure
At Rochem, we’ve specialised in process and chemicals for over 40 years. Our products help gas and oil maintain their equipment and prevent costly, unscheduled shutdowns.
With our help, implementing regular on-line cleaning using specialised nozzles and industry-leading will contribute to the effective and efficient running of your process compressor while extending its lifespan. If you’re interested in how we help our customers, read a recent case study .
Get in touch
While there are a range of potential causes when it comes to process compressor failure, fouling needn’t be one of them. If you’re interested in protecting your equipment and maintaining your profit margin, we’re here to help. Please with our knowledgeable team to discuss process compressor washing at your specific site.
