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Customized
MDP Hydraulics
We provide specialized hydraulic oil stations and lubrication systems for high-end compressors in the energy industry (petrochemicals, coal chemicals, power, natural gas). Our systems are not just accessories; they are the key to ensuring your compressors operate for a long period, with high efficiency and low energy consumption, directly impacting the continuity of production and the economic efficiency of operations.
Our system is strictly designed and manufactured in accordance with API STD 614 (the fifth edition), which exceeds ordinary industrial standards.
• Pipes and Materials: All pressure pipelines use seamless steel pipes with a wall thickness of SCH80 or above, and undergo acid washing and passivation treatment to eliminate the risk of leakage caused by corrosion or pressure fluctuations.
• Cleanliness control: All pipelines within the factory are pre-assembled, cleaned, passivated and sealed. A 72-hour circulation rinse is conducted before leaving the factory to ensure a cleanliness level of NAS 1638 6 or higher, avoiding equipment damage caused by on-site contamination.
• Safety redundancy design: Standard configuration includes two pumps (one in use and one as backup) with automatic uninterrupted switching, dual filters, and a high-level emergency oil tank. This ensures that in the event of a main pump failure, the system can continuously supply oil to the compressor bearings, allowing for a safe shutdown.
Traditional gas stations only offer basic alarms, while our system is an "intelligent monitor" for the health of the compressor.
• Core parameter monitoring: Real-time monitoring of supply pressure, temperature, flow rate and oil tank level, and intuitive display on the HMI.
• Oil quality health analysis (optional): Integrates online viscosity sensors and moisture sensors to monitor the quality changes of the oil in real time. It provides early warnings before the oil deteriorates, scientifically guiding the oil replacement cycle and avoiding excessive maintenance or lubrication failure.
• Remote operation and maintenance support: The data can be connected to the factory's DCS or uploaded to the cloud via the IoT module. You and our engineers can remotely monitor the system status and predict potential risks in advance.
The energy optimization of the lubrication system itself can bring long-term benefits to your enterprise.
• Efficient heat exchange design: Using plate or tube-type coolers with optimized flow channels, compared to traditional designs, the heat exchange efficiency is increased by more than 15%, reducing the consumption of cooling water.
• Frequency conversion drive option: For applications with significant fluctuations in operating conditions, a frequency control main oil pump can be provided. The pump speed can be adjusted according to the actual lubricating oil demand, avoiding waste of electrical energy. The typical energy saving rate can reach 20% - 30%.
• Synthetic oil application support: The system design is compatible with high-performance synthetic lubricants, assisting customers in replacing traditional mineral oils with synthetic oils. This can reduce friction losses and achieve a 1.5% - 3% energy-saving effect for the compressor main unit.
Compressor type | Core challenge | points of our solution |
|---|---|---|
Centrifugal compressors | High-speed sliding bearings (tilting pad bearings) are extremely sensitive to oil temperature and cleanliness. | Dual precision filters (with a precision of up to 3-5 μm) are used, along with a precise temperature control valve to ensure that the inlet oil temperature fluctuation is less than ±2℃. A pressure accumulator is also equipped to stabilize the pressure and prevent bearing wear caused by pressure fluctuations. |
reciprocating compressors | Different pressures of lubricating oil are required for the cylinders, stuffing boxes and crosshead slide ways. The system is complex and prone to leakage | A pressure-regulated lubrication system is designed, with the main oil circuit supplying the bearings and the independently pressure-regulated oil injector supplying the cylinders. A modular piping system and high-quality joints are adopted to minimize on-site leakage points. |
screw compressors | typically use dedicated lubricating oil, which has functions of lubrication, sealing and cooling. The oil is prone to aging | Optimizing the oil-gas separation and cooling process, shortening the residence time of hot oil in the system. Strengthening the oil filtration system to effectively filter out solid impurities in the oil-gas mixture, significantly extending the service life of the lubricating oil and the compressor rotor. |
Process gas compressor (such as recycle hydrogen, ammonia compressor) | The medium gas is flammable, explosive or toxic, and the sealing requirements are extremely high. The gas may seep into the oil. | A double-end face mechanical seal and nitrogen buffer system are adopted to prevent the leakage of process gas. A degassing oil tank or online vacuum dehydration device is equipped to continuously remove the hidden gas dissolved in the oil. |
Problem: The oil temperature of the original lubrication system fluctuated greatly, causing frequent high-temperature alarms in summer, which threatened the safety of the key equipment, and the oil deteriorated rapidly, resulting in high annual maintenance costs.
Our solution: Replace the large-capacity plate-type cooler, optimize the cooling water channels; add a precise temperature control valve to regulate the flow; upgrade the mineral oil to a more antioxidant synthetic oil.
Customer Value: Completely eliminates high-temperature alarms, extends the oil product service life from 1 year to 2 years, saves over 500,000 yuan in oil and maintenance costs annually, and significantly improves the operational stability of the equipment.
Problem: New project. The requirement is for a lubrication system that occupies a small space, has extremely high reliability, and enables unmanned operation and remote monitoring.
Our solution: We offer a fully integrated compact fuel station, integrating the pump unit, cooling system, filtration equipment, and control cabinet onto a single base, thereby saving 40% of floor space. It is equipped with a complete set of intelligent sensors and remote communication interfaces.
Customer Value: Installation and commissioning time has been reduced by 60%. All the status of the oil station can be monitored in real time through the central control room, enabling intelligent management of the lubrication system and meeting the requirements of modern factories.
Our engineers will jointly confirm the compressor parameters, on-site environment, special requirements (such as explosion-proof and low-temperature), and expected goals with you.
Provide a detailed solution including P&ID diagrams, layout diagrams, equipment list, and technical descriptions, along with a transparent quotation.
Both parties will confirm all technical details and sign the contract.
Complete the manufacturing in our own factory and conduct strict pre-delivery functional tests and circulation rinsing, providing test reports.
Properly package and transport, dispatch engineers to provide on-site installation and commissioning guidance until stable operation.
Provide operation training, enjoy a 18-month warranty, and receive lifelong spare parts and technical service support.
Your compressor lubrication requirements are unique. Please provide the following information and our application engineers will prepare a preliminary technical solution for you:
• Compressor model and manufacturer:
• Medium (air, nitrogen, hydrogen, syngas, etc.):
• Type of lubricating oil (ISO VG32/46/68, mineral/synthetic oil):
• Available on-site space and special requirements:
Contact us for reliable support for your critical equipment
Phone: +86-17853237388
Email: sales@mdphydraulics.com
Website: www.mdphydraulics.com
All technical data and cases in this article are based on real engineering practices. The specific design shall be subject to the final technical agreement. We are your reliable partner for lubrication of compression equipment.
A1: Yes, our lubrication system is a customized non-standard product. No matter which brand of centrifugal, reciprocating or screw compressors you use (such as Atlas Copco, Ingersoll Rand, Siemens, Shenggu, Shaanbu, etc.), we can design and manufacture a completely matching oil station based on their specific technical parameters (such as oil pressure, flow rate, interface size) and your process requirements. Please provide the compressor model or drawings, and we will be responsible for the adaptation work.
A2: API 614 is one of the highest international standards for lubrication systems used in the petroleum, petrochemical, and natural gas industries. Meeting this standard means that our system offers top-level guarantees in terms of reliability, safety, and long-term operation. Specifically, it includes: stricter materials and manufacturing processes, mandatory cleanliness control (professional flushing before delivery), redundant safety design (such as dual pumps and dual filters), and more comprehensive monitoring and protection. This fundamentally reduces the risk of unplanned downtime and is a necessary choice for high-end applications.
A3: Our energy conservation is mainly achieved through system optimization and integration of advanced technologies: 1) Efficient hydraulic design reduces pipeline resistance and lowers pumping energy consumption; 2) Provides variable frequency pump control options, adjusting power according to actual oil consumption to avoid electricity waste, which can save 20%-40% of electricity; 3) Optimizes cooling design to reduce cooling water consumption. The overall energy-saving effect needs to be evaluated based on specific working conditions. In the projects that have been renovated, we have achieved significant operational cost reduction for our customers.
A4: For standard oil stations, the typical delivery period is 8 to 10 weeks. For projects with special technical requirements or complex customization, the delivery period will be extended accordingly based on the complexity of the technical agreement. We will provide a detailed production and delivery plan after the contract is signed and strictly fulfill it.
A5: We provide a 18-month warranty period for all products (starting from the time of on-site debugging and qualification). During the warranty period, any issues arising from design, manufacturing, or materials will be repaired or replaced free of charge. In addition, we offer lifetime technical support, have a rapid spare parts supply system, and can provide value-added services such as remote diagnosis, regular inspections, and oil quality testing.
A6: The local display and alarm for core parameters (pressure, temperature, level) are standard configuration. A more comprehensive intelligent monitoring system (including online oil sensors, data recording and remote communication interface) can be selected as an option. Through it, you can view key health indicators such as oil pressure, oil temperature, viscosity, moisture content, etc. in real time on your mobile phone or computer, and receive warning information to achieve predictive maintenance.
A7: Our oil stations are highly integrated skid-mounted modules before leaving the factory, which significantly reduces the on-site installation workload. We strongly recommend and usually include on-site installation supervision services by our engineers. Our engineers will guide the pipeline connection, electrical wiring, and system debugging to ensure the installation is correct and error-free, and they will also provide training for your operators, which is crucial for the long-term stable operation of the system.
A8: We have extensive experience in such projects. The process is as follows: You provide the drawings or on-site photos of the original system. Our engineers will assess it and communicate with you on whether it is a partial upgrade (such as only replacing the control cabinet, pump set, or adding intelligent monitoring) or an overall replacement. We will design a new solution that matches the existing space and interfaces, ensuring a smooth renovation process and minimizing the impact on production.
A9: Yes. We can provide motors, instruments, control cabinets and wiring solutions that comply with the corresponding explosion-proof certifications (such as Exd IIB T4, Exd IIC T4, etc.) based on the explosion-proof level (e.g. Zone 1, Zone 2) and gas group of your site, ensuring safe operation in flammable and explosive environments.
A10: Please provide the following basic information, and we will prepare a preliminary technical plan and budget estimate for you:
• Compressor model, manufacturer and quantity.
• Lubricating medium (such as ISO VG46 mineral oil, synthetic oil, etc.).
• Process media (such as air, nitrogen, hydrogen, syngas, etc.).
The core demands you are concerned about (such as energy conservation, intelligence, specific certifications).
You can contact us through the website form, the sales email address, or by directly calling us. We will respond within 24 hours.
