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Customized
MDP Hydraulics
This product is a high-performance and intelligent active lubrication protection system specifically designed for compressors. Unlike traditional auxiliary equipment, our lubrication system is the guardian of the safe operation of the compressor, the core for maintaining efficiency, and the key to extending the lifespan. We fully understand the crucial role of compressors in core processes such as petrochemicals, natural gas treatment, and air separation units. Therefore, what we provide is not just an oil station, but a comprehensive lubrication solution for the entire life cycle of the compressor.
The lubrication requirements for compressors (centrifugal, reciprocating, and screw types) are unique: high speed, heavy load, continuous operation, and no failure is allowed. Our lubrication system is precisely designed based on these core requirements:
Key design points | The value of ensuring the operation of the compressor |
|---|---|
High-pressure oil supply capacity | Provides a stable high-pressure oil film for the stuffing box and crosshead of the high-pressure piston compressor, preventing medium leakage. |
Precise temperature control (43 - 48℃) | maintains the optimal oil viscosity, ensuring that the bearings of the high-speed centrifugal compressor form a perfect fluid dynamic oil film. |
Excellence Air Separation | Special oil tank design efficiently removes air from lubricating oil, preventing the decline in efficiency of screw compressors caused by compressible fluids. |
100% redundant design | ensures continuous lubrication for the centrifugal compressor under any operating conditions, preventing the costly main unit from being damaged instantly. |
Online precision filtration | protects the precision bearings and gears of the compressor, reduces wear, and extends the maintenance interval. |
• Customized pump sets: Based on the type of compressor (centrifugal/reciprocating/screw) and power matching, specific pump models are selected.
• Pressure adaptive control: Automatically adjusts the oil supply pressure to meet the full cycle requirements of the compressor, from startup, operation to shutdown.
• Emergency Power: Optional pneumatic or direct current emergency pumps can be equipped to ensure the safe shutdown of the compressor.
• Precise temperature control: Maintain the oil temperature within the optimal range of 43-48℃.
• Dual-cooler system: One in use and one as a backup, ensuring that the compressor's oil temperature does not exceed the limit even during summer's high temperatures or harsh operating conditions.
• Rapid heating: Quickly raise the temperature to the required level for the compressor to start in a low-temperature environment
• Three-stage filtration: Coarse filtration + Fine filtration + Loop filtration, achieving cleanliness level of NAS 7 or above.
• Online Monitoring: Real-time monitoring of oil quality to provide data support for preventive maintenance of compressors
• Automatic排污： Automatically discharges the separated water and impurities
Our system strictly adheres to the API Std 614 standard, providing the highest level of lubrication protection for compressors:
• When the compressor is powered off and in idle mode, it will continue to supply oil by gravity for 3 to 5 minutes.
Prevent the compressor bearings from burning out due to lack of oil during the shutdown process.
• Material: Fully stainless steel, designed in accordance with ASME standards
• In case of failure of the main pump, the backup pump automatically starts within 1 second.
The pressure fluctuation is less than 5%, and the compressor operates without any perception.
Independent power supply, dual protection
• Free surface area ≥ 60 cm²/(L/min), ensuring adequate heat dissipation and air release
• If the stay time exceeds 8 minutes, ensure that the oil has fully settled and cooled down.
Provide standard flange interfaces for seamless connection with various compressors
The electrical interface supports mainstream protocols such as Profibus DP and Modbus TCP.
Deeply integrated with the compressor control system to achieve intelligent linkage
Centrifugal compressor: High-speed bearing lubrication, sealing oil supply
Reciprocating compressor: cylinder, packing, crosshead lubrication
Screw compressor: Lubrication of rotor bearings and synchronous gears
Process gas compressor: Customized design for special medium operating conditions
Real-time monitoring of oil pressure and oil temperature before entering the compressor
Monitoring of oil return temperatures of each bearing of the compressor
Online monitoring of oil contamination degree
Analysis of the Relationship between Compressor Vibration and Lubrication Status
Proactively detect potential faults to prevent unplanned compressor shutdowns.
Oil life prediction, optimization of oil change intervals
Energy efficiency analysis, helping compressors operate more energy-efficiently
• Application: Provide lubrication for an 8000kW centrifugal compressor
• Result: Operated continuously for 3 years without any faults, and the vibration value of the compressor decreased by 15%.
Challenge: High pressure, high temperature, sulfur-containing medium
Solution: Stainless steel material, high-pressure piston pump, special sealing design
Result: The lifespan of the filler is extended by 50%, and the maintenance cost is reduced by 30%.
• Innovation: A single lubrication system serves multiple compressors
• Advantage: Saves 40% of investment, centralized management, intelligent distribution of lubrication flow
1. Condition Analysis: Understand the type of compressor, power, medium, and environment.
2. Scheme Design: Provide 3D layout diagram, PID diagram, and technical plan.
3. Collaborative Design: Work with the compressor manufacturer to optimize interfaces and parameters.
4. Factory Testing: Conduct joint tests with the compressor to ensure perfect compatibility.
• Installation Guide: Professional team provides on-site installation guidance
• Debugging service: Synchronous debugging with the compressor
• Training Services: Comprehensive training covering operation, maintenance, and troubleshooting.
• Spare parts supply: Original components, rapid response
• Remote support: 7×24-hour remote diagnosis
20 years of experience in designing compressor lubrication systems
Over 300 sets of compressor lubrication systems have achieved successful implementation.
Partner for collaborative design with compressor mainframe manufacturers
A deep practitioner of API 614 standard in China
Key component import brand (optional)
Continuous operation test for 72 hours before leaving the factory
FAT test in conjunction with the compressor
18-month quality guarantee period
Extend the compressor overhaul cycle by more than 30%
Reduce the failure rate of the compressor by more than 50%
Reduce lubricant consumption by more than 20%
The investment payback period is usually less than 2 years.
We are not only a supplier of lubrication equipment, but also your reliable partner for the smooth operation of your compressors.
From the design of the solution to lifelong maintenance, we ensure every rotation of each compressor.
This system has been successfully applied to dozens of large-scale projects both domestically and internationally, providing reliable lubrication protection for compressor equipment worth billions.
A1: This is the top priority in our design. The system strictly follows the API 614 standard and is equipped with two key safety barriers: Firstly, the A/B dual pumps are powered by separate power sources. If one power source fails, the backup pump immediately starts. Secondly, we have set up a high-level emergency oil tank, which is installed above the compressor. When the entire plant loses power and all oil pumps stop, the lubricating oil in the high-level tank relies entirely on gravity to provide at least 3-5 minutes of emergency lubrication for the compressor rotor to idle (safely coast to a stop), which is the last physical line of defense to prevent high-speed bearings from "dry grinding" and burning out.
A2: Our custom process begins with in-depth technical communication. You need to provide: 1) Compressor data: manufacturer, model, power, speed, number of lubrication points and required oil pressure/oil volume; 2) Lubricating oil information: oil brand and viscosity grade; 3) Operating conditions: ambient temperature, availability of cooling water, explosion-proof or special space restrictions. Based on these information, we will provide a customized solution including PID diagrams, layout diagrams and parameter tables to ensure that the lubrication station perfectly matches your compressor.
A3: API 614 is the global authoritative standard for lubrication systems in the oil, petrochemical, and natural gas industries. It not only specifies components, but also a complete set of reliability engineering principles, such as 100% redundancy, mandatory high-level oil tanks, and strict oil tank design specifications (such as a free surface area of 60 cm²/(L/min)). For us, it means that the system has undergone the most stringent reliability verification; for you, it means insuring your valuable compressors with "top-level insurance", minimizing the risk of unplanned downtime and production losses due to lubrication failures to the greatest extent.
A4: Yes. We have optimized energy consumption at multiple levels: 1) Using high-efficiency motors and pumps; 2) An intelligent temperature control system that only cools the required amount of oil to prevent the cooler from overloading; 3) Optional variable frequency control, which adjusts the output of the oil pump according to the actual load of the compressor to avoid throttling waste of the constant-speed pump. Over the long term, this can significantly reduce the power consumption of the auxiliary system.
A5: We offer flexible solutions. For new projects with ample space, we recommend an integrated design, which is compact and easy to manage. For projects with limited space or renovation projects, a split-type (or distributed) design can be adopted. The oil tank pump module and the cooling filtration module can be separately arranged and connected through pipelines, significantly enhancing the flexibility of the layout. Our engineers will provide detailed installation and layout guidance.
A6: Absolutely. The core of the system is controlled by PLC and is equipped with a touch screen, which can display all running parameters and alarm information in real time. What's more, it comes with an industrial Ethernet interface (such as Modbus TCP/IP), which can seamlessly connect to the factory's DCS or SCADA system. This means that you can monitor oil pressure, oil temperature, filter status, etc. in the control room in real time and receive remote alarms, achieving centralized and intelligent "unattended" management.
A7: The control cabinet of the system will provide a set of critical passive dry contact signal outputs to the main control system of the compressor. These typically include: "Lubrication system ready", "Low lubrication pressure alarm (shutdown signal)", "Filter blockage alarm", etc. When the lubrication system detects a fault that threatens the compressor (such as the pressure dropping below the shutdown threshold), it will immediately send a shutdown signal to ensure the safe interlock shutdown of the compressor, achieving integrated protection.
A8: The daily maintenance is straightforward and easy to understand: conduct daily inspections to check the oil level in the tank and ensure that the instrument readings are normal. The main regular tasks include: 1) Replace the filter element based on the pressure difference indication; 2) Take oil samples regularly for testing to monitor the moisture content, cleanliness, and wear metal content of the oil; 3) Conduct annual inspections of the pump, motor, and clean the cooler. Our HMI interface will clearly record maintenance reminders and provide a complete maintenance manual with the equipment.
A9: The key benefits are reflected in the reliability, economy, and lifespan of the compressors: 1) Enhancing reliability: Clean, constant-temperature, and constant-pressure lubricating oil can significantly reduce the failure rate of compressor bearings and gears; 2) Reducing total costs: Precise filtration extends the lifespan of the lubricating oil, reducing the costs of oil replacement and handling; Preventive maintenance avoids expensive unplanned shutdowns and major overhauls; 3) Extending equipment lifespan: Excellent lubrication conditions can significantly extend the major overhaul cycle of the compressors and protect the value of core assets.
A10: Yes, this is called a "centralized lubrication system". We can design a centralized lubrication station with a large flow rate and multiple output branches based on the total oil consumption of your multiple compressors, the layout, and the start-stop logic of each unit. The system will set independent flow regulation and monitoring for each supply line, and consider pressure stability measures when a single unit of the compressor is started or stopped. This solution can save initial investment, reduce floor space, and facilitate centralized management, especially suitable for situations where compressors are arranged in groups.
