INTRODUCTION

Industrial compressors are run at incredibly high

speeds under immense pressure every day. This stress

causes the rotors inside to naturally warp and bend,

creating imbalances over time due to their dynamic

nature. If these imbalances go unchecked for too long

they can lead to more catastrophic damage, expensive

field repairs, and unplanned downtime costs surpassing

$2MM per day. Consequently, there are long-standing

and recommended balancing practices in place to

prevent these problems.

Mitsubishi Heavy Industries Compressor International (MCO-I) is proud to launch their new state-of-the-art rotor balancing service. They have developed the most technologically advanced, high-speed balancing bunker in the industry. This bunker features variable input torques, ramp rates, and specialized software designed to handle the most difficult of balancing challenges when other methods are insufficient.

MCO-I’s new high-speed balancing (HSB) bunker is designed to simulate your specific rotor ’s response to unbalance at operational speed. The bunker ’s variable ramp rates can quickly climb through critical phases

to minimize unnecessary unbalancing speed ranges, and fine tune solutions to subtle imbalances at higher speeds. This comprehensive solution has placed Mitsubishi Heavy Industries Compressor at the peak of the industry for high-speed balancing, because of the specificity and accuracy of MCO-I’s new balancing bunker service.

HSB: Balancing As A Service

MCO-I has taken high-speed balancing to the next level

with their new bunker, however, their balancing service

does not stop there. The team at MCO-I has developed

a custom software that compiles data from the sensors

along several vector planes along the rotor, and

calculates balancing solutions—performing the required

advanced mathematical calculations. These complex

computations are coded into their influence coefficient

method software at MCO-I. Simply put, more precise

calculations result in longer compressor uptime and

greater profit margins.

HIGH SPEED BALANCING

In addition to more accurate calculations, MCO-I’s

software also reports on the test results in real time.

This allows MCO-I clients to view these results as they ’re

being reported, either from the beautiful on-site viewing

lounge or through the remote viewing interface.

Once testing and balancing is completed, MCO-I clients

are welcome to store their rotors inside of the storage

facility located on-site at MCO-I in Houston, Texas. Their

vertical storage facilities currently store a host of rotors

for their clients, including the largest rotor in North

America. MCO-I has become the premier North American

HSB service provider for any company with an industrial

compressor.

MCO-I’s high-speed balance pit features:

• Rigid, non-deflecting pedestals that won’t alter rotor

balance behavior, ensuring that the test conditions are as

close as possible to the field.

• High stiffness and high sensitivity so we can perform both

low and high speed precision balancing while minimizing

handling.

• Ability to balance using tilt pad bearings.

• Computer systems that provide real time evaluation data

for fast, yet careful, analysis and decision-making. Easy

networking enables cost-efficient remote witness.

Case Study: Modern Technology To Overcome A Client’s Obstacle

To illustrate why Mitsubishi Compressor ’s HSB is such

a crucial service, let’s look at the case for one of their

clients. At the end of 2019, one oil refinery ’s compressor

developed a high speed imbalance.

Their particular rotors had come from a manufacturer

overseas, which previously had to do their balancing

in-house, costing the customer tens of thousands in

shipping expenses and extended down times resulting in

millions in opportunity production loss. Local balancing

companies declined to service the rotor due to historical

issues with this particular OEM’s design and prior

attempts at high speed balancing.

The client brought the rotor to MCO-I, because they had

first hand knowledge of the HSB bunker ’s capabilities.

The team was able to quickly accelerate the rotor

through its first natural frequency and achieve

operational speed, which is where others have had

issues. At the first critical speed the rotor exhibited

acceptable absolute and relative vibration, however,

upon reaching the second natural frequency it began to

show the signs of imbalance previously observed on site.

MCO-I’s HSB team utilized their advanced influence

coefficient software to develop a solution for the

residual unbalance within hours of starting.

Their state-of-the-art balancing software is designed

to handle these advanced computational methods, to

ensure accuracy and consistency for every

client. By using these tools, MCO-I was able to

successfully balance the rotor quickly, saving the client

time and money. This new technology and the superior

commitment on behalf of the MCO-I team turned this

client’s hurdle into a success.

As previously indicated, unexpected downtimes can

create lost opportunity production costs of millions

of dollars per day, and emergency field service rotor

replacement could easily surpass $350,000. That’s why

having a team standing behind you that you can trust to

get the job done right is crucial.

CONCLUSION

Industrial compressor rotors are required to undergo

routine inspections and balancing tests. Mitsubishi

Heavy Industries Compressor International’s high-speed

balancing service will ensure you get the most thorough

testing available, while providing exceptional customer

service. With their advanced high-speed bunker and top-

of-the-line calculation software, MCO-I offers you a rotor

service that is unmatched.

Their team is happy to store your rotors in the MCO-I

storage facility, and each rotor is hung vertically to

ensure its integrity.

Additionally, MHI Compressor gives you access to all of

your rotor balancing test results in real time. You can

view these results remotely or from their beautiful on-

site viewing lounge in Houston, Texas.

Mitsubishi Heavy Industries is committed to channeling

big thinking into solutions that move the world forward.

They are doing just that with the development of the

most advanced high-speed balancing bunker service in

the industry. MCO-I’s commitment to this idea continues

to lead their team and their clients to the forefront of

the industry. By bringing people and ideas together

as one, Mitsubishi Heavy Industries Compressor

International continues to pave the way to a future of

shared success.

MCO-I Pearland Works14888 Kirby Dr.Pearland, Texas 77047Tel: 1-832-710-4700www.mhicompressor.com/en