A critical reciprocating compressor at a Spanish refinery, previously maintained by an independent service provider, began experiencing recurring operational issues. To restore reliability and ensure long-term performance, Blackstone Roteq was engaged to conduct a comprehensive inspection and technical assessment of the compressor’s key components, including the crankshaft and crankcase.

Fig 1. Crankcase as received  |  Fig 2. Crankcase machining  |  Fig 3. Crankcase external surfaces machining

Blackstone:

• Conducted a detailed on-site inspection of the compressor
• Performed dimensional and geometrical measurements of the crankshaft and crankcase
• Supplied a brand-new crankshaft based on inspection findings
• Executed the full overhaul and repair of the compressor crankcase
• Restored the asset to reliable, long-term operation

Fig. 1 Final CMM Check   |  Fig. 2 & 3 Ready for Shipment

The project required addressing significant technical challenges:

• Identifying and assessing the non conformities: the existing crankshaft, supplied by an independent service provider, displayed multiple dimensional and geometrical deviations, along with material hardness deficiencies.
• The crankcase exhibited substantial bearing housing concentricity issues, presenting a complex machining challenge with few precedents in the industry.

Successfully addressing these issues required advanced expertise and precision execution. This project included the first-ever crankcase machining of its kind performed by Blackstone, and one of only a very few made across the BH network, demonstrating our capability to handle highly complex repairs.

By bringing the asset under Blackstone Roteq’s supervision, the customer regained full control over reliability and performance while also benefiting from access to genuine spare parts through our partner BH. The installation of a new crankshaft and fully repaired crankcase eliminated the operational issues that had been affecting uptime, allowing the unit to run smoothly and predictably.

This project also marked a significant milestone. Blackstone Roteq secured full authorization from BH to operate on series H crankcases. Our team executed a complete suite of inspections and services, including:

• Visual inspection to identify surface and structural anomalies
• Magnetic particle inspection for precise detection of cracks or defects
• Advanced machining to restore critical tolerances and alignment
• Coordinate Measuring Machine (CMM) verification for exact dimensional accuracy

This achievement underscores Blackstone Roteq’s technical expertise, precision capabilities, and trusted partnership with BH, reinforcing our ability to deliver high-value, complex solutions for critical rotating equipment.

Through a combination of expert assessment, precision engineering, and strategic oversight, Blackstone Roteq restored reliability to a critical compressor while expanding our technical credentials and strengthening our long-term partnership with BH. This project exemplifies Blackstone’s commitment to helping customers get more from their industrial assets.