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Compressor Systems 

Compressor Revamp and Modernization

Revamping and modernization offers the possibility to adapt existing reciprocating and diaphragm compressors to changed operating conditions and to improve immobilization as well as availability, because in most cases it is less expensive to revamp compressors than to purchase a new system.

For this purpose, NEUMAN & ESSER implements engineering and creates a schedule of specifications for the optimum performance of existing compressors and system components in accordance with the current requirements specifications.

Our in-house tool KO³ (Compressor Optimization Version 3) is applied to check the technical options for a revamp. Within the scope of an extensive engineering study, the customer is provided with a binding offer for revamping.

The NEUMAN & ESSER experts for new machines assume the processing of the revamping in order to always ensure implementation of state-of-the-art technology. On-site revamping is then carried out by the NEAC Compressor Service team.

Good Reasons for Revamping and Modernization Measures

Reciprocating compressors are tailor-made machines which are designed for the defined operating conditions. Adaptation of the compressor output and changed parameters are the most frequent reasons for revamping and modernization measures. Customers also often decide to modernize their existing system in order to achieve technical improvements or modern, energy-efficient control systems.

Basically, the following major reasons exist for revamping and modernization:

  • Adaptation of the compressor output (rerating)
  • Adaptation to changed process parameters (reapplication)
  • Installation of modern, energy-efficient control systems (controls)
  • Technical improvements
  • Optimization of existing systems via pulsation analyses, torsion analyses, FEM, etc.

Approach for a Revamping Project

First, NEA checks the compressor design based on the original or current design conditions. Then, the compressor system is redesigned for the changed operating parameters, using the design tool KO³.

The KO³ tool checks the compressor components including valve design, mechanical properties, bearing load and crankshaft stability. Moreover, each compressor revamp requires in-depth checking of the load capacity of all accessories. The intense engineering in advance pays off because this is the only means to arrive at the safest and economically most sensible technical solution.

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