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Revamping, Modernization, Upgrade & Refurbishment

In the long operating life of process machinery, components may undergo important enhancement and new technology injection and modernization can help improve equipment performance and reliability. Sometimes, also plant requirements can change and revamping of existing compressors may be a cheaper and faster solution rather than buying a new machine.

To meet new operating conditions, compressor needs to undergo a design review, revision, modification & optimization study.

CST provides the latest and innovative technology and can help users update their equipment with the most advanced solutions. CST supports Customers with design and provision of several services and products, from the feasibility study up to installation and start-up in the field.

Modernization of machinery & components

CST Upgrade portfolio for reciprocating compressors includes:

CST Upgrade portfolio for centrifugal compressors includes:

  • Rotor and Diaphragm re-desing for Performance improvement
  • Uprating to increase mass flow
  • Seal modernization
  • Anti-surge system optimization
  • Gear upgrade
  • Coupling system uprating

Reconditioning of existing compressors

CST service is not limited to the design of new units but can assist its customers with repairs instructions, parts reverse engineering and provision, modification, and optimization of existing compressors to meet new plant requirements, different gas condition and improve compressor performance, including re-bundling and sealing system upgrade (i.e., changing from oil to dry gas type).

Upgrading with new technology

Old machinery can be upgraded with new generation technology. A typical example of this upgrading is the improvement from 2D to 3D impeller flow path, installation of on-board diagnostic systems with related sensors.

Inspection and Refurbishment of damaged units

Either in case of catastrophic failures or planned maintenance, it is necessary to ascertain the damage or define scope of the inspection, make a list of the parts/activities required for refurbishment and an action plan. CST and Blackstone Industrial can provide end-to-end solutions for both planned and unplanned events or complete rehabilitation packages.

Machines modifications due to new operating conditions

Often process plants face changes in their operating conditions. It is common that the feedstock changes, restrictions in regulations can enforce, changes occur in reservoir conditions, and so on. Users need support to introduce the necessary modifications to their equipment.

CST can support its customers from the feasibility study, up to the installation in the field through the design, project management and construction.

Plant Debottlenecking

Generally, the possibility to increase the throughput of a process plant is limited by one component of the whole system. Limit can sit on the compressor.

CST offers feasibility studies and then execute the complete engineering work to revamp the machine and thus expand the plant capacity.

 

Some examples of CST revamping, modernization,
upgrade & refurbishment activity

FROM GAS ENGINE TO ELECTRIC MOTOR

User wanted to change the driver of a reciprocating compressor

PERFORMANCE RECOVERY OF AN OLD CENTRIFUGAL COMPRESSOR

Corrosion caused increased clearance between impeller and casing which was cured with new labyrinth seal insertion

FRETTING ISSUES ON CONROD BEARING OF A HYPER-COMPRESSOR

Recurrent failures of big end conrod bearings were overcome by their redesign, changing material and crush

CENTRIFUGAL COMPRESSOR UPGRADING

An old centrifugal compressor could be uprated by modifying seals, balancing drum and gearbox bearings

CYLINDER LUBRICATION UPGRADE

Five reciprocating compressors were retrofitted wìth the new PLS-100 lubrication system with great advantage for opex and process contamination. ROI was less than one year

HYPER-COMPRESSOR FOUNDATION BLOCK REFURBISHMENT

A hyper-compressor had heavy cracks on the foundation block which had to be refurbished with a new one re-engineered together with a new better balanced crankshaft

CENTRIFUGAL COMPRESSOR STAGE: REVERSE ENGINEERING & UPGRADING

Design and implementation of mechanical modifications to house new sensors. Supply and installation of a new vibration monitoring cabinet, linked to the plant DCS

NITRIC ACID CENTRIFUGAL COMPRESSOR REVAMPING

After 30+ years of operation, the compressor casing started to leak between upper and lower semi-casings. The problem was solved by revamping the casings and bolting distribution defined by FEA