The current social and economic situation is strongly linked to climate change and the associated climate targets. For industry, energy consumption and the associated energy costs, CO2 footprint and CO2 taxes as well as greenhouse gas emissions are decisive factors. These also have an impact on compressor systems, which are still needed but whose efficient use is more important than ever before. During original planning for compressor units’ capacities have been considered, that are not completely needed in practice.  In addition, process requirements change over time. Existing control systems are often only of a rudimentary nature and by state-of-the-art control systems such compressor units can be operated flexible and efficient. Moreover, technical developments in components and processes are not always considered. These are all starting points for making an existing compressor system more efficient, reliable and safe in line with the current state of the art.

Procedure EEA

• requesting compressor type and SN
• mechanical and thermodynamic calculation is carried out using our KO³ compressor design software

• the following are required for NEUMAN & ESSER compressors

  1. gas analysis
  2. suction pressure
  3. suction temperature
  4. discharge pressure
  5. flow rate (control range)

 

• additionally required for non-NEUMAN & ESSER compressors (Other Brand Equipment = OBE) or licensed products:

  1. type and design, permissible rod load
  2. speed, stroke, rod diameter, bearing diameter, crosshead diameter, connecting rod length
  3. materials
  4. oscillating weights

Our Step Workflow:

1. modelling of the compressor system in our KO³ design software
2. thermodynamic recalculation 
3. comparison with the read process data (-> RCFA in case of major deviations)
4. set/actual comparison of the compressor capacity
5. evaluation of technical lay-out and the existing control system
6. status report on the current situation
7. target agreement in coordination with the customer/operator
8. recalculation/redesign of the compressor system
9. optimization with regard to the design and evaluation of a control system
10. of the current situation and the modernized design, naming the benefits!

Optimization Opportunities

Performance Optimization

Improvement of wear parts

• design and arrangement of piston and guide rings 
• design of piston rod seals/oil wiper-packing
• adaptation of compressor valves

Use of modern control systems

• requirements analysis
• design of the appropriate control system
• cost/benefit analysis

Opportunity for compressor control

• speed control
• clearance pocket
• suction valve unloaders (open-close or stepless)

Technical Adjustments

Adjustment to process requirements (gas, pressure, quantity)

• compressor layout
• classic Revamp

Improving the safety of assembly conditions

• state-of-the-art technical design
• safe handling during disassembly and reassembly of components

New (improved) auxiliary units and accessories

• drive system, engine lubrication systems, cylinder lubrication
• closed water system, temperature control system
• vessels, coolers, armatures
• instruments, process control

Further Engineering Services from NEUMAN & ESSER

• performing torsion analyses: required when replacing drive components
• performing pulsation studies: By NEUMAN & ESSER engineering or in cooperation with service providers
• vibration and oscillation measurements: status report with improvement measures
• advising operators on safety (HSSE): use of the NEA|XPLORE monitoring software
• performance/fitness check for compressors

Profiting Sustainably

• the EEA uncovers possible potential
• the EEA enables the optimization of existing compressors according to the actual requirements and process conditions
• efficient and sustainable: reduce energy consumption, protect the environment
• durable and reliable: proven quality ensures reliable operation

We Support You on Your Way to a Greener Future

• personal consulting
• detailed, state-of-the-art analysis
• identification of potential for improvement
• capacity optimization
• development of possible solutions
• system solutions from a single source
• long-term support and partnership