Challenge

A rental fleet compressor required inspection, repair, and certification before redeployment into a gas gathering application.

Enerflex Retrofit Solution

  • Comprehensive inspection of:
    • Engine
    • Compressor frame and cylinders
    • Control panel and instrumentation
    • Utility and process piping
    • Fuel and start systems
  • Repairs included:
    • Replacement of engine turbochargers and starter
    • Rebuilding of packing cases and cylinder valves
    • Re-certification and replacement of relief valves
  • Pre- and post-operational testing

Engineering Highlights

  • Standardized make-ready process
  • Field-proven inspection and repair methodology

Outcome

  • Unit certified and rental-ready
  • Reliable performance in gas gathering service
  • Repeatable solution across customer fleet

Challenge

A single-stage electric motor drive compressor system could not meet increased pressure requirements at a natural gas storage facility.

Enerflex Retrofit Solution

  • Conversion of a 5,750 HP single-stage compressor into a two-stage configuration
  • Removal and replacement of:
    • First-stage cylinders
    • Pulsation bottles
    • Motor hub
    • Kiene valves
  • Installation of:
    • New first- and second-stage pulsation bottles with supports
    • Interconnecting piping and orifice plates
    • Utility cooler and glycol tank, pump, and trim
  • X-ray and hydrotesting of all process piping

Engineering Highlights

  • Pressure capability redesign
  • Full compliance testing and commissioning

Outcome

  • Increased pressure capability
  • Successful commissioning
  • Reliable operation at Louisiana gas storage facility

Challenge

A midstream customer sought to maximize compressor capacity by fully utilizing available driver power while maintaining safe and predictable operation.

Enerflex Retrofit Solution

  • Re-engineering using Pulsation Attenuation Network (PAN) technology
  • Replacement of existing bottles, scrubbers, drains, piping, braces, and supports
  • Installation of PAN pipe structure welded directly to skid
  • Replacement of ET cylinders and E crosshead guides with larger T cylinders and guides
  • Installation of new beams and head-end A-frame supports

Engineering Highlights

  • Advanced pulsation control design
  • Structural reinforcement to support increased capacity

Outcome

  • Significant efficiency and capacity increase
  • Predictable and safe operation
  • Optimized performance of a 1,380 HP compressor system

Challenge

An aging electric motor drive propane refrigeration system required refurbishment to restore reliability and ensure safe operation at a gas processing facility.

Enerflex Retrofit Solution

  • Full teardown and inspection of the rotary screw compressor
  • Removal, inspection, repair, reinstallation, and re-alignment of the electric motor
  • Replacement of valves and piping across the skid
  • Control panel and hardware upgrade to meet NEMA 4 standards
  • Rebuild of refrigerant-cooled oil cooler temperature control valve
  • Ultrasonic thickness testing of oil separator and piping
  • Pressure and leak testing of all skid components

Engineering Highlights

  • Integrated mechanical, electrical, and controls scope
  • Quality assurance through inspection and testing protocols

Outcome

  • System successfully recommissioned
  • Reliable operation restored
  • Returned to service at a Texas gas plant

Challenge

A new grass-roots compressor station required refurbished compression systems optimized for gas boosting service, while minimizing capital and logistics costs.

Enerflex Retrofit Solution

  • Design, modification, procurement, and installation of two refurbished compression systems
  • Reuse of existing gas engine drive units, including:
    • Engines
    • Structural steel frames
    • Compressor frames
    • Engine-driven coolers
  • Fabrication and installation of new suction bottles, discharge bottles, and suction scrubbers
  • Completion of an acoustical study

Engineering Highlights

  • Asset reuse strategy to reduce cost and lead time
  • On-site retrofit execution to minimize transportation

Outcome

  • Successful on-site completion
  • Reduced logistics costs
  • Optimized performance for gas boosting service

Challenge

Legacy pneumatic control systems limited automation, reliability, and operational visibility.

Enerflex Retrofit Solution

  • Removal of pneumatic control panel, tubing, and end devices
  • Installation of new Allen-Bradley CompactLogix PLC panel
  • Installation of new conduit, wiring, and electrical components
  • Programming, calibration, startup, and commissioning

Engineering Highlights

  • Modern automation architecture
  • Improved diagnostics and control reliability

Outcome

  • Successful startup and commissioning
  • Enhanced system control and reliability

Future-ready controls platform

Challenge

A fire-damaged reciprocating compressor suffered extensive mechanical and structural impact, resulting in unsafe operating conditions and unplanned downtime.

Enerflex Retrofit Solution

  • Replacement of the gas engine and third-stage cylinder wear components
  • Installation of new compressor bearings
  • Structural integrity restored using new grout boxes, coupling shims, and crosshead guide support
  • Repair and replacement of process equipment including:
    • First- and third-stage suction and discharge bottles
    • Third-stage scrubber valves and instrumentation
    • Third-stage cylinder Kiene valves
    • Process piping and cooler panels

Engineering Highlights

  • Structural re-alignment and frame stabilization
  • Multi-discipline mechanical, piping, and instrumentation scope
  • Coordinated execution to minimize outage duration

Outcome

  • Compressor restored to full service and safe operation
  • Minimal downtime

Asset life extended without full system replacement

Challenge

A flash fire caused extensive damage to an existing Gemini F604 compressor frame and components.

Enerflex Retrofit Solution

  • Removal of damaged Gemini frame, cylinders, bottles, and sub-base
  • Fabrication and installation of new compressor base
  • Supply and installation of:
    • Two Ariel JGK/4 frames
    • Multiple replacement cylinders
    • Seven replacement bottles and associated spools
    • New pressure safety valves
    • New HMI for control panel
  • Phased execution aligned with building installation

Engineering Highlights

  • Multi-phase retrofit planning
  • Structural redesign and base fabrication

Outcome

  • Unit exceeded predicted flows upon commissioning
  • Safe and reliable return to service

Upgraded compression capability