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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