Revamping, Modernization, Upgrade & Refurbishment

Revamping, Modernization, Upgrade & Refurbishment

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.

  • Remote-diagnostics
  • Diagnostic systems
  • Healthcare Pakages (HCP)
  • General Plant assessment

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

short piston ring life
short piston ring life
Paper mill compressor piston seals quick wear was troubleshooted by piston rings improvement.
high hyper-compressor piping vibration
high hyper-compressor piping vibration
High piping vibrations on a Hyper-compressor was investigated and cured by strain-gage pressure measurement, pulsation analysis, orifices insertion and support modification.
steel mil igcc failure
steel mil igcc failure
After two catastrophic failures of an integrally geared centrifugal compressor, CST RCA allowed to put it back online successfully by changing bearings.
power generation steam turbine start-up failure
power generation steam turbine start-up failure
Two steam turbines had the same severe rubbing at the start-up. CST found the cause and the solution
polypropilene screw compressor troubleshooting
polypropilene screw compressor troubleshooting
Frequent piping support failure was eliminated by FEM analysis and new support design.
ldp high pressure cooler ruptures
ldp high pressure cooler ruptures
Repeated Hyper-compressor interstage cooler ruptures due to excessive vibrations were cured by FEM study, new support design introduced.
cylinder valve catastrophic failure
cylinder valve catastrophic failure
RCA assessed the failure being caused by overpressure due to sudden liquid ingestion.
knocking sound from a cylinder
knocking sound from a cylinder
RCA and FEM revealed faulty piston rod dimension and tightening procedure

For information on CST activities, email to:

FILIPPO CINELLI at filippo.cinelli@cstfirenze.com

LUCIA MATTESINI at lucia.mattesini@cstfirenze.com

GIULIA TOSI at giulia.tosi@cstfirenze.com

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