Dresser-Rand offers many different solutions for revamping and remanufacturing reciprocating compressors. There are many important benefits of revamping, reapplying, rerating and modernizing your reciprocating equipment.

Revamp, reapply or upgrade existing reciprocating compressors and gas engines

Revamping, reapplying, or upgrading existing equipment can help you meet new or changing compression requirements with existing equipment, provides a cost-effective alternative to the purchase of new equipment — and projects can generally be completed in a shorter time period. Additionally, it can help to extend equipment life, increase reliability and availability by incorporating the latest material and design technology, and decrease engine exhaust emissions and/or reduces compressor cylinder fugitive emissions to meet current and future environmental requirements.

Rerate existing reciprocating gas engine

Rerating an existing gas engine can help to increases horsepower and efficiency.

Comprehensive OEM review of all known current and future requirements

Includes consideration of equipment ratings and limitations for a reliable conversion and safe operation, and provides economical revamp solutions focused on standardization of wearing parts, maximum efficiency and reliability

Close OEM / customer coordination

By working closely with the client, Dresser-Rand helps to minimizes the number of unknowns to help achieve a cost-effective solution.

Reduce harmful emissions

Dresser-Rand is a pioneer in lean burn technology to reduce NOx. Standard and custom-designed retrofit kits are available.

Depending on engine model and exhaust emissions goal, conversions could involve:

Using precombustion chambers (PCCs) to ignite lean engine mixture

Increasing engine air flow for leaner combustion

Installing new or upgraded engine combustion air coolers

D-R's Fuel Management Systems

Incorporating improved engine control features

Evaluating compatibility of existing auxiliary systems

Precombustion Chambers (PCCs)

Features	Benefits
Highest energy ignition source	Provides the necessary energy to consistently ignite the lean mixtures required for low NOx emissions; supports consistent firing via multiple simultaneous ignition sites along the torch path; reduces main chamber ignition delay while promoting complete combustion; supports combustion stability over engine's entire operating range
Consistent ignition	Reduces misfire, detonation and cycle-to-cycle firing pressure variation
Enhanced performance at varying speeds and loads	Provides the ignition energy necessary to reduce NOx while keeping carbon monoxide (CO), non-methane hydrocarbons (NMHC) and fuel consumption at acceptable levels for best overall engine performance
Allows engines to meet or exceed today's emission requirements	Adapts to changing needs when applied with other Dresser-Rand lean burn combustion system hardware upgrades
Proven OEM technology	Assures component compatibility for unmatched efficiency and reliability

Engine Air Flow

Increasing Engine Air Flow for Leaner Combustion

By increasing engine air flow, the peak combustion temperature is lowered and NOx is reduced. Air flow can be increased by:

Reducing load on piston scavenged two stroke units and/or increasing speed (depends on model or serial number)

Converting non-turbocharged units to turbocharged style engines (for example, converting HBA to HBA-T or KVGR to KVSR)

Modifying or upgrading existing turbochargers (simply changing the turbo nozzle ring results in minor increases)

Replacing original turbochargers with modern high performance turbochargers specifically chosen using OEM engine design parameters

Engine Combustion Air Coolers

New or Upgraded Engine Combustion Air Coolers

As air flow increases, the need increases for cooling combustion air before it enters the power cylinders.

Engine air cooler upgrades include:

Internal scavenging air coolers (TLA 2 stroke engine models)

On or off-engine scavenging air coolers

Scavenging air cooler or plenum adapters

Scavenging air header

On and off-engine turbocharger air aftercoolers (4 stroke engine models)

Rework of existing air intake manifold

Replacement or "exchange" air intake manifolds

Modification or replacement of existing auxiliary water pump

Fuel Management Systems

Improving Fuel and Air Mixture

Engines converted to lean burn design require attention to fuel injection. Optimum fuel admission measures differ from engine to engine, but may include:

Using directional fuel injection (DFI)

Modifying fuel cams and using DFI

Upgrading to Dresser-Rand's Fuel Management System for four-cycle gas engines

Directional fuel injection:

Provides high velocity gas injection that improves mixing

Provides the initial stratification within the main chamber to support adequate mixing in the precombustion chamber

Is used with modified cam timing to support lean burn conversion for some Dresser-Rand engines

Engine Controls

Improving Engine Controls

Depending on the engine type, controls are updated to meet lean burn operational requirements. It is possible to incorporate required/desired features in existing control systems or with add-on control panel and associated control devices.

Auxiliary Systems

Evaluating Compatibility of Existing Auxiliary Systems

Engine modifications may affect suitability of the following existing auxiliary systems and accessories:

Unit utility cooler

Cooling system piping and temperature control devices

Air intake filter and piping system

Exhaust silencer and associated piping system

Control system, including on-engine components

Operating procedures

Revamps & Remanufactures for Reciprocating Products.