Process Compressor Packaging

The operational success of medium and small scale process plants is often critically-dependent on appropriate machinery selection and effective package engineering and fabrication.  More than 80% of our completed projects include one or more process compressors, the vast majority of which we have designed and built.  We have experience in:

• Up to five stages of compression per stream

• Multiple stream services per frame

• Complex distance piece arrangements for hydrogen and toxic gases

• Condensing, fouling and corrosive streams

• Oil-free and high purity applications

• Duplex systems for uninterrupted operation

• High pressures up to 8,000 psig, including metal diaphragm machines

Headwaters works with U.S. and International compressor OEM’s to source bare process compressors best suited to client project needs, and engineers and supplies complete process compressor packages, usually with AC induction motor electric drive.  Our main focus is on reciprocating piston and diaphragm compressors packaged in accordance with API 618, although we have experience implementing various rotary hydrogen compressor packages when that proves more technologically-appropriate.

We have especially rich experience in the field of smaller drive power process compression, below 1,500 horsepower.  This is the heart of the market for typical clean energy, industrial gas and petrochemical compression of hydrogen and synthetic gas mixtures, and is an under-served segment of the market by generalist compression packaging firms and prohibitively-expensive to execute as field-constructed EPC projects.  We have extensive experience handling contaminated hydrogen-rich streams, dissociated ammonia, refinery and petrochemical gas streams and pure hydrogen product, and a deep understanding of hydrogen compatibility issues with materials of construction of the compressors themselves and the balance of the package equipment.

Although we can execute compressor packages using traditional local operator mechanical gauge panels and racks of on-transmitter displays, our-in-house controls engineering capabilities offer greater cost effectiveness and functionality using local HMI systems and I/O marshallling.  Depending upon the automation philosophy of the plant, these local panels can be controlled either from the client DCS, from a plant-level PLC system, or with a local PLC dedicated to the compressor package.