Success Stories

Click on a link below to learn more about particular customer situations and needs, and how ACI implemented innovative solutions to meet these needs. For more detailed information on ACI solutions to any particular job, please contact ACI and indicate the job number (Case #, Customer).

This list of key jobs is available to detail ACI’s expertise in the reciprocating compressor industry, and to give an overview of ACI’s innovative solutions to solve particular compression needs. This list does not constitute any endorsement of ACI by any of the companies listed.

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  • Case #30

    The existing compressors, (4) Worthington BDCcompressors, no longer supported by the OEM. Old pipeline plant moth-balled for many years. Purchased by Spire Storage with limited reciprocating compressor experience.

  • Case #29

    The existing cylinders on large integral angle engines, were unable to meet the flow and pressure conditions associated with the available gas.

  • Case #28

    Existing cylinders attached to existing integral engines were unable to respond to the increased flow requirements of the system. The cylinders and engines were not manufactured by the same OEM.

  • Case #26

    Customer has been operating cast steel compressor cylinders in a high pressure application. Welded on water jackets consistently cracked and resisted all attempts at repair.

  • Case #25

    A reapplication of an existing four throw motor driven compressor unit rendered the original arrangement incapable of meeting the new demand.

  • Case #24

    The customer had an existing integral angle compressor engine with cylinders which no longer served the stations requirements.

  • Case #23

    Customer installation involved a number of integral angle engines. Flow requirements changed over time and further lacked sufficient capacity control equipment to meet expected variations in flow requirements.

  • Case #22

    Customer experienced an increase in natural gas supplies which they could make available for industrial and residential use.

  • Case #21

    Customer’s attempt to obtain gas transmission cylinders to re-cylinder existing engines met with no response from the OEM.

  • Case #20

    The customer had purchased several five stage, single throw, 3000 psi air compressors from an OEM. These were skidded and incorporated with portable air separation plants. Mechanical problems with the compressors proved to be highly resistant to repair or modifications that would permit them to operate in a reliable manner.

  • Case #19

    A packager sold a packaged compressor unit for application in a hops processing plant. The process required a substantial volume of oil free CO2 gas.

  • Case #18

    Customer had large volumes of a gas mixture, which was primarily comprised of carbon dioxide, available for use elsewhere in their system. The gas was to be delivered at a pressure of 1580 psi.

  • Case #17

    Customer’s well head pressure was declining and as a result oil flow rates also were declining.

  • Case #16

    The piston in the customers first stage hydrogen service experienced excessive wear and in some cases structural failures. Designs by other aftermarket suppliers provided no improvements.

  • Case #15

    Customer experienced a crack in a cylinder in hydrogen service. Loss of the cylinder would curtail plants production of gasoline. OEM replacement cylinder delivery time was unacceptable.

  • Case #14

    Customer’s existing cylinders were constantly under attack from the extremely corrosive nature of the gas being compressed. Cylinder life norm was 3 to 5 years. OEM offered no assistance in resolving the problem and customer attempted to produce replacement cylinders of the same geometry in a ni-resist material.  The cylinder geometry and jacketed design were not compatible with ni-resist foundry practices and requirements.

  • Case #13

    Customer requirement for ethylene gas at elevated pressures without contamination from hydrocarbon type lubricants.

  • Case #12

    Customer had the need to compress large volumes of a hydrogen and methane gas mixture. Because of the range of operating conditions, capacity control equipment would be a major factor in the machines performance.

  • Case #11

    Customer operating integral angle I-R units in a multi stage injection/withdrawal service using cylinders equipped with an infinite step capacity control system.

  • Case #10

    Customer had a need for an increase in capacity at a station whose future was uncertain. Management was contemplating the removal of the station from service in the years ahead. The existing cylinders were at the maximum size offered by the OEM. The OEM’s solution required the use of the next larger class of cylinder. This approach would necessitate piping and pulsation vessel changes and perhaps an analog study.

  • Case #9

    Customer was operating integral angle compressor units that were experiencing excessive valve losses.

  • Case #8

    Customer has large integral angle compressor units with infinite step capacity control devices over compressor valves to effect the desired load and capacity control of the units. The system was basically a one of a kind system and the OEM no longer made replacement parts available. Maintenance of the valve plate depressors required specialized skills which also are not generally available.

  • Case #7

    Customer required the reapplication of large horsepower integral engines and compressors. The range of ratios required a reduction of existing fixed clearance.

  • Case #6

    Customer was operating multi-stage hydrogen compressors in a refinery that compressed a gas which was hydrogen rich. Flow requirements changed in more recent times and in addition load requirements had become more variable.

  • Case #5

    Customer owned four throw nine inch stroke, DeLaval units previously in a natural gas BTU stabilization service were to be re-cylindered for natural gas injection/withdrawal service.

  • Case #4

    A total revamp of the refinery process resulted in the obsolescence of all cylinders previously used on two different integral angle compressor units.

  • Case #3

    OEM high stage cylinders failing on a consistent basis.

  • Case #2

    Existing OEM’s gas transmission service failed in service.

  • Case #1

    Customer had OEM cylinders w/o nameplates and no known pressure rating. This was considered a safety hazard. Driver is an I-R KVG and cylinders were non I-R but those of another OEM.