This milestone project first began when Jacobs Engineering Group Inc. – one of the world’s largest providers of technical professional services – contacted D-R requesting a quotation for remanufacturing a competing original equipment manufacturer’s (OEM) compressor. The compressor was to be a "duplicate" of the company’s existing two units at its Flint Hills Resources – formally Koch Petroleum Group – facility in Corpus Christi, Texas.

The project, part of Flint Resources’ Low Sulfur Gasoline Program, is designed to produce fuels with 80 percent lower sulfur levels and continue to improve Texas air quality. D-R’s Applied Technology group was assigned to the project.

The Applied Technology group, located in Grove City, Pennsylvania, is an extension of the company’s Engineered Solutions groups based in Painted Post, Wellsville, and Olean, New York. Applied Technology was formed as a result of clients preferring to have one supplier work on all of their equipment. As a result, the Applied Technology group can take D-R’s state-of-the-art technology and total solutions capabilities and apply them to all makes and models of installed process reciprocating compressors and integral gas engines.

"This is exactly the type of project the Applied Technology group was modeled after," said Fred Tanneberger, director, engineered solutions for D-R Product Services in Painted Post. "It involves providing the latest technology and designs for improved efficiency and reliability, while utilizing or matching whatever existing equipment is available in the field. In this manner, we are able to minimize the expense for the client while maximizing their value and return on investment."

As soon as D-R began investigating the project, it was faced with a series of challenges. After Jacobs Engineering supplied D-R with the original instruction manuals, it was determined the compressors at the Flint Hills Resources facility were different from the previously thought two-throw, 30,000-pound rod load frames.

"This presented a challenge for us, because the original manufacturer had provided an 11-inch stroke, two-throw, 60,000-pound rod load frame with a nine-inch stroke crankshaft," said Joe Lottes, senior project development engineer at D-R. "This was done to provide a higher rod load frame unit for the specific application, while keeping the piston speed below the maximum limit required per the original specifications."

After contacting various equipment suppliers, D-R was able to locate two 11-inch stroke, two-throw, 60,000-pound rod load frames from an experienced equipment dealer. However, a nine-inch stroke crankshaft was still needed.