Upgrade and modernize your existing GEA screw compressor package

Feedback regarding the GEA Screw Compressor Retrofit carried out by GEA Italy customer Frigotherm Ferrari

‘Thanks to the great local support by GEA, the retrofit of two MC screw compressors to M series was simple and including upgraded control to GEA Omni everything ran from the beginning without any significant problems.’

My SH or MC Series compressor is running, why should I consider upgrading it?

Screw compressors when maintained and serviced in accordance to the OEM guidelines and recommendations normally run well for many years, however the industrial refrigeration world is challenging and as a result compressors are often exposed to events which can negatively affect their overall performance, for e.g. liquid refrigerant carryover, excessive stop starts, dirty oil to name a few. Many of these events will cause levels of wear or deterioration to the performance parts and as a result the compressor efficiency can reduce gradually over time.

Levels of compressor wear can differ greatly depending upon compressor and plant design / operation however in nearly almost all cases some wear will be present, and if the compressor is older than 10 years, the likelihood is of wear is greater still, especially if there is no, or an unknown service history.

It is very difficult to accurately know if a compressor is performing optimally (COP) without measuring devices like flow meters which are rarely fitted on installations but approximately every 10 years in a compressors lifetime there is a proactive one in ten year opportunity which we refer to as the major service interval.

At the major service interval you have the opportunity to ensure the compressor goes back on the package in optimal condition, and there are different options available to achieve this (see GEA Screw Compressor Service Portfolio), one of which is the GEA Screw Compressor Retrofit.

GEA Screw Compressor Retrofit is suitable for the former GEA screw compressor series referred to as SH (Small) and MC (Medium) which was replaced by the current M Series compressor in 2015 and 2017 respectively. Although the compressor design has changed, we made it very simple to retrofit the compressor on to the existing package in as little as 2 – 3 days, perfect for customers who must carry out the major service interval in as short a time frame as possible.

So why should you consider an upgrade, well aside from the fact you would be replacing an obsolete compressor, where we may not able to guarantee the always availability of spare parts, you would be benefitting from the latest compressor technology which offers an immediate increase in efficiency up to 7%* on a like for like design basis. Factor in the likelihood of wear on the existing older compressor and energy savings up to 25%* are not unrealistic in many cases.

As a result, for a little more investment in upgrading your compressor vs maintaining your existing compressor, the Return on Investment (ROI) can be achieved in as little as 1 – 3 years* in almost all cases – for a very important service activity which should be carried out regardless.

ROI is not just connected to retrofitting from the former SH or MC Series.

Directly exchanging like for like screw compressors, for example, replacing a GEA LT Series screw compressor with a new LT Series compressor has significant potential to save energy due to the likelihood of wear on the existing compressor.

For many customers, upgrading their compressor for new could prove to be a wiser all round investment vs some of the other maintain options found in the GEA Screw Compressor Service Portfolio, especially when factoring in the short downtime combined with the potential energy savings. Even a small amount of wear on the existing compressor could result in very short payback periods; especially for the larger frame size compressors found in the LT Series family.

Why not maximize further value from the major service opportunity. If the existing compressor controller is dated, unsupported, or obsolete, combing a GEA Screw Compressor Retrofit or Upgrade with GEA Omni will not only future proof the control system, it will help to optimize the compressor control and performance 24/7/365, and with built in energy saving tools, customers can benefit from the same level of ROI for their combined compressor and controller investment.

Benefits of GEA Screw Compressor Retrofit

• More efficient
• Improved reliability
• More service friendly
• Improved spare parts availability
• Reduce overall operating costs
• Sustainable solution
• Full GEA standard warranty
• Extend the life of your GEA compressor package

Retrofitting a GEA Screw Compressor is made easy for our customers with comprehensive documentation, including a detailed service guideline and checklist to support upfront sales and site execution planning.

Additional Benefits with Options

• Maximize compressor COP by retrofitting from Fixed VI to Variable Vi
• Optimize compressor energy, reliability, and safety when upgraded with a GEA Omni Retrofit Panel
• With GEA Omni fitted, subscribe to GEA InsightPartner® Blu-Red Care to digitally optimize the availability and safety of your equipment
• With GEA Omni fitted, subscribe to GEA OptiPartner® BluRed Energy which focusses on continued energy optimization and reducing CO₂ footprint.

* Results may vary by application.

If you wish to learn more about GEA Screw Compressor Retrofit, or need any support with proactively planning your next screw compressors major service, please get in touch with your local GEA representative.