Innovative anti‑surge control valve (ASCV) retrofit saves time and money for offshore compressor protection projects.
Retrofitted ASCV with upgraded concentric cage trim for high‑performance compressor protection. Severn engineering team performing rapid ASCV retrofit and valve overhaul services in UAE facility. Completed offshore ASCV retrofit solution ready for shipment after accelerated valve manufacturing and assembly.
The challenge
An offshore operator was increasing the capacity of compressors on a facility located off the Dubai coast. Consequently, critical anti‑surge cycle control valves (ASCVs) involved in the compression system needed to meet exacting new requirements for severe‑service valve applications, high‑performance compressor anti‑surge protection, and rapid response control valve actuation.
Procuring such engineered anti‑surge control valves typically takes 24 weeks. The operator needed the valves within four weeks, making traditional new ASCV procurement impossible for urgent brownfield offshore modification projects.
The solution
Innovative ASCV retrofit saves time and money.
Severn’s valve engineering and retrofit specialists within the Technical Products and Services team devised an innovative ASCV retrofit solution delivering a fast‑track anti‑surge valve upgrade for offshore oil and gas operations.
It involved the development of custom ASCV internal components that could be fitted into the body of the existing ASCVs, increasing their capacity and maintaining performance in line with the complex demands of the upgraded compressor system — without full valve replacement, re‑piping, or extended offshore shutdowns.
Activity followed a five step process:
- Valve shipped back to the operator
- Valve stripped and relevant data gathered to inform the custom ASCV retrofit design
- Upgraded anti‑surge valve trim designed within 24 hours
- Material sourced and ASCV components manufactured locally in the UAE
- Valve reassembled and witness tested anti‑surge control valve for offshore readiness
Utilising Severn’s proven concentric cage valve technology, new trim elements were sized and designed to offer comparable performance to the original valves, while maintaining the same key dimensions. This allowed for the re‑use of existing valve actuators and instrumentation, significantly reducing retrofit project cost, integration risk, and offshore commissioning time.
Severn managed the full ASCV retrofit engineering process, conducting the anti‑surge valve technical design and collaborating with our local repair partner Adyard Abu Dhabi for manufacturing and assembly. This valve retrofit partnership approach enabled advanced technical services to be combined with rapid turnaround valve repair, delivering a high‑reliability offshore ASCV retrofit solution optimised for maximum compressor uptime.
The entire process took ten days for the first ASCV retrofit. It was then further streamlined, enabling an additional valve — with a completely separate design — to be turned around in just four days, demonstrating Severn’s rapid‑response valve engineering capabilities for urgent offshore valve remediation.
The outcome
Each of the retrofitted anti‑surge control valves has been installed successfully. Opting for an ASCV retrofit instead of new valve procurement shaved 94% off delivery time. There was also a significant cost saving, zero interruption to offshore operations, and continued protection of compressor performance and process integrity.
- ASCV retrofit solutions satisfy extreme demands for technical capability, severe‑service performance, and fast offshore turnaround, making them an ideal choice for:
- Brownfield offshore upgrades
- Compressor optimisation projects
- Time‑critical offshore maintenance campaigns
- Emergency anti‑surge valve replacement alternatives
- If you want to read more of our industrial valve retrofit case studies, you can find them by clicking the Case Studies button below.
If you would like to contact us with an ASCV application query, offshore valve engineering requirement, or anti‑surge valve retrofit assessment, click the Contact Us button below.
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