Construction of compressor stations

Professional design, supply, installation and commissioning of industrial compressor stations of any complexity.

Providing an enterprise with high-quality compressed air — is not just the purchase of a compressor, but the creation of a reliable and energy-efficient engineering system. LLC «Dalgakiran Compressor Ukraine» performs a full range of works on the construction and modernization of compressor stations «turnkey».

We take full responsibility for each stage — from the initial analysis of the needs of your production to the final launch and further service maintenance.

Why is it worth choosing a «turnkey» solution?

Single contractor and responsibility: You receive a ready-made facility from one contractor without involving third-party organizations.
Maximum energy efficiency: Optimally selected equipment reduces electricity costs by up to 30-50%.
Reliability guarantee: All works are performed in accordance with the current construction and technical standards of Ukraine.
Production continuity: Well-thought-out backup schemes eliminate the risk of stopping technological lines.

Stages of construction of a «turnkey» compressor station

1. Pneumatic audit or calculation of compressed air demand

The first stage of project implementation is determining the actual or calculated demand of the enterprise for compressed air.

For operating enterprises (modernization): A detailed
pneumatic audit of the existing system is carried out. We analyze the operation of the available compressors, dryers, receivers, filters, pipelines and control systems.

The actual air consumption, operating pressure, peak loads, pressure losses, leaks and energy efficiency of the system are determined.

For new facilities (construction from scratch): The volume and modes of compressed air consumption by new technological equipment are calculated. For this purpose, the characteristics of consumer equipment, their operating mode, simultaneity of switching on, operating pressure, air quality class and prospects for production expansion are analyzed.

Stage result: Determination of clear parameters of the future station: capacity, pressure, number and type of compressors, air treatment scheme, quality requirements and the need for redundancy.

2. Calculation of the economic effect of modernization

When modernizing an existing station, we calculate the economic efficiency of implementing new equipment and engineering solutions.

Specialists compare the current state of the system with the proposed solution and calculate:

Projected reduction in electricity consumption;
Reduction in service maintenance costs;
Savings due to elimination of leaks and optimization of operating modes;
Reduction of emergency production shutdowns;
Exact payback period of the new equipment (ROI) and the overall economic effect.

Stage result: The customer receives a substantiated feasibility study (FS) and clear investment payback periods.

3. Development of project documentation

At the third stage, a complete set of project documentation is developed for the construction or reconstruction of the compressor station.

We determine the composition of the main and auxiliary equipment (compressors, dryers, receivers, main filters, condensate drainage systems, pipelines, shut-off valves, ventilation, power supply and automation).

Project documentation includes:

Equipment layout plan and technological scheme;
Connection scheme to the compressed air main;
Electrical diagrams and solutions for automation/dispatching;
Requirements for foundations and base;
Solutions for ventilation, cooling, heat recovery and noise protection;
Occupational safety and labor protection measures.

Stage result: Agreed technical solutions, approved estimate, work schedule and equipment specification.

4. Preparation of the premises or construction of a new compressor room

The fourth stage — is the creation of safe and technically correct conditions for equipment installation.

New construction: Construction works, site preparation, installation of foundations or industrial flooring, construction of premises (or installation of a modular container station), installation of ventilation ducts, laying of cable routes and lighting systems are carried out.
Preparation of existing premises: Dismantling of outdated equipment, floor preparation, modernization of the ventilation system, electrical networks and provision of connection points are carried out.

Stage result: Ready premises that comply with all construction, fire safety and technological standards.

5. Supply, installation and mounting of equipment

The fifth stage provides for prompt delivery of equipment to the facility, unloading, rigging works and professional installation.

Our specialists carry out:

Installation of compressors, dryers, receivers, filters and automation systems;
Installation of pneumatic mains made of modern materials (aluminum, stainless steel, etc.);
Connection to power supply, ventilation and condensate drainage systems;
Installation of shut-off and control valves and dispatching systems.

Stage result: An installed compressor station, checked for tightness and compliance with the project documentation.

6. Start-up, adjustment of equipment and personnel training

The final stage — is commissioning works and putting the compressor station into operation.

Specialists of «Dalgakiran Compressor Ukraine» perform:

Initial start-up of equipment and checking of automation systems;
Precise adjustment of operating parameters to production needs;
Testing of protection systems and backup modes;
Compressed air quality control for compliance with standards (ISO 8573-1);
Testing of the compressor station under full load.

Personnel training: We provide instruction and training for the customer’s employees on operating rules, daily monitoring, scheduled service and actions in case of emergency situations.

Stage result: A compressor station ready for operation, a signed commissioning certificate and transfer of a set of as-built documentation.

Additional opportunities from «Dalgakiran Compressor Ukraine»

Modular compressor stations (containerized version): Ready-made mobile solutions that do not require capital construction and can be deployed at the facility in the shortest possible time.
Heat recovery systems: Use of heat generated by compressors for space heating or water heating for technological needs.
Official 24/7 service: Own service center, warehouse of original spare parts and prompt dispatch of engineers throughout Ukraine.