Screw Compressor Replacement in EVA Unit (High-Load Operation)

1. Project Overview

• Industry: Petrochemical

• Application: EVA Production Unit

• Original Equipment: VM140

• Replacement Model: CS160H

• Operating Condition: 3.5 bar / High Load / Continuous Duty

2. Project Background

The client operates an EVA production unit requiring stable compression performance under high-load and continuous operating conditions.

The system originally used a VM140 screw compressor, which was operating close to its design limits over a long period. This resulted in increasing failure frequency and rising maintenance cost, impacting production stability.

3. Challenges

• Equipment operating close to design limits

• High failure rate under continuous operation

• Increasing maintenance cost

• High dependence on original brand spare parts

• Risk of system instability in critical production process

4. Our Solution

Procetek provided a CS160H oil-free screw compressor, designed for high-load industrial applications:

• Fully matched flow, pressure, and power parameters

• Designed for stable operation under near-limit conditions

• Seamless replacement without system modification

• Improved reliability through optimized internal design

5. Scope of Supply

• Oil-free screw compressor

• Procetek Model: CS160H 

Equivalent / Reference Model Mapping

Original Model	Procetek Replacement
VM140	CS160H

6. Performance Comparison

Parameter	Original (VM140)	Procetek (CS160H)
Flow (m³/min)	171.06	171.5
Pressure (bar g)	3.5	3.42
Power (kW)	767	767
Speed (rpm)	6247	6258

7. Installation & Site Photos

Before Replacement

• Original VM140 compressor operating under high-load conditions

  

  

After Replacement

• CS160H compressor installed in EVA unit

• Equipment operating under real production conditions

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Compared to the original unit, the replacement provides improved reliability under high-load conditions and significantly reduces maintenance requirements.

8. Results

• Maintenance cost reduced by 30–50% 

• Improved operational stability

• Reduced failure frequency

• Enhanced system reliability under continuous operation

9. Why It Worked

• Accurate parameter matching under high-load conditions

• Robust design for near-limit operation

• Form-Fit-Function compatibility

• Proven performance in petrochemical applications

10. Conclusion

This project demonstrates that high-load compressor systems can achieve stable and reliable operation with optimized replacement solutions, while reducing long-term operational cost.

11. Call to Action

If your system is operating close to design limits or experiencing high failure rates,

👉 contact us for high-load compressor replacement and optimization solutions.