To ensure that additional compatibility issues would not surface, D-R asked the OEM to review the original bills of materials for the two located units and compare them to the unit supplied to Flint Hills Resources in 1991. The manufacturer was cooperative with D-R and agreed to review the bills and also provided a quotation for the nine-inch stroke crankshaft. The results of the research presented even more of a challenge to D-R’s Applied Technology group.

"The two frames held by the equipment supplier were fabricated frames while the two units operated by Flint Hills Resources were cast frames," Lottes explained. "If this was not challenge enough, the manufacturer also informed us that the crankshaft supplied with the Flint Hills Resources’ units would not fit into the older style fabricated base. In addition, it had never designed a nine-inch stroke crankshaft for the 11-inch stroke, two-throw, 60,000-pound rod load fabricated frame."

To keep the project moving, D-R contacted several known 11-inch stroke, two-throw, 60,000-pound rod load frame owners to determine if they had any immediate plans to decommission any of their units. This yielded no results. Having exhausted these possible solutions, D-R contacted the manufacturer again to determine if it would be able to manufacture a new frame with running gear. However, the manufacturer had discontinued this product line in 1996 and closed the plant.

It was decided that the OEM could produce a new frame with running gear at one of its other plants. However, the estimated lead-time for the new frame was 34 weeks.

"Considering we would then need to assemble the distance pieces, cylinders, do all of the tubing, conduit runs and oil piping, as well as run tests, we were looking at nearly a 45-week time period to provide the unit to Jacobs," Lottes recalled. "A new D-R unit could be provided in far less time."

When Flint Hills Resources considered all of the options, it was determined that the familiarity of working with "duplicate" equipment, as well as the advantages in replacement parts, outweighed the reduced lead time factor of a new unit.

The first order is for D-R to provide Jacobs with one new two-throw, 60,000-pound rod load frame compressor. The scope of supply includes a new frame with two new D-R forged steel cylinders, distance pieces and auxiliaries, including pulsation vessels, motor, lube oil console, jacket water console, nitrogen buffer and control panels. This order represents the "duplicate" unit Flint Hills Resources needed to satisfy increased demands at its Corpus Christi facility.

The second order encompasses a new motor with drive components and auxiliaries including pulsation vessels, motor, lube oil console, jacket water console, nitrogen buffer and control panels for an existing smaller, single-throw compressor that Flint Hills Resources has had in storage since 1992. This equipment was delivered in September 2002.

"The success of this project can be attributed to many things," Lottes said. "But, what it really comes down to is the excellent relationship D-R has developed and maintained with Jacobs Engineering and Flint Hills Resources."