Keep the machine. Upgrade the brain.
Retrofit your legacy centrifugal compressors with modern PLC/SCADA controls, remote monitoring, and predictive maintenance — without replacing the compressor. Typical payback: 12–18 months from energy savings alone.
Problems you might be facing
Obsolete control system with no support
Your Quad or Maestro panel is 20+ years old, parts are unavailable, and a board failure means an indefinite shutdown.
No visibility into compressor energy use
You can't optimize what you can't measure. No trending, no KPIs, no way to justify efficiency improvements.
Manual start/stop and no remote monitoring
Your operators have to physically walk to the compressor room. No alarms, no remote access, no after-hours coverage.
Capabilities
PLC/SCADA retrofit
Complete replacement of legacy controller with modern PLC (Allen-Bradley, Siemens) and SCADA software.
HMI & visualization
Industrial touchscreen with custom compressor graphics — live data, trends, alarms, and performance KPIs.
Remote monitoring
Cloud-based or on-premise remote access — monitor your compressors from anywhere, receive mobile alerts.
Predictive maintenance
Vibration trending, bearing temperature monitoring, and surge detection with configurable alarm setpoints.
Energy optimization
Advanced surge control, auto-sequencing, and load/unload optimization to reduce specific energy consumption.
Full documentation
Electrical drawings, I/O lists, PLC programs, and O&M manuals — full turnover package.
Why customers choose us
- Typical energy savings: 10–15% from advanced surge control alone.
- Reuse existing field instruments where possible — reducing cost.
- Integration with plant DCS and historian systems.
- Cybersecurity considerations built into the design.
- 1 year of remote support included with every retrofit.
Process
Survey
Assess existing controls, I/O count, communication requirements, and integration points.
Design
Panel layout, PLC program, HMI screens, and I/O mapping — reviewed and approved by you before build.
Build & test
Panel fabrication, PLC programming, factory acceptance test with simulated I/O.
Install & commission
On-site installation, wiring, startup, tuning, and operator training.
Frequently asked questions
Can you keep the existing instruments and just replace the controller?+
Yes — if your transmitters and actuators are in good condition, we connect them to the new PLC. This significantly reduces scope and cost.
How much downtime is needed for installation?+
Typical installation requires 3–5 days of compressor downtime. We pre-build the panel, pre-test with simulated I/O, and pre-wire as much as possible to minimize shutdown duration.
What if our compressor is from the 1980s?+
No problem. We've retrofitted controls on machines from every era. Older machines often benefit the most — the energy savings from modern control algorithms can be dramatic.
Do you integrate with our existing DCS?+
Yes — hardwired, Modbus, Ethernet/IP, Profinet, OPC-UA — we interface with all major DCS platforms.
Ready to get started?
Get a no-obligation technical assessment within 48 hours.