Nexus Increases Safety and Reduces Environmental Emissions Through Replacement Equipment Design

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Two workers in red protective coveralls and hard hats stand at an industrial refinery site, discussing operations while one reviews information on a handheld device amid large processing units and piping.

Confidential Client
Midwest USA
Refining

The Nexus Team developed a design to replace the propane compressor for a major refining client in the Midwest to reduce emissions, increase safety, and ensure reliability.

Overview

A major refinery in the Midwest came to the Nexus Team to design and replace an aging compressor. The current compressor is made from cast iron which poses multiple safety risks for workers and the environment and does not comply with current API standards. Replacing the compressor not only increases operability and reliability but would mitigate risks posed by emissions and leaks. A compressor replacement would help the facility comply with API standards for the foreseeable future and align with the company’s rigorous ESG standards, where safety and environmental protection are of the upmost importance.

Challenge

The Nexus Team was presented with the challenge of engineering a new compressor for the existing operation. Since this was not an identical replacement, a new piping design was required to connect the compressor with existing equipment and additional instrumentation was needed to integrate the new compressor into the facility.

Solution

The Nexus Team began with an assessment of current 3D models where the compressor is located, surrounding equipment, and piping systems. This assessment provided crucial insights into how the new compressor could be seamlessly integrated.

Recognizing the vital need for new piping to connect the compressor with existing equipment, the Nexus Team’s engineers worked to design a piping system that not only met the technical specifications but also aligned with safety protocols and environmental regulations. This involved close collaboration with the refinery’s operations team to ensure minimal downtime during the installation process.

By addressing the safety risks posed by the outdated cast iron compressor and ensuring compliance with API standards, the Nexus design enhanced operability and reliability, mitigating the potential for emissions and leaks.

Services

Equipment Design
Piping Design
3D Modeling
Pipe Stress Analysis
Equipment Layout Assessment

About Nexus Engineering Group

Nexus Engineering Group is a full-service, independent engineering, procurement, and construction management (EPCm) firm headquartered in Cleveland, Ohio, with offices in Toledo, Ohio; Midland, Michigan; and Oak Brook, Illinois. Founded in 2005, Nexus partners closely with clients to support project goals from concept through startup, delivering practical, reliable solutions across the refining, petroleum midstream, chemical, manufacturing, power & energy, and renewables markets.

Nexus integrates engineering, procurement, and construction management services to help clients plan and execute complex projects with confidence. Through close collaboration and a client-first approach, Nexus supports informed decision-making, manages project risk, and delivers practical solutions that enhance safety, reliability, and long-term project value.

June 18, 2026