GE Power Systems Oil & Gas Nuovo Pignone S.p.A. Via Felice Matteucci, 2 50127 Florence - Italy Tel. +39-055-423211 Fax +39-055-4232800 e-mail: info.geoil&gas@np.
[email protected] ge.com www.gepower.com/geoilandgas
2 0 0 2 / 1 1 i s a F e r T o i d u t S I I / 2 6 7 K R A M / K M O C
GE Power Systems Oil & Gas
SRL Centrifugal Compressors for Air and Process Gas Nuovo Pignone started production
- Number of stages
of overhung-impeller centrifugal
- Shaft rotational speed
- High efficiency and reliability
compressors (SRL) in 1966. The first
- Diameter of impellers
- High compression ratio
unit with an integral gear was
- Height of impeller blades
completed in 1979. With their simple, compact structure
- Exchange surface of coolers
- Superior Operation
- Wide range of flow rate - Optimum rotor balance for low vibration level
and excellent reliability, SRL compressors are especially suited to
Advantages of SRL Compressors
a wide range of heavy duty
- Simplicity of Installation
applications with air, steam and
- Unit prepackaged and tested at factory
other gases such as those employed
- No special foundations required
in the Petrochemical Industry. The high efficiency, reliability and operational flexibility of the SRL line of compressors is the result of the advanced centrifugal compressor design achieved through: extensive experience with machines in service all over the world; continuous improvement of the aerodynamic and mechanical design; use of sophisticated computer design codes; advanced manufacturing processes; and innovative R&D programs. Customers benefit from Nuovo Pignone’s advanced technology through improvement in plant productivity. The custom-built compressors in this line are individually engineered to meet each customer’s specific needs using proven standardized components. SRL compressors combine the advantages of custombuilt machines (maximum efficiency, layout flexibility, materials selection etc.) and standardization (proven, reliable components; availability of spare parts). The SRL compressor series comes in a range of sizes. For each size the baseplate, gearbox, stage volutes, cooler shells, oil and gas piping and auxiliaries are standardized. Machines can be produced to meet the individual requirements of each application through appropriate selection of key design factors including:
©2002 Nuovo Pignone S.p.A. all rights reserved (Any use or reproduction even if partial is prohibited without a specific written authorization)
2
- Absence of Lube Oil in Process Gas - Advanced seal system options available
SRL Centrifugal Compressors for Air and Process Gas
- Ease of Maintenance
- Designed for maintainability - Accessibility of components
SRL design options
• Single or multi-shaft models •
(electric motor, steam or gas
Package concept
turbine, gas or diesel engine)
SRL compressors are usually mounted on a single base together
• Oil-free gas delivery system •
Automatic capacity control and safety system to reliably match any operating condition
Direct or gear (integral or separate) driven
• Auxiliary systems to meet international standards and
• Fixed or variable speed drivers
customer specifications
with all auxiliaries (e.g. oil pumps, oil reservoir, control instruments) and are delivered fully assembled and tested. Outstanding reliability, ruggedness, low installation and operating cost, plus ease of maintenance are the key features of these packages which are especially designed for heavy-duty continuous service. The packages are usually installed outdoors and can be fully automated for remote control.
Compressor nomenclature Casing sizes and number of impellers are indicated in the compressor designation by the digits following the compressor model. For example, SRL 806 is the designation for a six stage compressor, size 800. The letter D before the compressor designation indicates a double flow configuration. (DSRL)
SRL 1001 Propane compressor for Qatar
3
C ompressor Components CASINGS
- two cover flanges (suction and
Welded casings
driver side). The seal area, is contained
Welded casings consist of the
in the driver side cover and all the
following parts:
vent/supply channels to the seal are
- a scroll with the delivery nozzle in
drilled in the cover. The shaft support
a tangential position - an end cover that can be bolted
is overhung and bolted to the driver side cover
either to a gearbox casing or to a
- a diaphragm that shrouds the impeller
shaft support (the end cover
- a suction duct that guides flow to
contains the seal area; all the vent/supply channels to the seal are drilled in the cover) - a suction duct to guide the flow
the impeller’s leading edge - a discharge diffuser (vaneless or vaned) - an aerodynamic internal volute.
through the impeller’s leading edge - a diaphragm that shrouds the impeller
Cast casings
- a discharge diffuser (vaneless or
Cast casings are normally used for
vaned).
1
2
standard air and steam machines, but
The scroll is generally fixed to the end
may also be adopted for low-pressure
cover with a simple split locking ring
process gas applications. They consist
that allows easy disassembly.
Forged casings Forged casings are used for small diameter impellers and for high design
3
pressures, and consist primarily of two pieces: - a scroll (produced from a single forging); - a diaphragm (with the dual function of suction duct and discharge diffuser). The scroll can be bolted either to a gearbox casing or to a shaft support. It contains the seal area; all the vent/supply channels to the seal are drilled in the casing. The diaphragm shrouds the impeller and the discharge diffuser (vaned or
4
vaneless type) is machined into it. The diaphragm is fixed to the scroll by means of bolts or for very high
of the following main components:
pressures with shear rings.
- a cast scroll - an end cover that can be bolted
Fabricated casings
either to a gearbox casing or to a
Fabricated casings are selected for
shaft support
large single impeller, directly driven
- a discharge diffuser (vaned or vaneless);
compressors, and consist of the
- a suction duct
following parts:
- a diaphragm that shrouds the impeller.
- one external housing (with the
The scroll is generally fixed to the end
delivery nozzle welded in a
flange with a simple split locking ring
tangential position)
that allows easy disassembly.
4
1 - Welded casing 2 - Forged casings 3 - Fabricated casing with internals during assembly 4 - Cast casings
C ompressor Components
INLET GUIDE VANES
placed at the inlet of the stage.
IMPELLERS
The Inlet Guide Vane (IGV) system
The blades can rotate around their
All impellers used in Nuovo Pignone
allows wide capacity control of the
aerodynamic center in order to give
centrifugal compressors come from a
compressor with reduced energy
the suction flow a pre-swirl that
number of standard families. Each
losses.
guarantees an optimum incidence
family contains a set of geometrically
IGVs consist of a row of
angle with the impeller’s leading edge
similar impellers with different flow
aerodynamically shaped blades
even at reduced flows, minimizing
coefficients to match flow
inlet losses.
requirements. All geometries have been tested in the company’s R & D
1
THE DISCHARGE DIFFUSER
laboratory.
The discharge diffuser can be either
The following types of impellers are
vaneless or vaned (DGV).
used on SRL compressors:
Vaned diffusers are used for high
- semi-open, 3D impellers for
Mach number machines to reduce
high Mach number applications
thermodynamic losses in the very high
and/or when high tip speeds are
speed impeller exit flow.
needed (mainly air and steam applications); - closed 3D impellers for lower-head, high flow applications; - closed 2D impellers for small flow stages (ie, small process compressors or last stages of high
2
discharge pressure machines). Semi-open type impellers are machined from heat-treated, solid forgings so that both the hub and blades are of uniform strength. Closed impellers are welded to the shroud. Cast impellers may be used for special applications. The blades are generally backswept to different angles in accordance with the required performance. Each impeller is dynamically balanced and overspeed tested before
3
4
assembly; the shafts are then dynamically re-balanced at low speed with the impeller mounted. Nuovo Pignone has acquired vast experience in manufacturing open and closed impellers with a large variety of materials such as carbon steel or stainless steels (ASTM A 705 gr. 630, X12 Cr 13), materials to NACE requirements or special materials (Titanium, INCONEL 718 or INCONEL 625).
1 - Vaned diffuser 2 - Fully open inlet guide vanes 3 - Rotor assembly during balancing
5
C ompressor Components
SHAFTS
- Gear meshing: The gear unit can be
Unless the compressor is integrally
rated in accordance with AGMA or
geared, the shaft is machined from a
with API Codes. The toothed portion
single forging of 40NiCrMo7
of pinions is integrally forged with
(AISI 4340). The impeller can be
the shaft. The bull gear is shrunk on
overhung mounted at the end of the
the low speed shaft.
shaft by means of a frontal Hirth
1 - 3D Semi-open impeller 2 - Support casing with shaft 3 - Gearbox for a 6-stage electric motor driven SRL 806 compressor 4 - Gearbox for a 4-stage steam turbine driven (direct input) DSRL 504 compressor
- Shafts: The shafts are sized to
coupling, by a flange (for high speed
transmit the gear rated power within
applications), or hydraulically fitted
the stress limits of AGMA Codes.
with a tapered coupling. Thrust collars
They are made of one-piece, heat
can be either replaceable or
treated forged or hot-rolled alloy
non-replaceable.
steel, and the entire length of the
1
shaft is machined. Nuovo Pignone
SUPPORT CASING
will take complete responsibility
The support casing of the compressor
for the lateral and torsional
(except for the Integrally Geared type)
analysis of the entire train.
contains the compressor journal and
- Radial bearings: The radial
thrust bearings. The journal bearings
bearings are of the hydrodynamic
are of the hydrodynamic fluid film
fluid film, tilting-pad type for the
type, tilting pad type for higher
high speed shaft and fixed profile
speeds, or built to Customer
type for the low speed shaft.
specifications.
The bearings are split for
The bearings are split for ease of
ease of assembly, equipped
assembly, equipped with anti-rotation
with anti-rotation pins and are
pins and are firmly secured in the
firmly secured in the axial direction.
axial direction.
The bearing design suppresses
The bearing design suppresses
hydrodynamic instabilities and
hydrodynamic instabilities and
provides sufficient damping to
provides sufficient damping to limit
limit rotor vibrations while the
rotor vibrations while the compressor
compressor is operating,
is operating (either loaded or
loaded or unloaded, at the
unloaded) at the specified operating
specified operating speed.
speed. The thrust bearings are of the
- Thrust bearings: The thrust
tilting pad type designed for equal
bearings are designed for equal
thrust capacity in both directions and
thrust capacity in both directions,
sized for continuous operation under
and are sized for continuous
all specified conditions including all
operation under all specified
forces transmitted by the coupling or
conditions including all
by the impeller.
external forces transmitted by the couplings or by the gear mesh.
INTEGRAL GEARBOX
The thrust bearings of high speed
The integral gearbox consists of a bull
shafts can be the thrust collar type
gear and high speed pinions, with a
(standard for multi-stage
single-helical gear mesh.
compressors) or the tilting pad type
- Casing: The gearbox casing is
for single impeller shafts with high
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2
horizontally split. The lower part is
axial thrust. Thrust bearings of low
fixed to the baseplate and the
speed shafts are generally the
compressor stages are fixed to it.
hydrodynamic tapered land type
The gearbox casings can be either
(a tilting pad arrangement
cast or fabricated.
can be supplied on request).
3
4
C ompressor Components
SHAFT ARRANGEMENT
solution) or by a turbine (gas or
With Integrally Geared compressors,
steam); the number of pinions can
gases cannot be discharged, into
many shaft arrangements are possible
vary (depending on the size of the
the atmosphere.
in order to suit the required duty. In
stage casings) from one to four.
Seals can be supplied in several
- Dry gas seals: Used when treated
configurations:
particular, the bull-gear can be driven directly by an electric motor (standard
SEALS
1. A tandem seal ring with
The following types of seals can be
intermediate labyrinth.
installed on SRL compressors:
2. A tandem seal ring without
- Labyrinth seals: Commonly used
intermediate labyrinth.
when non-toxic gases are handled or
3. A double (face to face)
when operating pressures are low.
arrangement.
The seal material can be either
4. A single ring arrangement.
aluminium alloy or stainless steel.
5. Single, tandem or double arrangement with carbon ring third-stage seal (in order to limit nitrogen buffer gas consumption). The face of the seal’s rotating ring is recessed over more than 50 percent of its surface by grooves from 7.5 to 10 micrometers in depth etched into the face material. They extend to the dam against which the process gas forms a seal. The grooves are the key to noncontact operation of the seal. They
2
serve two vital functions: 1. Provide hydrostatic separation of the sealing faces (utilizing only the pressure of the process gas, without rotation of the seal). 2. Generate a pumping action due to viscous drag through the gas, thus creating hydrodynamic separating forces between the faces, or lift-off. - Oil mechanical seals: Supplied for special types of service in which polymerization of the gas is possible
4
and no clean buffer gas is available, or at the customer’s request. Seals are supplied in easily replaceable cartridges.
Typical seal arrangement 1 - Labyrinth seal 2 - Tandem dry gas seal 3 - Double dry gas seal 4 - Mechanical oil seal
7
A uxiliaries • top level diagram • unit controls to start / stop and
control the compressor, auxiliary motors and heaters (with status display)
• process data monitoring (pressure, temperature, level)
• alarm display • shutdown display • surge controller monitoring • hour meter • event recorder. If field instrumentation includes analogue signals from pressure and
1
PI
PCV
PDI
PI
PI
PIT
PI
Dry gas seal system
PDI
BUFFER/ PURGE GAS
PDI PI
PI
PI FO
supplies filtered gas (either process or
PCV
PI FO
other clean gas) and nitrogen buffer gas
PIT
PI
PAH PAL
Po C
to the dry gas seals at the correct
E1
E
F
pressure. The system is designed based
I
LEGEND A - Impelle r B - Balancin g line C - Seal gas E - Purge E1 - Buffer E2 - Purge F - Increasing speed gear L1 - Primary vent L2 - Secondary vent S - Frame
A
on Nuovo Pignone’s extensive experience
S
with this type of sealing system.
B
L1
L2 L3
It generally consists of:
L3
• twin filters allowing cartridges to be
PIT
PI
PDIT
PDI
PAHH
I
PDAH
I
TOSAFE AREA
FI FO PCV PDIC PDIT
changed during operation
PDIT
PDI PIT
• control valves for adequate • monitoring and safety instrumentation
L3
I
PDAH
FI
The dry gas seal control system
buffering of the seals
SEALGAS FOR STARTUP
PAH PAL
PDIT
G
L3
TOFLARE
PI
- Locally mounted instrument -Panel mounted instrument -Function on PLC and display (I.O.P.) -Flow indicator -Flow orifice - Pressure control valve - Pressure differential indicator controller - Pressure differential indicator transmitter - Pressure differential indicator - Pressure indicator transmitter - Pressure indicator
2
The seal gas system can be either on a separate console or integrated on
Compressor control panel
temperature transmitters, the operator
the main baseplate with the machine.
The control panel implements the
interface can perform additional
compressor start/stop sequence logic,
functions:
3 alarm annunciator sequence logic, capacity control logic etc. The PLC is programmed prior to
• operating parameter display • PLC set point adjustment • trend recording of process data
shipment and includes a serial
The compressor vibration monitoring
communication interface RS422 with
system is also located on the control
Modbus protocol for connection to a
panel.
supervision and control system (i.e. DCS, PC, telemaintenance etc.). The control panel front includes a video terminal connected to the PLC, which provides the following functions organized in pages:
1 - Dry gas seal control panel for a 4 stage SRL 254 compressor 2 - Typical tandem dry gas seal system diagram 3 - Typical control panel
9
G eneral OPERATION CONTROL
TEST FACILITIES
Full-load, full-pressure tests (including
The following methods are available to
Compressor components are subject
flammable gases) to check rotor
control flow and suction or discharge
to a long series of tests in order to
stability as well as performance of
pressures under varying process
guarantee perfect matching to their
machines or complete systems can
conditions:
design specifications. Casings are
also be carried out.
• compressor speed variation: this
submitted to hydraulic or pneumatic
A number of outdoor full load test rigs
method is utilized when a compressor
pressure testing, depending on the
are available at the Florence and Massa
is driven by a variable speed driver
type of service. Impellers are checked
shops providing Nuovo Pignone
with ultrasonic and dye penetrant
Customers with test facilities to meet
fitted in the discharge piping so that
liquids. Facilities allow overspeed
virtually any need.
pressure at the compressor outlet
testing of single impellers.
nozzle may increase while
All compressors are mechanically
maintaining the normal value
tested before delivery. The test driver
downstream of the valve
may be an electric motor, a steam
• discharge throttling: a valve is
• suction throttling: a valve is fitted
turbine (the test facility is equipped
in the suction piping so that suction
with a complete plant for production of
or discharge pressure can be
steam at 55 bar and 500°C) or a gas
regulated according to the process
turbine.
requirements
When Nuovo Pignone supplies a
• adjustable inlet guide vanes:
complete compressor unit with motor,
these vanes alter the gas flow
steam or gas turbine driver, a string
direction as it enters the
mechanical test can be carried
impeller, thus varying the pressure
out on the complete train.
ratio and flow of the compressor.
Performance testing with air or
These guide vanes can be placed
other gases in a closed loop
before each compression stage
can also be carried out. Nuovo Pignone has uprated
ANTISURGE CONTROL
and updated its test facilities
Should a flow below the compressor
with the construction of a new
surge limit be required a by-pass must
test room designed for maximum
be used. Part of the compressed gas
flexibility to adapt to various test
is recirculated to raise the compressor
conditions and requirements.
suction flow above the surge limit. The system is standard for all
Th
1
centrifugal compressors and comes into operation as a relief mechanism or when other control system options are not capable of handling excess flow or pressure.
2
When air or inert gas is being compressed it may be blown-off to the atmosphere instead of being recirculated.
1 - Operation control 2 - Indoor facilities for performance tests or full-load tests with inert gas
10
Flow Control: by adjustable guide vanes by suction throttling by speed variation by discharge throttling
G eneral
performance prediction in all
1 RESEARCH AND DEVELOPMENT Research and Development plays
applications.
an important role in Nuovo Pignone’s
Advanced knowledge of non-
strategies and therefore receives
stationary flow phenomena and high
substantial resources.
speed rotor dynamics has led to the
One of the main objectives is
unsurpassed reliability and
continuous updating and improvement
availability of these machines.
of existing products to extend the stateof-art in the traditional Oil & Gas
QUALITY ASSURANCE
applications such as natural gas,
The Nuovo Pignone Quality
fertilizers, methanol, refining and related
Assurance group is centered in
chemical industries.
Florence and has a staff of over 60
New products are developed driven
people stationed throughout the Company’s plants. One of the
by customer needs in applications
2
fundamental duties of the group is the development of quality standards and assistance in the correct application of all quality assurance processes in all product development, manufacturing, and testing operations. Special laboratories certified by Sinal, are equipped for measuring mechanical properties, chemical and optical emission spectrometric analyses,
Pride & The Commitment
that fit within Nuovo Pignone’s
fatigue tests and macro and
business strategy and expertise.
micrographic examinations (scanning
Research on centrifugal compressors
electron microscopy). A calibration
accounts for a substantial portion of
room certified by SIT for checking and
the company’s total research activity.
calibrating lengths, forces and
Nuovo Pignone’s test laboratory is
temperatures is also available.
equipped with a number of advanced
Nuovo Pignone’s Quality Assurance
test facilities both for developing and
System has been certified to meet
tuning major compressor components
ISO 9001 standards for design,
(stages, seals, bearings) and for
manufacture, installation and after-
performing all kinds of stress, vibration
sales service of centrifugal
and rotor dynamic investigations.
compressors, centrifugal pumps,
Besides testing, continuous effort is
reciprocating compressors, gas and
dedicated to development and
steam turbines, gas expanders, heat
improvement of analytical tools used
exchangers and pressure vessels by
in the fluid dynamic, structural and
Lloyd’s Register Quality Assurance
rotor dynamic design of components
Ltd., one of the most authoritative
and complete compressors.
international certification
Many years of analytical and
organizations.
experimental research work on components has led to establishing a wide selection of standardized stages, each individually tested and tuned and application engineering tools that provide maximum reliability in
1 - Modal analysis of centrifugal impeller by holographic interferometry with a laser system 2 - ISO 9001 certification
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S ervice
CUSTOMER SERVICE
A global service network ensures rapid 1
Nuovo Pignone provides the users of
response to maintenance needs
its machines with prompt, efficient and
anywhere in the world.
technologically advanced
This organization consists of:
maintenance and repair service to
• Service centers in strategic locations
guarantee high machine efficiency, continuity of operation and maximum
worldwide
• Traveling Service Teams which
safety. This service includes:
maintain contact with users through
• Technical support • Periodic visits to plants • Diagnostic analysis of installations • Overhauls, repairs and conversions
periodic visits to plants
• Authorized shops which carry out machine maintenance with Nuovo Pignone technology.
of installed machinery
• Customized original spare parts supplies
• Maintenance contracts • Personalized training courses for customers’ personnel.
Service contracts Highly-skilled engineers, an extensive spare parts inventory and an efficient global service network allow Nuovo Pignone to offer its customers tailormade service packages.
SERVICE ORGANIZATION Nuovo Pignone Global Services is an organization dedicated to meeting
2
customer service needs. It is fully integrated with the new product engineering and manufacturing organizations to provide state-of-the-art solutions to the installed fleet. Global Services operates a Service Shop adjacent to the main production plant in Florence for the high tech overhaul and refurbishment of machines and components. A warehouse containing over 40,000 different parts is maintained and a modern computerized parts management system is in place to insure rapid delivery of replacement parts on either a scheduled or an emergency basis.
1-
Computerized system for spare parts warehouse management 2/3 - Customer Training features shop visit
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3
A ir Compressors
General
100
) R A B ( E R U S S E R P E G R A H C S I D
Air compressors are used in air separation, synthetic fibre and fertilizer
50
6 STAGES
40
plants as main process gas compressors, and in all industrial plants
30 20
Technical data vary from 10,000 to 200,000 m3 /h (6,000 to 120,000 cfm), with a max. discharge
2 STAGES
pressure of up to 50 bar (730 psi).
3
1 10
4 STAGES 3 STAGES
4
1.5
as service air compressors. The inlet flow for such machines can
10 9 8 7 6 5
2
5 STAGES
0 0 0 0 0 6 0 8 0 9 0 1 0 L L L L S R S R S R S R
0 4 5 L S R
Main characteristics
1 STAGE
Air compressors are generally multi-shaft, integrally geared type, single
20
30
40
50 60 70 80 90 100
200.000
or multi-stage (up to 6 stages).
3
SUCTION VOLUME FLOW (m /h)
1
1 - Performance range 2 - SRL 453 service air compressor installed in an Alfa Romeo workshop in Milan - Italy (17000 Nm 3 /h from 1 to 8 bar-abs)
Compressors are modularized in order to meet varying Customer needs. High compression efficiencies are acheived by using 3-D impellers
3
3 - SRL 806-Air compressor for GE’s test bed in Schenectady, NY - USA (4900Nm /h; Suct. press. 1 bar-abs; Disch. press. 27.8 bar-abs; Inst. power 7550 kW) 2
specially designed for this service. Inlet Guide Vanes are available for each compression stage, permitting extremely large compressor turndown with high efficiencies throughout the range. Seals are generally labyrinth type (single, dry gas type for last stages of high pressure applications). Multi-stage compressors are equipped with inter-coolers with an integral condensed water separator.
Drivers Drivers for this type of compressor are generally electric motors, but it is also possible to use steam and gas turbines (either as a direct driver or through an intermediate gearbox).
3
Package arrangement In multi-stage compressors, coolers are located below the compressor together with the lube oil system in order to provide a very compact arrangement of the unit. Lube oil systems can be either separate or integrated on the main compressor baseplate.
Applicable codes and standards Compressors may be designed either according to API 617 or API 672, or customized to Customer’s specific requirements.
13
P rocess Gas Compressors (Single Stage - Directly Driven) This type of compressor is mainly
speed), or by a steam or a gas turbine 1 (directly coupled or via an external
used as a booster in petrochemical
gearbox to increase or decrease
applications, or as a recycle
speed).
General
compressor in polyethylene and polypropylene plants.
Package arrangement
Axial inlet flow guarantees an optimum
The baseplate generally accommodates
aerodynamic design, and therefore
both the compressor and its driver.
very high efficiency. Due to their
The lube oil system can be either
rugged mechanical design, this type
integrated with the main machine
of machine delivers very high
baseplate or provided as a separate
reliability.
console.
Almost all gases can be handled by this type of compressor with
Applicable codes and standards
appropriate construction materials and
Generally designed according to
seal systems.
API 617, or customized to Customer’s specific needs.
Technical data Flows can vary from 5,000 to 120,000 3
m /h (3,000 to 70,000 cfm), with discharge pressure up to 50 bar (730 psi).
Main characteristics Several configurations are available to cover all applications of this type of machine.
2
Impellers are 3-D, backswept, semi-open or closed type, overhung mounted on the shaft. The thrust bearing is located between the two journal bearings and is of the tilting-pad type. A special design, with internal spiral volutes (to avoid any dead-point in the flow), is available for process gas that may polymerize during operation (for example in PP and PE plants). Inlet Guide Vanes are available for fixed-speed units to increase the operating range of the compressor while maintaining high efficiency. Seals can be dry gas, mechanical oil or labyrinth type, depending on the service requirements.
Drivers This type of unit can be driven either by an electric motor (directly coupled or via an external gearbox to increase
14
3
1 - SRL 801 for a polyethylene plant (during assembly) (871,000 Nm 3 /h from 25 to 26.3 bar-abs 2,300 kW installed power) 2 - SRL 1001 propane booster compressor (594,000 Nm 3 /h from 12.3 to 15.6 bar-abs 4,800 kW installed power) 3 - SRL 451 propane compressor directly driven by an NG 32/25 steam turbine (168,000 Nm 3 /h from 33 to 47.5 bar-abs 1,800 kW installed power)
P rocess Gas Compressors (Integrally Geared) 1
flow guarantees an optimum aerodynamic design, and therefore very high stage efficiency. Due to its rugged mechanical design, this types of machine delivers very high reliability. Almost all types of gases can be handled by this compressor design with appropriate construction materials and seal systems.
Technical data Flows can vary from 500 to 50,000
1 - SRL 251 natural gas recycle compressors (2,200 Nm 3 /h from 1 to 1.5 bar-abs 70 kW installed power) 2 - SRL 253 dichloromethane compressor all in AISI316 stainless steel materials, (500 Nm 3 /h from 1 to 5 bar-abs 455 kW installed power) 3 - SRL 254 natural gas booster compressor (70,700 Nm 3 /h from 33 to 68 bar-abs 2,500 kW installed power)
m3 /h (300 to 30,000 cfm), with discharge pressure up to 100 bar (1,500 psi).
Main characteristics Several configurations are available to cover all applications of this type of machine. Impellers are 3-D or 2-D, backswept semi-open or closed type, overhung mounted on the shaft. The thrust bearing is located on the pinion shaft and is of the thrust collar type. The journal bearings of the pinions are the
2
tilting-pad type.
3
Inlet Guide Vanes are available to increase the operating range of the compressor with low impact on efficiency. Seals can be of the dry gas, mechanical oil or labyrinth type, depending on the service requirements.
Drivers This type of unit can be driven directly either by an electric motor, or by a steam or a gas turbine.
Package arrangement The baseplate generally accommodates both the compressor and its driver. The lube oil system can
General
four high speed pinions. One or two
This type of compressor is used in
impellers can be mounted on each
several petrochemical processes,
pinion shaft. The multi-shaft
either for low-flow/high pressure
configuration allows frequent
applications, or for high-flow/low
intercooling, and therefore better
Applicable codes and standards
pressure applications.
compression efficiency
Generally designed according to API
The integrally geared compressor
compared to traditional in-line
617 or customized to Customer’s
features a bull gear and from one to
centrifugal compressors. Axial inlet
specific requirements.
be either integrated with the main machine baseplate or provided as a separate console.
15
S team Compressors General
1
Rising energy costs have led to a demand for high efficiency machines for energy recovery. Steam compressors are employed in various sectors, such as the agriculturefood Industry, chemical industry, paper industry and desalination plants. Another application of SRL compressors is in Geothermal power stations to extract non-condensable gases from the steam turbine condensator.
Technical data Flows can vary from 5,000 to 250,000 m3 /h (3,000 to 150,000 cfm) per
1 - SRL 903 for geothermal application (4,200 Nm 3 /h from 0.1 to 1.2 bar-abs 550 kW power) Directly driven by a steam turbine
impeller, with discharge pressure up to 10 bar (150 psi).
Main characteristics Steam compressors are of the integrally geared type, single or multi-stage (up to
2 - SRL 1001 steam compressor for a food industry (101,000 Nm 3 /h from 0.8 to 1.6 bar-abs 3,850 kW installed power)
6 stages) machines. The compressors are modularized, for flexibity in meeting Customer requirements. High pressure ratios together with high
3 - Typical process diagram for a food industry application
compression efficiencies are reached by using 3-D open impellers specially designed for this service. Inlet Guide Vanes are available for each
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compression stage to provide a large turndown for the compressor with high efficiencies throughtout the range. Labyrinth type seals are always used.
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Drivers Drivers for this type of compressor can be either electric motors or steam FC
turbines (as a direct driver).
PI TIAH
Package arrangement
PI
The baseplate generally accommodates
PI
PI
TI
both the compressor and its driver. The lube oil system can be either integrated with the main machine baseplate or provided as a separate console.
E T A R T N E C N O C
T C U D O R P
CONDENSATE
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SRL COMPRESSOR
I nstallations
1. SRL 601 Polypropylene recycle compressor installed in Tarragona, Spain 3 - Flow 229,000 Nm /h
- Suct. Press. 14.5 bar-abs - Disch. Press. 15.6 bar-abs - Inst. Power 850 kW
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2. SRL 603 Air+carbon monoxide compressor installed in Geel, Belgium 3 - Flow 265,00 Nm /h
- Suct. Press. 1 bar-abs - Disch. Press. 5.3 bar-abs - Inst. Power 2,600 kW
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3. SRL 454 Air compressor for a Caprolactam plant in Shijiazhuang, China The compressor is driven by a steam turbine through an external gearbox 3 - Flow 17,000 Nm /h
- Suct. Press. 1 bar-abs - Disch. Press. 13 bar-abs - Inst. Power 2,350 kW
3 4. SRL 454 Psa tail gas compressor installed in Tula, Mexico 3 - Flow 21,300 Nm /h
- Suct. Press. 1.1 bar-abs - Disch. Press. 9 bar-abs - Inst. Power 2,800 kW
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I nstallations
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5. SRL 603 and SRL 453
Compressor for an air fractionating plant in Middle East 3 - Flow 27,000/18,000 Nm /h
- Suct. Press. 0.8/0.8 bar-abs - Disch. Press. 7.5/9 bar-abs - Inst. Power 2,800/2,060 kW
6 6. SRL 601 Recycle gas compressor for an EO/EG plant in Pralca, Venezuela Single stage compressor, electric motor, driven through an external gearbox speed increaser 3 - Flow 238,000 Nm /h
- Suct. Press. 19 bar-abs - Disch. Press. 23 bar-abs - Inst. Power 1,750 kW
7 7. SRL 801 Nitric acid compressor installed in Ambes, France The compressor is driven by a steam turbine through an expander 3 - Flow 168,000 Nm /h
- Suct. Press. 4.6 bar-abs - Disch. Press. 11.5 bar-abs - Inst. Power 7,250 kW
8. SRL 903 For geothermal application installed in Le Prata, Italy 3 - Flow 4,200 Nm /h
- Suct. Press. 0.1 bar-abs - Disch. Press. 1 bar-abs - Inst. Power 550 kW
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