endend Compressor technology
endend Barrel Horizontal Split Pipeliner - Axial Inlet Pipeliner - Horizontally Opposed Flanges Centrifugal compressor /01 PPT26/03/99
endend Compressor experience Installed or on order Pipeline Centrifugal835 Multi-Stage Centrifugal687 Total Achievement1522 Installed or on order Pipeline Centrifugal835 Multi-Stage Centrifugal687 Total Achievement /02 PPT26/03/99
endend Multi-Stage barrel centrifugal compressors Over 480 sold since 1957 Vertical split barrel-type design Designed for a broad range of oil and gas applications Four frame sizes Standard impeller selections for performance predictability Maximum working pressure up to 450 bar Suitable for direct-drive by Cooper Rolls/Allison gas turbines, without the need for a gearbox Uses same lube oil as power turbines - no requirement for separate oil systems Over 480 sold since 1957 Vertical split barrel-type design Designed for a broad range of oil and gas applications Four frame sizes Standard impeller selections for performance predictability Maximum working pressure up to 450 bar Suitable for direct-drive by Cooper Rolls/Allison gas turbines, without the need for a gearbox Uses same lube oil as power turbines - no requirement for separate oil systems /01 PPT26/03/99
endend /03 PPT26/03/99 Multi-Stage barrel compressors Full range of hydrocarbon gases High pressure ratio/head capability Up to highest operating pressures Cast/forged steel casings Custom casing design within established frame sizes Full range of hydrocarbon gases High pressure ratio/head capability Up to highest operating pressures Cast/forged steel casings Custom casing design within established frame sizes
endend RBB RCB RDB REB Maximum Pressure Rating [BAR] [PSIG] Number of Stages 1 – 8 Max. Design Inlet Flow [m³/h] [ACFM] ,300 Max. Running Speed [RPM] Standard Impeller Diameters [mm]/[IN] 351 / / / / / / / / /07 PPT26/03/99 Active barrel compressor frame sizes
endend Multi-Stage barrel compressors /08 PPT26/03/99
endend Front-to-Back Back-to-Back /05 PPT26/03/99 Multi-Stage centrifugal impeller arrangements
endend /02 PPT26/03/99 Barrel and horizontally split combination
endend Pipeline compressors Over 800 sold since 1955 Seven different models suitable for direct-drive by Cooper Rolls Gas Turbines Tilt-pad journal and thrust bearings Designed to API 617 Dry gas seals Up to five impellers Uses same lube oil as power turbine, no requirement for separate oil system Choice of axial inlet or opposed-flange casings Over 800 sold since 1955 Seven different models suitable for direct-drive by Cooper Rolls Gas Turbines Tilt-pad journal and thrust bearings Designed to API 617 Dry gas seals Up to five impellers Uses same lube oil as power turbine, no requirement for separate oil system Choice of axial inlet or opposed-flange casings /09 PPT26/03/99
endend Conventional Horizontally opposed nozzles/side inlet Beam-style (and overhung) rotor designs Wide pressure ratio/head flexibility - up to five stages High aerodynamic efficiencies Fixed casing design per frame size Fixed pressure ratings up to 155 bar Axial inlet Highest aerodynamic efficiencies: Near 90% isentropic Limited to single-stage designs Overhung rotor design Pressures up to 125 bar Fixed casing design per frame size Conventional Horizontally opposed nozzles/side inlet Beam-style (and overhung) rotor designs Wide pressure ratio/head flexibility - up to five stages High aerodynamic efficiencies Fixed casing design per frame size Fixed pressure ratings up to 155 bar Axial inlet Highest aerodynamic efficiencies: Near 90% isentropic Limited to single-stage designs Overhung rotor design Pressures up to 125 bar Fixed casing design per frame size Pipeline compressor types /01 PPT26/03/99
endend RC14RF20RF30RF36RF42RFA24RFA36 Nozzle ArrangementSide InletSide InletSide InletSide InletSide InletAxial InletAxial Inlet Bearing ArrangementO’HungBeamO’HungO’HungO’HungO’Hung O’Hung & Beam& Beam& Beam& Beam Number of Stages Max. Casing Rating [BAR] / /125 [PSIG] / /1800 Max. Design Inlet Flow [m³/h] [ACFM] Max. Operating Speed [RPM] Max. Impeller Diameter [mm]495/457660/ / / / [INCH]19.5/1826/2148.5/ / / RC14RF20RF30RF36RF42RFA24RFA36 Nozzle ArrangementSide InletSide InletSide InletSide InletSide InletAxial InletAxial Inlet Bearing ArrangementO’HungBeamO’HungO’HungO’HungO’Hung O’Hung & Beam& Beam& Beam& Beam Number of Stages Max. Casing Rating [BAR] / /125 [PSIG] / /1800 Max. Design Inlet Flow [m³/h] [ACFM] Max. Operating Speed [RPM] Max. Impeller Diameter [mm]495/457660/ / / / [INCH]19.5/1826/2148.5/ / / /06 PPT26/03/99 Active pipeline booster frame sizes
endend /10 PPT26/03/99 Pipeline centrifugal compressors
endend /02 PPT26/03/99 Pipeliner cross section
endend /05 PPT26/03/99 Typical RFA 36 pipeline booster performance map
endend Rotor supported by a hydrodynamic pressurized oil film generated between the rotor & white metal lined bearing pads Well established & accepted technology Compact cartridge design High stiffness & damping capabilities High load capacities High reserve capacities - Resistant to upsets Requires complex oil supply & control system Rotor supported by a hydrodynamic pressurized oil film generated between the rotor & white metal lined bearing pads Well established & accepted technology Compact cartridge design High stiffness & damping capabilities High load capacities High reserve capacities - Resistant to upsets Requires complex oil supply & control system Fluid film tilting pad bearings /05 PPT26/03/99
endend Bushing Seals:Principle:Injection of regulated high pressure oil between two adjacent cylindrical white metal / aluminum lined rings at each end of compressor Config’s:-Single breakdown seals up to ~ 140 bar -Double breakdown seals for higher pressures Dry Gas Seals:Principle:Use cleaned & dried process gas at discharge pressure bleeding across highly polished & profiled radial faces separated by very small clearances Config’s:-Tandem seal with second stage as safety back-up -Triple seal required above 140 bar Bushing Seals:Principle:Injection of regulated high pressure oil between two adjacent cylindrical white metal / aluminum lined rings at each end of compressor Config’s:-Single breakdown seals up to ~ 140 bar -Double breakdown seals for higher pressures Dry Gas Seals:Principle:Use cleaned & dried process gas at discharge pressure bleeding across highly polished & profiled radial faces separated by very small clearances Config’s:-Tandem seal with second stage as safety back-up -Triple seal required above 140 bar Shaft sealing technologies /01 PPT26/03/99
endend AdvantagesOil Free Simple, low maintenance control system LimitationsTandem seals limited to 140 bar No rotor damping Limited axial travel Requires clean & dry sealing gas Sensitive to lube oil migration - Requires buffer air and barrier seal Complex design No on-site maintenance Requires high installation skill Sticking problems High cartridge cost AdvantagesOil Free Simple, low maintenance control system LimitationsTandem seals limited to 140 bar No rotor damping Limited axial travel Requires clean & dry sealing gas Sensitive to lube oil migration - Requires buffer air and barrier seal Complex design No on-site maintenance Requires high installation skill Sticking problems High cartridge cost Dry gas seals /04 PPT26/03/99
endend Carbon Faces (Stationary) Primary Rings (Rotating) Tandem dry gas face seal /03 PPT26/03/99
endend MagneticRotor supported by electromagnetic fields Requires significant air cooling for power outages Requires auxiliary bearings Promising technology - Fairly new to large industrial turbo machinery (1988) Large bearing dimensions Reduced stiffness & damping capabilities Limited load capacities Limited reserve capacities - Easy to upset Requires complex digital control system Requires careful system tuning MagneticRotor supported by electromagnetic fields Requires significant air cooling for power outages Requires auxiliary bearings Promising technology - Fairly new to large industrial turbo machinery (1988) Large bearing dimensions Reduced stiffness & damping capabilities Limited load capacities Limited reserve capacities - Easy to upset Requires complex digital control system Requires careful system tuning Active magnetic bearings /06 PPT26/03/99
endend Magnetic and auxiliary journal bearings /09 PPT26/03/99 Magnetic and auxiliary journal bearings Magnetic and auxiliary journal bearings Magnetic and auxiliary journal bearings Magnetic and auxiliary journal bearings
endend RF2BB30 with magnetic bearings /07 PPT26/03/99
endend /01 PPT26/03/99 Inlet guide vanes
endend /03 PPT26/03/99 Inlet guide vane performance
endend Type of test Purpose Modified ASME PTC 10 Class 3:Performance Validation - Typical on Pipeline Compressors Full ASME PTC 10 Class 3:Performance Validation - All Compressors Full ASME PTC 10 Class 1:Performance Validation on High Pressure Multistage Compressors Confirmation of Rotor Stability Absence of Rotating Stall Type of test Purpose Modified ASME PTC 10 Class 3:Performance Validation - Typical on Pipeline Compressors Full ASME PTC 10 Class 3:Performance Validation - All Compressors Full ASME PTC 10 Class 1:Performance Validation on High Pressure Multistage Compressors Confirmation of Rotor Stability Absence of Rotating Stall Compressor running tests Aerodynamic performance /05 PPT26/03/99
endend Type of test Purpose Standard API-617 Mechanical:Confirmation of Mechanical Performance - All Compressors Full Density & Speed String:Confirmation of Mechanical Performance - High Pressure Multistage Compressors Confirmation of Rotor Stability Absence of Rotating Stall Full ASME PTC 10 Class 1 String:Same as Above Type of test Purpose Standard API-617 Mechanical:Confirmation of Mechanical Performance - All Compressors Full Density & Speed String:Confirmation of Mechanical Performance - High Pressure Multistage Compressors Confirmation of Rotor Stability Absence of Rotating Stall Full ASME PTC 10 Class 1 String:Same as Above Compressor running tests Mechanical and rotordynamic performance /06 PPT26/03/99
endend Continuous Stage Efficiency Improvement Allison Compressor Frame Size Development Cycle Time Cost Reduction Continuous Stage Efficiency Improvement Allison Compressor Frame Size Development Cycle Time Cost Reduction Major compressor development programs /01 PPT26/03/99
endend Development Plan Select / develop new advanced aerodynamic design software Calibrate the new software with development testing Perform parametric studies necessary to define basic stage geometry Redesign both barrel and pipeline compressor families as necessary to upgrade performance Populate each family with standard designs Development Plan Select / develop new advanced aerodynamic design software Calibrate the new software with development testing Perform parametric studies necessary to define basic stage geometry Redesign both barrel and pipeline compressor families as necessary to upgrade performance Populate each family with standard designs Compressor stage efficiency improvement /02 PPT26/03/99
endend RCBB-14RFBB-20RFA-24RBB Flange Size, in No. Stages Max. Power Design Speed Max. Design Point Flow (ACFM) (m 3 /h) Optimum Eff’cy83-85%83-85%86-88%78-80% Typical Driver501-KC5601-KC9501-KC5501-KC5 501-KC7601-KC11501-KC7501-KC7601-KC9601-KC11 MWP, psig bar RCBB-14RFBB-20RFA-24RBB Flange Size, in No. Stages Max. Power Design Speed Max. Design Point Flow (ACFM) (m 3 /h) Optimum Eff’cy83-85%83-85%86-88%78-80% Typical Driver501-KC5601-KC9501-KC5501-KC5 501-KC7601-KC11501-KC7501-KC7601-KC9601-KC11 MWP, psig bar Compressors for the CR-501 and CR /03 PPT26/03/99
endend Lead time Objective:Start 1-Jan % Target 65% Measures: Improved Engineering Tools Rationalization of Supplier Base Expansion of Manufacturing Cells concept to all components Improved Fabrication & Packaging Techniques Lead time Objective:Start 1-Jan % Target 65% Measures: Improved Engineering Tools Rationalization of Supplier Base Expansion of Manufacturing Cells concept to all components Improved Fabrication & Packaging Techniques Cycle time and cost reduction /04 PPT26/03/99
endend Summary 50 years of experience in centrifugal compressors Concentration on oil and gas applications since 1972 Broad model range for all natural gas applications High, field-proven efficiency and dependability Single to multiple unit trains, gas turbine or motor driven (including variable speed motors up to 30MW) Early introduction and leadership in the use of advanced shaft sealing and bearing technology, eg - more than 200 compressors with dry gas seals since pipeline compressors with active magnetic bearings - 5 to 25MW, 8500 to 5000 rpm State-of-the-art fabrication, testing and packaging techniques Compliance with all major international technical standards 50 years of experience in centrifugal compressors Concentration on oil and gas applications since 1972 Broad model range for all natural gas applications High, field-proven efficiency and dependability Single to multiple unit trains, gas turbine or motor driven (including variable speed motors up to 30MW) Early introduction and leadership in the use of advanced shaft sealing and bearing technology, eg - more than 200 compressors with dry gas seals since pipeline compressors with active magnetic bearings - 5 to 25MW, 8500 to 5000 rpm State-of-the-art fabrication, testing and packaging techniques Compliance with all major international technical standards /07 PPT26/03/99
endend End of Compressor technology Please press “Esc” to return to main menu