Ge Centrifugal And Axial Compressors Brochure NP Centri CompressAM2006

Ge-Centrifugal-And-Axial-Compressors-Brochure-656391 ge-centrifugal-and-axial-compressors-brochure-656391

2015-03-11

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GE Oil & Gas
Centrifugal & Axial
Compressors
2GE
Centrifugal & Axial Compressors
GE Centrifugal & Axial Compressors
Tradition, Experience and Innovation
Types and Characteristics
MCL / V series
BCL, RB, VH series
PCL series
SRL Integrally Geared series
SRL / DH series
Blowers D series
Axial Compressors AN series
Compressor Components
Oil and Gas Seal Systems
Control Systems
Test Facilities
Service
Training
Exploration and Production,
Floating Production Units, LNG
Pipeline and Storage
Refinery and Petrochemicals
Compressor Specifications
Product Line Range
3
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3GE
Centrifugal & Axial Compressors
GE’s Oil & Gas Business manufactures a complete range of centrifugal compressors
for all major compression applications. They are used in oil & gas production, gas
transportation, refinery and petrochemical industries, fuel gas boosting and other
similar processes. We hold the record of key milestones for centrifugal compressor
applications having designed and manufactured the first high pressure compressors
for ammonia and urea plants, the most powerful compressors for offshore
applications (over 30,000 HP) and re-injection compressors with delivery pressures as
high as 10,000 psi (700 bar).
Specific requirements are met by custom configuring each compressor using
standardized advance technology components proven over a wide range of process
conditions. This approach delivers reliable, high performance compressors for natural
gas, refinery, petrochemical, GTL and LNG applications.
A highly skilled staff of local engineers and technicians provides on-site technical
support for installation, commissioning, overhaul, repair and maintenance of our
equipment.
Extensive research and development, advanced design procedures, modern
manufacturing techniques and first hand on-site experience in compressor operation
are behind the success achieved by our compressors.
Tradition, Experience and Innovation
4GE
Centrifugal & Axial Compressors
Horizontally-split compressors
Used primarily for low and medium pressure
applications in ethylene and fertilizer plants
refineries, LNG for refrigeration, air
compression, etc.
Vertically-split barrel compressors
Used primarily for high pressure applications
such as ammonia, urea and methanol
synthesis, refinery recycle, natural gas
compression and injection and hazardous
gases.
Pipeline compressors
Used for low and medium pressure ratio
pipeline service and in recycle applications
such as those performed in methanol plants,
etc.
Types and Characteristics
BCL 405/C Re-injection Compressor offshore
installation North Sea
Propane Compressor for Qatar LNG Plant Pipeline Centrifugal Compressor PCL 603
5GE
Centrifugal & Axial Compressors
Mixed Refrigerant
Compressor for LNG Plant
Axial compressors
Used for low pressure, high flow applications
such as catalytic cracking plants, air service,
air separation, LNG, nitric acid and GTL
applications.
Single stage overhung compressors
Used as boosters or recycle compressors in
many petrochemical applications, such as
polyethylene, polypropylene, ethylene oxide,
chlorine, sulfuric acid plants, MVR.
Integrally geared compressors
Used for low and medium pressure air, steam
and inert gas, and fuel gas service and in
petrochemical applications.
DH Single Stage overhung
compressor for API 617
applications
SRL 603 for Air + Carbon
Monoxide - Belgium
6GE
Centrifugal & Axial Compressors
MCL compressors are designed in several sizes and pressure ratings to cover different applications.
The compressor casing is either cast (cast-iron, cast steel) or fabricated. The diaphragms are
cast-iron, cast steel or fabricated.
The impellers and diffusers are selected from a wide range of standard stages in accordance
with the application and desired performance.
The radial and thrust bearings are of the tilting pad type.
Shaft-end seals are mainly dry gas seals but can be labyrinths or oil film seals.
Inter-stage leakages are controlled by labyrinths (static or rotating) or abradable seals.
Double flow models (DMCL) are used to compress very high flows. This solution allows the casing
size and speed to remain within an acceptable range to couple the compressor to drivers and/or
other compressor casings.
Different washing options can be offered as required.
MCL / V series
Horizontally split VS compressor for refrigeration service
2MCL Horizontally split compressor being machined
MCL series
Double stage models (2MCL) are used when intermediate cooling is required or when a
process calls for two separate compression stages.
2MCL compressors have the same general features as the MCL type with the two compression
stages in a back-to-back arrangement.
Additional side stream nozzles can be provided with the 3MCL model for special requirements
such as in refrigeration applications, particularly for propane in LNG plants.
All connections can be oriented upward or downward to meet plant layout needs.
7GE
Centrifugal & Axial Compressors
2MCL series
8GE
Centrifugal & Axial Compressors
These compressors are designed to cover a wide range of applications and pressures (hydrogen
mixtures, hazardous gases, high pressure).
Casings can be rolled steel or forged with one or two end covers bolted or secured by shear rings.
For improved performance, diaphragms are, when practical, 100% machined.
Radial and thrust bearings are of the tilting pad type. Active Magnetic Bearings are also
available as an option.
End seals are of the dry gas type and other sealing solutions are also available.
In addition to conventional labyrinths, inter-stage seals can be abradable or honeycomb seals
to optimize the overall performance of the machine.
In-line, back-to-back or double flow configurations are also available.
Materials are adapted to the process requirements. Specific materials are selected to withstand
the various forms of corrosion present in sour or acid gas applications based upon extensive
experience in corrosive applications.
BCL, RB, VH series
BCL series
2BCL very high pressure
RB series
9GE
Centrifugal & Axial Compressors
PCL series
These compressors have been designed to meet the range of flow and compression ratios required
by gas pumping stations.
A variety of standard casing sizes are available to cover a wide range of gas flow.
The same casing can house different numbers of impellers to optimize performance in terms of
efficiency, compression ratio and operating range.
Field modification of the impeller configuration can be made to accommodate changes in
operating conditions.
The compressor casings are made of forged steel to provide maximum material strength and
metallurgical stability. Vibration-free operation is assured by positioning bearings at both casing
ends which provides the necessary rigidity to the rotor.
Dry gas seals are normally used to prevent gas leakage.
Floating bushing oil seals are also available on request.
The suction and delivery nozzles are generally located opposite each other to meet station layout
requirements. Axial inlet is also available when the pressure ratio allows for a single impeller.
PCL series
Pipeline Centrifugal Compressor
PCL 603
10 GE
Centrifugal & Axial Compressors
Integrally Geared Compressors are used in several petrochemical applications, either for
low-flow/high pressure, or high-flow/low pressure conditions. This type of compressor has a bull
gear and from one to four high speed pinions. One or two impellers can be mounted on each
pinion-shaft. Optimal impeller speed and the ability to inter-cool compression stages guarantee
very high efficiency. Due to its rugged mechanical design, this type of machine has very high
reliability and is easy to maintain. A large variety of gases can be handled by this compressor line
with appropriate construction materials and seal systems. This line is designed for process air and
gas service.
SRL Integrally Geared Series
SRL series
11 GE
Centrifugal & Axial Compressors
SRL / DH series
Overhung compressors are mainly used as boosters in petrochemical applications or for recycle
in polypropylene and polyethylene plants.
The single-stage overhung configuration is simple and easy to maintain. Almost all gases can be
handled by this type of compressor with appropriate construction materials and seal systems.
12 GE
Centrifugal & Axial Compressors
The Blower compressor is a low-pressure, single-stage overhung design typically utilized
where a tough process gas application requires a relatively high flow of gas at a moderate
differential pressure.
It features a compact, efficient design and the ability to handle a wide range of applications.
Features like three-piece casing construction, horizontally split bearing housing and our exclusive
impeller balance ring are examples of how this compressor is designed from the ground up to
provide maximum reliability and serviceability to its operators.
These compressors offer a choice of models and seal options, as well as the design flexibility and
optional equipment to conform to customer specifications.
Accessory packages include a variety of drivers, sound attenuation, a lubrication console
and advanced control functions.
Optional API configurations also available.
Blowers D series
D series
Axial compressors are designed for high volume, relatively low pressure applications and have
high efficiency and a broad operating range.
An external fabricated horizontally split casing holds an inner stator blade carrier.
The first stator blading rows are adjustable by external devices for better performance control
and for broader operability.
The number of blade rows is variable to better fit the process needs.
Both rotor and stator blades are robustly designed, for optimum aerodynamic and mechanical
behavior.
The radial and thrust bearings are of the tilting-pad type. Shaft-end seals can be labyrinths
either with extraction or buffer systems, oil film seals or dry seals depending on service
requirements.
All connections can be oriented upward or downward to meet plant layout needs.
13 GE
Centrifugal & Axial Compressors
Axial Compressors AN series
14 GE
Centrifugal & Axial Compressors
Casings
Depending on the compressor family the
casings can be
- Horizontally split
- Vertically split
Horizontally-split casings consist of two half
casings joined along the horizontal center-
line. All connections such as suction and
discharge nozzles, side stream nozzles (if any)
and oil piping are normally fitted to the lower
half so that the upper half becomes an easily
removable cover. The casings may be cast-
iron or cast or fabricated steel depending on
the compressor duty, service temperatures,
gas handled and compressor size.
Vertically split casings have different shapes
and thickness depending on the pressure
rating.
Casings up to 350 bars are steel cylinders
with end covers either bolted or secured by
shear rings. Nozzles can be welded to the
casing or machined directly.
Casings with ratings over 350 bars are cup-
shaped forgings with one end cover only. This
cover is secured to the casing by a patented
shear ring locking device.
Shear rings offer the advantage of being
simple to assemble and provide the
necessary sealing assurance for very high
gas pressures.
By removing the end cover it is possible to
remove the rotor diaphragm bundle assembly
and to gain access to the internal
components without removing the outer
casing which remains connected to the plant
piping package.
Diaphragms
Suction, intermediate and discharge
diaphragms create the
gas flow path within
the stationary
components. The
suction diaphragm
conveys the gas into
the eye of the first
impeller and can be
fitted with adjustable
guide vanes to
optimize the inlet flow
angle. Intermediate
diaphragms perform the dual function of
forming the diffuser passage (where gas
Compressor Components
velocity is transformed into pressure) and the
return passage to channel gas to the eye of
the next impeller. The discharge diaphragm
forms the diffuser for the last impeller as well
as the discharge volute. The diaphragms are
usually horizontally-split.
In the small to medium sizes of the MCL series,
the upper half of the diaphragms is fixed to the
upper half casing to facilitate inspection, and
for the large sizes, it is fixed to the lower half of
the diaphragms, while the barrel family
internals are assembled into a bundle which
can be easily extracted from the casing.
The diaphragms are made of cast-iron, steel or
stainless steel and when practical 100%
machined to improve efficiency.
Easily removable labyrinth seals are installed
on the diaphragms at impeller shrouds, to
prevent return flow from discharge to suction
and on the shaft sleeves to eliminate
interstage leakage.
Rotors
The rotor consists of shaft, impellers, sleeves,
balance drum and thrust collar. Impellers are
selected from a number of standard families.
Each family groups a set of geometrically
similar impellers with different flow
coefficients to meet specific flow
requirements. All geometries have been
tested in the company’s R & D laboratories.
Impellers are shrunk on the shaft. Impellers
may be either of the closed or open design.
Closed impellers are made of forged steel.
Their blades may be welded or brazed to
both the disc and the shroud or milled from a
solid disc and welded or brazed to the shroud.
Solid weld-free impellers produced by milling
or electrical discharge machining technology
are also available.
The blades are generally back-swept to
different angles in accordance with the
required performance.
Open impellers are machined from solid
forgings.
Each impeller is dynamically balanced and
overspeed tested before assembly.
The rotor is balanced after the assembly of
each individual component on the shaft.
15 GE
Centrifugal & Axial Compressors
16 GE
Centrifugal & Axial Compressors
Seals
Shaft end seals eliminate or minimize the
leakage of compressed gas or the entry of air
into the compressor casing. Depending on the
nature of the gas to be compressed and on
the degree of sealing to be achieved, different
types of seals may be used.
Labyrinth seals
They are used when the properties and
pressure of a gas permit a minimal leakage.
The labyrinths are made of light alloy or other
corrosion-resistant material and are easily
replaceable. The number of teeth and
clearance depend on the operating
conditions, as well as the geometry (plain,
step, ring type, honey-comb, etc.). To minimize
leakage, abradable seals are used. In this
case the labyrinth teeth are fitted to the rotor
and are in contact with an abradable material
on the stator.
When no leakage whatsoever is permissible
(poisonous or explosive gases, etc.) labyrinth
seals are combined with extraction and/or
injection systems.
Dry gas seals
Sealing is ensured by a gas lock created by
the grooves machined into a rotating seal
fitted on the rotor. Depending on the
application it is possible to use gas - taken off
the compressor at different levels: first
impeller diffuser, intermediate or discharge
nozzles or an insert gas.
Hydrostatic and hydrodynamic forces balance
to maintain a clearance of a few microns
between the rotating seals and the stationary
face. This very small clearance reduces gas
leakage to a negligible amount.
Different patented solutions are available to
temper the seals to prevent liquid or hydrate
formation or for controlling the temperature of
the seal.
Extensive experience has been accumulated on
dry gas seal systems that have been developed
to meet specific process requirements.
Oil seals and mechanical seals are available at
request, tend to be replaced by Dry Gas Seals.
Compressor Components
Bearings
Hydrodynamic bearings
- Journal bearings
Tilting pad bearings are generally used,
and are normally equipped with
thermocouples to monitor the bearing
temperature.
- Thrust bearings
Double-acting, tilting pad bearings with an
equalizing device are typically installed.
The bearing pads can be fitted with
thermocouples for temperature monitoring
and with load cells in high pressure
applications to measure axial thrust.
Active magnetic bearings
In recent years several machines have been
equipped with active magnetic bearings.
Operating on the principle of electromagnetic
suspension, the active magnetic bearings
perform the same functions as hydrodynamic
journal and thrust bearings with two major
advantages:
- reduced mechanical losses owing to the
absence of friction
- adjustable axial and radial position and
stiffness of the rotor and damping
characteristics of the bearings.
17 GE
Centrifugal & Axial Compressors
18 GE
Centrifugal & Axial Compressors
Oil systems
Pre-engineered solutions, designed in accordance with API 614 are implemented for continuous
compressor operation. Integrating the experience from the large number of units in operation
ensures high reliability and short cycle times.
The oil system can be a separate console or be integrated with the compressor base plate for
compact packages that are easy to install on-shore or off-shore including special criteria for
FPSO applications.
The lube oil system provides lube oil to the radial and thrust bearing of the compressor, to
the gear box, and to the driver (except for some gas turbines).
A seal oil system supplying filtered oil to the liquid film rings or to mechanical type seals at
the required pressure and temperature can be provided upon request.
The seal oil system may also be combined with the lube oil system. In this case the same oil
reservoir is used for both functions.
Oil and Gas Seal Systems
Gas seal systems
These systems are available to cover the
needs of the different Dry Gas Seal
configurations.
They provide, as a sub assembly, the required
buffer gas for the primary, secondary and
tertiary seals, and the instrumentation to
properly monitor the seals.
19 GE
Centrifugal & Axial Compressors
With extensive experience as a manufacturer of compressors and all types of drivers, and
engineering and field services for compression stations, our specialized teams develop systems to
control the equipment packages and the associated auxiliaries or processes as required.
Control systems:
Our Integrated Driver-Compressor Control system is a complete integrated solution, providing
protection and monitoring to maximize the security of the compressor against potentially harmful
surge conditions, while enhancing process efficiency and availability. This integrated control
system provides critical process control for the entire compression train, its auxiliaries and related
process equipment. Compatible with a variety of drivers and compressors, it runs on the GE Mark
family of control platforms or on GE Fanuc PLC’s as dictated by the applications. Simplex, Dual,
and TMR control system redundancy options are available.
Combining the driver and load compressor control in a single platform provides advantages to the
customer:
- Common spares for both driver and compressor control systems reduce the overall inventory
requirements
- A smaller physical footprint means that compressor control hardware can be included in the
same cabinet as the driver control hardware.
- The same Technical Advisor can handle commissioning and startup of both the compression
train and driver.
- Common software tools and diagnostics for maintenance of driver and compressor controls
simplify maintenance and uprates, and also reduce startup time and cost.
- Training time and costs are reduced with a single control system used for both driver and
compressor controls. This applies to both initial and on-going training costs over the life of the
control system.
Control Systems
Anti-surge protection and process
control
Anti-surge control algorithms implemented
within the integrated control system are based
on the knowledge acquired through our
expertise as a leading compressor
manufacturer and experience on thousands of
applications. Different control strategies are
available to meet the needs of the application.
All provide both closed and open loop controls
to better react to small and large process
disturbances. Different process control and
load bearing functions can be provided.
Dynamic simulation
Dynamic simulations ranging from a single
loop to a more complete process configuration
are possible to define anti-surge valves, hot by
pass requirements, piping optimization for
improved compressor protection and starting
conditions for electric motor drives.
20 GE
Centrifugal & Axial Compressors
Centrifugal compressors are carefully tested throughout the manufacturing
process in order to guarantee a perfect match to their design criteria and to
assure long lasting, continuous operation.
The following tests are typically carried out on components and assembled
machines:
- casing: hydraulic pressure test
- impellers: ultrasonic and dye penetrant liquid tests; over speed testing
- impellers/rotors: over-speed testing
- mechanical run test
Optional tests may be performed based on the specific job requirements. For
example:
- performance tests (with air or other gases in an open or closed loop)
- full load - performance tests (including flammable gases) to check rotor
stability and the performance of the machine
- mechanical string test.
Numerous indoor and outdoor test beds together with a sophisticated system
for data acquisition and processing of test results distinguish the Florence,
Massa and Le Creusot facilities.
We have the largest and most complete testing capability in the industry to
perform tests under actual load and pressure conditions (including LNG and
re-injection) for trains driven by gas turbines or electric motors.
Test Facilities
21 GE
Centrifugal & Axial Compressors
GE’s Oil & Gas business provides a complete set of services to support the entire centrifugal &
axial compressor product line. We offer an extensive portfolio of proactive and interactive service
products such as condition-based maintenance, Conversions, Modifications and Uprates (CM&Us)
and Contractual Service Agreements (CSAs) complementing the traditional service offerings of
OEM spare parts, repairs, and field services.
Our innovations are not limited to mechanical engineering. We have developed business
solutions such as remote monitoring & diagnostics to help drive customer value by providing
higher equipment reliability, availability, and productivity at a predictable cost.
Other advanced information-based developments include electronic parts catalogs, and e-
commerce solutions.
Global Services engineers are backed up by our new product design engineering groups and by
the GE Global Research Center - hundreds of creative minds working to provide the high-tech
products and business solutions for the 21st century.
Service
GE’s Oil & Gas business offers Training for the Operation and Maintenance of our complete line of
machinery and equipment.
This Training can be provided either at the client’s site or at the Learning Center located at the GE
Infrastructure Oil & Gas headquarters in Florence, Italy. Instructors are field-seasoned experts
who combine their understanding of theory with practical experience.
The quality training that they provide is a prerequisite for improving the skills of operating and
maintenance personnel, to ensure safety, and superior equipment efficiency and availability.
Courses and documentation are designed to meet Customer needs, focusing on the GE machinery
and equipment actually installed at their sites.
Traditional training tools are augmented with computer-based training and interactive
multimedia technology. Courses and technical literature can be provided in a variety of
languages.
CENTER OF EXCELLENCE FOR TRAINING
Florence Learning Center Facilities:
-5600 m2of Space
-More than 20 Training Rooms
-Speedtronic Mark V & Mark VI
-Bently Nevada Simulators
-Laboratories
-Multimedia Rooms
-Conference Center
-Auditorium Seating for 230 (under completion)
TRAINING SOLUTIONS:
-For all level in your organization
-Tailored for your specific needs
-Prescheduled offerings or on request
-Provided in various languages
-Formal classroom training and interactive learning
COVERED EQUIPMENT
Nuovo Pignone, Thermodyn, Rotoflow, Bently Nevada
and other GE equipment.
Training
22 GE
Centrifugal & Axial Compressors
23 GE
Centrifugal & Axial Compressors
Exploration and Production, Floating Production Units, LNG
BCL 406/B + BCL 305/C + BCL 305/D
compressor driven by MS5002 Gas
Turbine installed in Venezuela
Mixed refrigerant train AN 200 axial
compressor and 2BCL 806 Centrifugal
Compressor, driven by
MS7001E-A Gas Turbine - Malaysia
BCL 406/B + BCL 305/C driven
by MS5002 Gas Turbine installed
on Nkossa platform - Congo
Ekofisk platform - North Sea
24 GE
Centrifugal & Axial Compressors
Pipeline and Storage
PCL 800 San Fergus
PCL compressor installed in
Transcanada pipeline
A PCL 1002 booster compressor
on the Soyuz gas pipeline
The PCL 802 centrifugal compressor
boosting natural gas on board the main
Ekofisk platform
GDF Chemery Gas Storage
Storage to Pipeline Compressor
Gazprom
25 GE
Centrifugal & Axial Compressors
Refinery and Petrochemicals
Urea synthesis compressor
trains in a petrochemical
plant - Qatar
Steam recompression
evaporation - USA
Ammonia synthesis
Mesaieed - Qatar
Ammonia synthesis
Refrigeration train in an
Ammonia plant, Turkmenistan
26 GE
Centrifugal & Axial Compressors
Compressor Specifications
COMPRESSOR FAMILY AND TYPE
Centrifugal Vertical Split LP/MP 1917 855 167 28 895
BCL, RB, RH, VH
Centrifugal Vertical Split HP 531 531
BCL
Pipeliners 545 545
PCL
Centrifugal Horizontally Split 1362 141 107 1114
MCL, V
Integrally Geared 71
SRL
Overhung 331
SRL, DH
Blower 931
D
Axial 29
AN
Total 5717 1527 819 28 2009
-0,9 (-13) up to 60,000 200 40,000 3,000-20,000 GT; EM; ST Sour and Acid gas
(up to 35,300) (2,900) (54,400) High Speed Motors available Active mag bearings
83 (1200) up to 15,000 700 30,000 7,000-18,000 GT or EM Re-injection: Ultra High
(up to 8,800) (10,000) (40,800) Pressure Sour Gas
20 (290) up to 100,000 130 40,000 3,600-13,000 GT; VSDS; hydraulic Oil free trains (AMB)
(up to 58,800) (1,900) (54,400) converter or High Speed Motors
-0,9 (-13) up to 500,000 40 70,000 3,000-15,000 ST; EM or VSDS Cryogenic
(up to 294,000) (580) (95,200) down to - 100°C available
-0,9 (-13) up to 350,000 70 15,000 3,000-50,000 EM; ST possible Open closed impellers
(up to 206,000) (1,000) (20,400) high mach stages
-0,9 (-13) up to 100,000 86 14,900 1,200-20,000 EM Single stage
(up to 58,800) (1,250) (20,000)
-0,9 (-13) up to 408,000 14 6,000 2,000-20,000 EM Single stage
(up to 240,000) (200) (8,000)
-0,9 (-13) 100,000-600,000 25 70,000 ST; GT; VSDS possible Variable Stator Vanes
(58,800-353,000) (360) (95,200)
number of units
installed Experience
Upstream
Gas Rejniection
Enhanced Recovery
Gas Lift
Gas Production
and Processing
Fuel Gas Boosting
Gas Gathering
Midstream
Gas Liquefaction (LNG)
Gas Pipeline
Gas Storage
Downstream
Ethylene & Derivatives
Fertilizer
Refinery (Cracking)
Refinery (H2 Recycle)
GTL
Air Separation
Minimum Suction
Pressure bar (psig)
Inlet Flow Range m3/h
(acfm)
Maximum Discharge
Pressure bar (psig)
Maximum Power
kW (HP)
Speed Range - rpm
Driver Type
Comments
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Model Designation
Product Line Range
27 GE
Centrifugal & Axial Compressors
GE imagination at work
GE Oil & Gas
Global Headquarters
via Felice Matteucci, 2
50127 Florence, Italy
T +39 055 423 211
F +39 055 423 2800
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www.ge.com\oilandgas
COMK/MARK 768/II - Designed by: Studio Tre Fasi
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