CENTRIFUGAL COMPRESSORS FOR PROCESS GASES

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1 CENTRIFUGAL COMPRESSORS FOR PROCESS GASES A Member of KNM Group Berhad

2 BORSIG ZM Compression GmbH BORSIG ZM Compression GmbH is a member of the BORSIG Group, whose headquarter is based in Berlin. The BORSIG Group offers customised solutions for compressors, pressure vessels, heat exchangers, membrane technology, as well as comprehensive industrial services. The compressors and compressor units are manufactured in Meerane/Saxony. Meerane is situated in the centre of the economic area of Leipzig, Chemnitz and Zwickau which is well known as birth place of the composer Robert Schumann and the beginning of automobile industry in Saxony in the highly industrialized German State of Saxony and has been developing as a modern and efficient business location over the past few years. Our experience is based on more than 170 years of company history. The resulting competence enables us to successfully master all economic, technical and social challenges both today and in the future. BORSIG ZM manufactures centrifugal compressors for process gases for almost 50 years. The BORSIG ZM T-Jet series comprises one- to four-stage integrally geared centrifugal compressors which comply with the corresponding API design standards, such as API 617, API 672, API 614. BORSIG ZM Compression GmbH innovative solutions, state-of-the-art technology, perfectly trained specialists and comprehensive know-how are the basis for our position as a single source supplier of leading technology. BORSIG ZM Compression GmbH your capable partner for the future.

3 Typical fields of application: - Chemical and petrochemical plants - Oil and gas industry - Refinery plants - Fuel gas delivery for gas turbine plants - Various industrial processes

4 2 Performance Range Integrally Geared Centrifugal Compressors for Process Gases Pressure ratio: Capacity / flow 1) : Power 1) : ; max. 4-stages 1,100 40,000 m³/h ,000 kw 1) referring to atmospheric conditions and air

5 3 Impeller The Impeller is the heart of the centrifugal compressor stage. Impellers with backwards curved blades develop a considerably higher static pressure than impellers with radial blades. The residual kinetic energy (moderate exit velocity) is converted into additional pressure by a long parallel-wall diffuser and a precisely calculated volute channel. This results in high efficiencies. The BORSIG ZM impellers are open types and designed with highly sophisticated CFD tools and are able to reach a very high efficiency. Special materials for the impellers and volutes e.g. Stainless Steel or Titanium, guarantee that the requirements of the process industry will be met.

6 4 Control Performance Range a) 1 IGV at stage 1 b) 4 IGV s c) speed variation surge flow % (surge flow % Overload: of design flow at turndown) % of design flow a) 64% 36% 104% b) 60% 40% 107% c) 69% 61% 112%

7 5 Inlet Guide Vane/Volute Casing The adjustable inlet guide vane device enables a stepless modification of the volume flow. The volume flow can be changed in a range from 60% to 115%. By the construction of BORSIG ZM s inlet guide vane, over the complete control range an excellent efficiency can be accomplished. The inlet guide vane is controlled by means of an electrical or pneumatically driven shifting device. Furthermore the flow control is realized by speed variation of the turbo drive. Depending on the process requirements, the volute casing is cast in ductile iron, cast iron or stainless steel. Special materials are possible, too. It is designed with the newest techniques of aerodynamics in association with CAD-tools and FEM. In accordance with the inlet guide vane and the impeller highest levels of efficiency are reached.

8 State-of-the-Art Technology Effective inlet guide vane Aerodynamically shaped volute Compact skid design

9 Three-dimensionally curved impeller, high efficiency Stable gear with axial limitation by thrust collar Sealing system optimised according to process

10 8 Drive / Gearbox The drive unit of BORSIG ZM s centrifugal compressors basically consists of electric motor, coupling and gearbox. The gearbox is used to enable the required speed levels as well as a multistage compressor design. It is a helical spur gear. The axial forces of the compressor impeller and of the helical gearing are transmitted via thrust collars at the gear to the driving wheel and absorbed at lower rotational frequencies by the impellent shaft. The bearing of the gear shafts is effected by plain tilting pad bearings. The oil supply of the bearings and the toothing is realized by a pressure lubrication. The lubricating oil may be cooled alternatively by means of an oil/water cooler or oil/air cooler.

11 9 Oil System API Manufacturer s Standard The oil supply system of BORSIG ZM s centrifugal compressors is designed either integrally with the base frame or as an independent system. An integral oil system is characterized by a compact design of the complete unit and will be delivered completely assembled. Compared with this, the location of an independent system is not predetermined which enables a better integration into existing plants. BORSIG ZM uses only high-quality and reliable components for its oil supply systems and so achieves a high reliability which may be further increased by means of main components. The design of BORSIG ZM s oil supply systems complies with a range of standards, such as API 614.

12 10 Sealing and Supply System Dry gas seals Integrally geared compressors are high speed machines. The sealing of the compression chamber towards the atmosphere is a matter of importance. In particular, when toxic or explosive media are compressed, this sealing serves as protection from danger to life. Dry gas seals are designed for special application and are adapted to the various process conditions. There are appropriate sealing types available for the different requests and conditions, such as: Single seals: Used in Air-, Nitrogen- or CO2-Compressors. Leakage towards the atmosphere is harmless. The radial shaft sealing protects the dry gas seal. To be connected to the flare or for venting purposes, this sealing type can also be used as zero-emission model. Tandem sealing with intermediate labyrinth: This type is particularly recommended when leakage towards the atmosphere as well as product contamination by sealing gases are not allowed. The process gases are toxic and/ or explosive. The gas pressure is relieved via the seal ring pair which is mounted on the gas side. The entire leakage is discharged via the flare connection. The atmosphere side sealing is pressurised under Nitrogen or air. The pressure of the sealing gas has to ensure that the flow goes via the labyrinth to the flare. Thus, the process gas cannot get to the atmosphere side pair of sealing rings. Monitoring: Each sealing is equipped with a monitoring system which controls the supply of purge gas, sealing gas and separating gas. It also monitors the leakage gas. The monitoring system is adapted to the specified statutory orders on hazardous incidents and to the safety requirements of the operator. purgegas flare purgegas flare processgas

13 11 Process Measuring and Control Technology BORSIG ZM provides state-of-the art solutions for instrumentation according to national and international standards. The instrumentation devices follow a high safety standard and are available worldwide to an advanced standard with application using high quality techniques. These requirements are continuously controlled and adapted according to customer demands and along with new developments. BORSIG ZM provides centrifugal compressor units customized with field instrumentation wired to junction boxes and machine monitoring / control systems installed in a unit control panel. For local operations, a local operating panel with start / stop buttons for compressor and auxiliaries, signal lamps, ESD-button etc is provided. Safety-relevant operating data such as oil pressure, oil temperature, bearing temperature, vibrations and various process measurements are controlled, analysed and recorded. In addition, the control system includes an anti surge control or a separate anti surge controller as loose supply is provided. The integration of the control system into a control centre will be realized in cooperation with the customer.

14 12 Quality BORSIG ZM s Quality Management System is certified according to DIN EN ISO 9001:2000. In order to comply with the high quality demands made by clients, BORSIG ZM has successfully undergone further certification processes such as DIN EN ISO Environmental Management Systems and the SCC (Safety Certificate Contractors) for its service department. A high product quality level is guaranteed when competent engineer performance goes hand-in-hand with state of the art production processes and a complete chain of quality control. BORSIG ZM applies modern portable measurement techniques such as FARO laser tracker, scanner, index arm etc. The work of the Quality Assurance Team is based on appropriate testing schedules, measurement equipment administration and is linked to the production, planning and control system (PPS). The team runs its tests and checkups completely independent of manufacturing and production control. It guarantees the compliance of processed material, manufactured components, equipment, products and services in accordance with the requirements of national and international standards, with regulatory and contractual requirements, and also with BORSIG rules and policies. As a leading manufacturer of compressors, BORSIG ZM offers a comprehensive service from one source.

15 13 Service The After Sales Service takes care of your concerns, whether you require service for a BORSIG ZM product or for compressors made by other manufacturers. Competence based on long-term experience in the field of compression and the high quality of the services, BORSIG ZM offers the partner on which you can depend. BORSIG ZM s products are known worldwide for their reliability even under difficult conditions. In order to keep this brilliant availability, a broad service is offered for various types and ranges of compressor application systems. BORSIG ZM provides its support throughout from the erection and commissioning of the machine and equipment up to the point of revamp and remodelling based on its engineering. To keep the system availability at a high level, a comprehensive maintenance service is provided. In emergency cases you can rely on prompt assistance by BORSIG ZM s service staff. A short-term supply of spare parts subject to high quality standards guarantees a minimal downtime for your compressor.

16 BORSIG ZM Compression GmbH Seiferitzer Allee 26 D Meerane/Germany Phone +49 (0) 3764 / Fax +49 (0) 3764 / [email protected]