CENTRIFUGAL COMPRESSORS · Centrifugal compressor 405-21-1С is designed to trans-mit gas via gas...
Transcript of CENTRIFUGAL COMPRESSORS · Centrifugal compressor 405-21-1С is designed to trans-mit gas via gas...
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CENTRIFUGAL COMPRESSORS
COMPETITIVE ADVANTAGES
Scientificandtechnologicalpotential,uniquedesignandprocesssolutionssolutions;
Extensivemanufacturing,engineeringanddesigncapabilities;
Successfulexperienceinlocalizationofadvancedforeigntechnologies;
Productionofmodernenergy-savingturbo-com-pressorequipment;
Unifiedproductionmanagementsystem;
Allstagesofthemanufacturingcycle,fromdesigningtoservicing;
High
reliability
and
operational
readiness
of
the
units;
Automated
manufacturing
techniques;
Improved
environmental
measures.
THE HOLDING ENTERPRISES DESIGN
AND MANUFACTURE
JSC «REP HOLDING» IS A LEADING RUSSIAN POWER ENGINEERING COMPANY,
DESIGNER, MANUFACTURER AND SUPPLIER OF NEW-GENERATION POWER EQUIPMENT.
REP HOLDING
REP HOLDING. KEY COMPETENCE 3
CENTRIFUGAL COMPRESSORS PRODUCED BY REP HOLDING
REP HOLDING DEVELOPS AND MANUFACTURES NEW GENERATION CENTRIFUGAL COMPRESSORS WITH A HIGH-PERFORMANCE FLOW PASSAGE FOR ELECTRICALLY-DRIVEN AND GAS TURBINE GAS-PUMPING UNITS OVER THE POWER RANGE FROM 4,0 TO 32,0 MW.
4 REP HOLDING. CENTRIFUGAL COMPRESSORS
Based on the accumulated design experience REPHoldingdevelopshigh-performanceflowpassagesforcentrifugalcompressorsoverawideoperationrange.Thenewmodelshaveadvantagesover thepreviousgenerationcentrifugalcompressors,especially inthepolytropicefficiencyandcommonalityandstandard-ization of the compressor flow passage componentsandassemblies.
The impellers with 3D blades are developed usingmodels (model test bed). Stages with 3D impellerblades increase essentially the efficiency of the cen-trifugal compressor flow passage. The domestic ad-vanced engineering technologies used in the designof centrifugal compressors enabled REP Holding toprovidehighefficiencyoftheflowpassagesduetoin-creasedpolytropicefficiency.
REPHoldinghasitsownproductionofmagneticbear-ings (under the license from SKF). Active magnetic
bearings are successfully applied not only in electri-cally-drivengas-pumpingunits,butalsooncentrifugalcompressorsaspartsofthegas-pumpingunitsatthegas trunk line facilities and booster compressor sta-tions.
ADVANTAGES OF REP HOLDING COMPRESSORS WITH MAGNETIC BEARINGS:
Operatingcostsreduction;
Increasedservicelifeofthebearingscomparedwithoilones;
Higherefficiencyduetonomechanicallosses;
Feweradditionalequipmentisneeded;
Higherreliability;
Enhancedenvironmentalperformance
According to the program of GPA standardization(PJSC“Gazprom”)REPHoldingcompanyhasdevel-oped and manufactured a standardized centrifugalcompressorratedat16MWandwithpolytropiceffi-ciencynolowerthan87–88%.Standardizationofcen-trifugal compressors consists in the development ofuniversalelementsof the flowpassage,bearingandsealassemblies.Reductionoftheproductiontimeandcostsisoneoftheadvantagesofstandardizedcentrif-ugalcompressors.
VARIETY OF COMPRESSORS
CENTRIFUGAL COMPRESSORS FOR GAS TRANSFER UNIT
REPLACEABLE BUNDLE FOR PEPLACEMENT OF OPERATING
COMPRESSORS
VARIOUS TYPES OF COMPRESSOR PACKAGE CONTENT
REP HOLDING. CENTRIFUGAL COMPRESSORS 5
COMPRESSORS FOR UNDERGROUND GAS
STORAGE
COMPRESSORS FOR COMPESSIONS OF
ASSOCIATED OIL GAS
Replacementofcompessorsthat
reachedtheendoftheirservicelife
ReplacementduetoChangeof
CSMode
ElectricMotorDrive
(GasandSteam)TurbineDrive
Bearings
Oil Magnetic Oil DryGas
Sealings
CENTRIFUGAL COMPRESSORS FOR GAS INDUSTRY
405-21-1С
170-31-1С 300-21-1СМП
220-11-1СМП
200-21-1СМП 400-21-1С
CONFIGURATION
Compressorcasing;
Compressorpackagewithrotor;
Lubricationsystem;
Drysealssystem;
Toolkitforassemblyanddisassemblyofthecompressor;
Compl.setofoilbearings.
Compressor170-31-1СisusedaspartofGPA-4RM-03units and is designed to compress and transmitnatural gas via gas trunk lines. Efficiency – no lessthan0,85.
REP HOLDING. NATURAL GAS CENTRIFUGAL COMPRESSORS 7
TECHNICAL CHARACTERISTICS
Commercialcapacity,MMSCMD
5,25
Finalpressure,abs.,MPa
3,74
Pressureratio 1,7
Compressorrotorspeed,rpm
10300
CENTRIFUGAL COMPRESSOR 170-31-1С
POWER RATING
4 MW
CONFIGURATION
Compressorpackagewithrotor;
Compressorcasing;
Gasdynamicsealssystem(GDS);
Activemagneticbearingsystemfortherotor(compl.setofmagneticbearings)producedunderthelicensefromSKF(S2M);
Confuser,compl.setoftransducerstomeasuregasflowforoperationoftheanti-surgeprotectionsystemandprocessmeasurementoftheCCca-pacitywithanerrornomorethan4%;
Toolkitforassemblyanddisassemblyofthecom-pressor.
CENTRIFUGAL COMPRESSOR 220-11-1СМП
8 REP HOLDING. NATURAL GAS CENTRIFUGAL COMPRESSORS
POWER RATING
4 MW
TECHNICAL CHARACTERISTICS
Commercialcapacity,MMSCMD
1,25
Finalpressure,abs.,MPa
4,41
Pressureratio 1,26
Compressorrotorspeed,rpm
8200
CONFIGURATION
Compressorpackagewithrotor;
Compressorcasing;
Gasdynamicsealssystem(GDS);
Activemagneticbearingsystem(AMB)fortherotor(compl.setofmagneticbearings)producedunderthelicensefromSKF(S2M);
Confuser,compl.setoftransducerstomeasuregasflowforoperationoftheanti-surgeprotectionsys-temandprocessmeasurementoftheCCcapacitywithanerrornomorethan4%;
Toolkitforassemblyanddisassemblyofthecom-pressor.
CENTRIFUGAL COMPRESSOR 200-21-1СМП
REP HOLDING. NATURAL GAS CENTRIFUGAL COMPRESSORS 9
POWER RATING
6,3 MW
TECHNICAL CHARACTERISTICS
Commercialcapacity,MMSCMD
12
Finalpressure,abs.,MPa
5,49
Pressureratio 1,44
Compressorrotorspeed,rpm
8200
CONFIGURATION
Compressorpackagewithrotor;
Compressorcasing;
Gasdynamicsealssystem(GDS);
Activemagneticbearingsystem(AMB)fortherotor(compl.setofmagneticbearings)producedunderthelicensefromSKF(S2M);
Confuser,compl.setoftransducerstomeasuregasflowforoperationoftheanti-surgeprotectionsystemandprocessmeasurementoftheCCca-pacitywithanerrornomorethan4%;
Toolkitforassemblyanddisassemblyofthecompressor.
CENTRIFUGAL COMPRESSOR 300-21-1СМП
10 REP HOLDING. NATURAL GAS CENTRIFUGAL COMPRESSORS
POWER RATING
12,5 MW
TECHNICAL CHARACTERISTICS
Commercialcapacity,MMSCMD
22,1
Finalpressure,abs.,MPa
7,45
Pressureratio 1,5
Compressorrotorspeed,rpm
6500
CENTRIFUGAL COMPRESSOR 405-21-1С
REP HOLDING. NATURAL GAS CENTRIFUGAL COMPRESSORS 11
CONFIGURATION
Compressorpackagewithrotor;
Lubricationsystem;
Drygassealssystem;
Toolkitforassemblyanddisassemblyofthecompressor;
Compl.setofoilbearings.
THE MAIN ADVANTAGES
Commonalityofassembliesandelementsoftheflowpassage;
Efficiency–87,2%;
CompatibilitywithvarioustypesofGTU.
Centrifugalcompressor405-21-1Сisdesignedtotrans-mitgasviagastrunklines.Itscasingisverticallysplit,thecompressorisequippedwithdrygassealsandoilslidingbearings.Thecompressorprovidesapplicationofreplaceableflowpassageswithpressureratio1,35,1,44(1,5)and1,7forfinalpressure9,91MPa.
TECHNICAL CHARACTERISTICS
Commercialcapacity,MMSCMD
33,00
Finalpressure,abs.,MPa
7,45
Pressureratio 1,44
Compressorrotorspeed,rpm
5200
POWER RATING
16 MW
THE MAIN PARAMETER AND DESIGN FEATURES
Efficiencynolessthan0,85;
Pressureratio1,44;
Capacityreferredtotheinitialconditions505m3/min;
Compressorrotorspeed5550rpm;
ApplicationofvariousgeometryflowpassagesprovidinggasflowandcompressionrequiredbytheCustomer;
Applicationofforgedcasingsmakesitpossibletooperateatahigherfinalpressure,longerservicelife;replaceableflowpassagescanbereplacedonsite.
CENTRIFUGAL COMPRESSOR 400-21-1С
12 REP HOLDING. NATURAL GAS CENTRIFUGAL COMPRESSORS
Centrifugalcompressor400-21-1Сisdesignedtotrans-mitgasviagastrunklinesaspartofthegas-pumpingunitratedat32MW.
CONFIGURATION
Compressorcasing;
Compressorpackagewithrotor;
Lubricationsystem;
Drygassealssystem;
Toolkitforassemblyanddisassemblyofthecompressor;
Compl.setofoilbearings.
DELIVERY DESTINATIONS
ThecompressorissuppliedaspartofGPA-32“Lado-ga” to the compressor stations of gas trunk linesandforreconstructionandconstructionofthePJSC“Gazprom”facilities.
POWER RATING
32 MW
TECHNICAL CHARACTERISTICS
Commercialcapacity,MMSCMD
78,9
Finalpressure,abs.,MPa
11,86
Pressureratio 1,4
Compressorrotorspeed,rpm
5550
CENTRIFUGAL COMPRESSORS FOR OIL INDUSTRY
К320-131-1
DELIVERY DESTINATIONS
The equipment is supplied to the facilities of Gaz-prom Neft, LUKOIL, Rosneft, Russneft, SIBURHolding, Surgutneftegaz, Tatneft, TNK-BP Holding,AK“Transneft”,KazMunaiGas.
CENTRIFUGAL COMPRESSOR К320-131-1
14 REP HOLDING. CENTRIFUGAL COMPRESSOR TO COMPRESS OIL-ASSOCIATED GAS
Centrifugal compressor К320-131-1 is designed tocompressoil-associatedgasatgasprocessingplants.
The compressor and all its accessories are explo-sion-proof.Itcanbeoperatedinexplosion-hazardouspremisesofClassВ-1А,withexplosivemixtureof2Т-2categoryandgroup.
Thecompressoristwo-cylinder,two-section,13-stage.The compressor cylinder tightness is provided bymeansofoilendseals.Thelowpressurecylinderhasacaststeelcasinghorizontallysplit.Thehighpressurecylinderhasaforgedbarrel-typecasingwiththeendcover.
Compressor К320-131-1 has been designed for thefoundation dimensions of the К380-103-1 and К354-101-1 units, providing replacement of the old equip-mentatminimumcosts.
TECHNICAL CHARACTERISTICS
Commercialcapacity,MMSCMD
1,16
Finalpressure,abs.,MPa
3,1
Pressureratio 12,4
Compressorrotorspeed,rpm
10800
CENTRIFUGAL COMPRESSORS FOR METALLURGY
K5500-41-1М
DELIVERY DESTINATIONS
ThecompressorequipmentproducedbyREPHoldingis supplied to themetallurgicalplantsandenterpris-esinRussiaandabroad,includingIntegratedIronandSteel Works in Magnitogorsk , Novolipetsk, NizhniyTagil,Severstal,ironandsteelplants,suchasMechel,Evraz, Kazakhmys Corporation (Kazakhstan), Metin-vestGroup(Ukraine),BokaroSteelPlant,BhilaiSteelPlant,DurgapurSteelPlant(India),PaksteelIntegratedIronandSteelWorks(Pakistan)etc.
TECHNICAL CHARACTERISTICS
Commercialcapacity,MMSCMD
5000
Finalpressure,abs.,MPa
0,51
Compressorrotorspeed,rpm
3450
CENTRIFUGAL COMPRESSOR K5500-41-1М
16 REP HOLDING. CENTRIFUGAL COMPRESSORS FOR METALLURGY
Centrifugal compressor К5500-41-1М, with a capac-ity of 5200 m3/min, driven by a heavy-duty steamcondensing turbine rated at 23 MW, is designed tocompress atmospheric air and supply it to the blastfurnace (OJSC “NLMK”). It is incorporated into theТКА-5200/22turbo-compressorunit.
CENTRIFUGAL COMPRESSORS FOR CHEMICAL INDUSTRY
540-41-1
DELIVERY DESTINATIONS
The equipment produced by REP Holding is installedatchemicalindustryfacilities,suchasUnitedChemicalCompany“Shchekinazot”,“Akron”,“Kirovo-ChepetskyChemical IntegratedPlant”,“GrodnoAzot”,“Naftan”,“Nizhnekamskneftekhim”, “Kazanorgsintez”, “Ufaorg-sintez”,“EUROKHIM”,“FOSAGRO”,“Minudobreniya”,“GazpromNeftekhim”.
CENTRIFUGAL COMPRESSOR 540-41-1
18 REP HOLDING. CENTRIFUGAL COMPRESSORS FOR CHEMICAL INDUSTRY
Centrifugalcompressor540-41-1isdesignedtocom-pressnitrousgasintheproductionofweaknitricacid.
CONFIGURATION
Compressorwithabuilt-inturboexpander;
Speedincreaser;
El.motordrive;
Lubricationsystem;
Thermalmonitoring,control,protectionandalarmsystem
TECHNICAL CHARACTERISTICS
Commercialcapacity,MMSCMD
540
Finalpressure,abs.,MPa
0,41
Pressureratio 4,42
Compressorrotorspeed,rpm
8455
DELIVERY DESTINATIONS
The active magnetic bearing system is used as partof electrically-driven gas-pumping unit (EGPA) ratedat 4MW at “GazpromTransgazTomsk” compressorstations, 6,3 MW - at “Gazprom Transgaz Saint Pe-tersburg” compressor stations, “Gazprom TransgazUkhta”, 16 MW - at “Gazprom Transgaz Samara”,“Gazprom Transgaz Belarus”, “Gazprom DobychaNoyabrsk”.
REP HOLDING. ACTIVE MAGNETIC BEARING SYSTEM 19
ACTIVE MAGNETIC BEARING SYSTEM
CONFIGURATION
Bearings;
Electroniccontrolsystem.
ADVANTAGES:
Operatingcostsreduction;
Increasedservicelifeofthebearingassemblies;
Increasedefficiencyduetonomechanicallosses;
Reductioninthequantityoftheadditionalequip-ment;
Higherreliability;
Enhancedenvironmentalperformance.
REPHoldinghassetupatitsfacilitiesitsownproduc-tionofelectricdrivesandmagneticbearingsunderthelicense of SKF (S2M). The innovative production ofcentrifugalcompressorsusingmagneticbearingsanddrygasdynamicsealshasbeenlocalized.
Theactivemagneticbearingsystemprovidescontact-less rotation or the rotor in the controlled magneticfield.
REPLACEABLE FLOW PASSAGES
20 REP HOLDING. REPLACEABLE FLOW PASSAGES
Replaceable flowpassagesaredesigned to renovatetheoperatingcentrifugalcompressors.Thereplacea-ble flowpassagesare installed into theexistingcas-ings,withoutchangingtheoveralldimensionsofthestandardequipment.
REPHoldingproducesreplaceableflowpassageswithvarious design versions of seals (dry gas dynamicseals,oilseals)andbearings (magneticbearings,oilbearings). Up-to-date replaceable flow passages canbedesignedandmanufacturedforinstallationintothecompressorsmadebyotherManufacturers.
TherangeofREPHoldingproductsincludesreplacea-bleflowpassagesforboosterandlinecompressorsta-tions,gasundergroundstoragecompressorstations.
ThereplaceableflowpassagesmadebyREPHoldingundergoafullcycleoftestsatitsowntestingfacilities.
Thefull lifecycleofreplaceableflowpassagesusingactivemagneticbearingsisnolessthan20year.Therepairintervalis50ths.hours.
THE MAIN PARTS OF THE REPLACEABLE FLOW PASSAGES
Package(statorandrotorelementsoftheflowpassage);
Sealassemblies(ifnecessary);
Compl.setofbearings(ifnecessary);
Compl.setofreplacementparts;
Changingpartsandtools.
REP HOLDING. SERVICE MAINTENANCE 21
SERVICE MAINTENANCE
REPHoldingperformsawholepackageofservicesonerectionsupervisionandservicemaintenanceforthewholerangeoftheunitsproduced,includingroutinerepair and overhaul, and training of the Customer’spersonnel.AspecialsubdivisionofREPHoldingpro-videsservicemaintenanceandsupplyofsparepartsforthewholeperiodoftheunitoperation.
HighlyqualifiedspecialistsoftheInstallationandSer-vice Maintenance Department perform installation,pre-commissioningactivities,aswellaswarrantyandpost-warrantyserviceduringthewholelifetimeoftheunits.
ParticipationintheequipmentacceptanceattheCustomer’swarehouse
Erectionsupervision
Pre-commissioning
Stafftraining
Fullpackageofservices
Scheduledpreventiveinspection
Technicalsupervision
Diagnostics
Sparepartssupply
Engineeringsupport
Equipmentupgrade
WARRANTY PERIOD
SERVICE LIFE EXTENSION
POST-WARRANTY PERIOD
TESTING FACILITIES
22 REP HOLDING. TESTING FACILITIES
TheREPHoldingproductionsitesareequippedwithunique high-tech test beds. Mechanical, gas dynam-icand investigationstring testsof theproduced tur-bo-compressorequipmentareperformedatthesetestbeds.
Theproductqualityisassuredandcontrolledinaspe-cialsubdivisionofREPHolding–InterplantMetrology,TestsandInspectionLaboratory.
Thelaboratoryisequippedwithup-to-dateequipmentfromtheleadingforeignManufacturers:
Spectrometer–ARL3460Advantage;
Machinesforsamplepreparation–HerzogVNU300and grinding machine – Herzog HT 350, machinesforexpressanalysisofchemicalcompositionwhenmeltingsteelsandcastironinmeltingfurnaces;
Flawdetector–P920Magnaflux–formagneticpar-ticleinspectionoftherotorpartsandcastingsoftheturbineandcompressorcasingparts;
Equipment produced by Zwick company to deter-mine the mechanical properties of metal (strengthand viscosity) – testing machine Z250 and impacttestingmachineRKP450.
Awide rangeof investigations isperformed in thelaboratory: X-ray flaw detection, chemical, spec-trum, capillary analysis, magnetic particle inspec-tion,ultrasonictesting
Testbedforcentrifugalcompressors
Replaceableflowpassageonthetestbed(upto16МW)
3Dimpellerstestbed Schenkhigh-speedbalancingmachine
Replaceableflowpassageonthetestbed(over16МW)
Testingfacilitiestodefinethemechanicalperformancesforbladesmetal
Testbedforcompressor405-21-1С
DELIVERY DESTINATIONS
REP HOLDING. DELIVERY DESTINATIONS 23
Morethan40regionsofRussia
Morethan20neighboringcountriesandbeyond
Morethan180unitsofdifferenttypesinoperation
JSC “REP Holding”51, Let. AF, Obukhovskoy Oborony pr., Saint-Petersburg, 192029, RussiaTel.: +7 (812) 372 58 80, +7 (812) 372 58 81Fax: +7 (812) 412 64 84www.reph.ru