Dresser Rand Compressor

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Dresser Rand compressor

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  • Bringing energy and the environment into harmony.

    Process reciProcating comPressorsProven solutions for the most demanding upstream, midstream and downstream applications.

  • 2Look for our more info icons throughout this brochure indicating additional publications are available on our website for that product or service.

    processreciprocating compressors

    Manufacturing, installing and

    maintaining systems around

    the world.

    COMMITTED TODELIVERING VALUEFor more than 100 years, Dresser-Rand has been a world leader in energy conversion technology, designing, manufacturing and servicing a wide range of field-proven centrifugal and reciprocating compressors, gas and steam turbines, expanders, and control systems. D-R supplies reliable, efficient energy-conversion solutions that provide the highest value to our clients by delivering the lowest total cost of ownership over the operating life of the equipment. Our engineers constantly seek improvements in design, production and testing to make our equipment even more efficient and reliable. This R&D focus is reflected in every product and service we offer, from new equipment to upgrades, that extend the life of your installed equipment. Our emphasis on maximizing the value you receive also extends to the way we work with you. Our Corporate Product Configurator (CPC) coordinates all elements of the bidding, engineering, design, and manufacturing process. It improves communication and results by fostering closer collaboration with our clients and within D-R. Best of all, it has dramatically cut our cycle times for all project phases, so your equipment can be on-line and producing sooner.

    Our leading-edge technology, some of the shortest cycle times in the industry, advanced business processes, and global presence help our clients reduce unit operation costs, which are 70 to 80 percent of the total cost of compression assets. That helps our clients be more competitive.

    Dresser-Rand pioneered reciprocating gas compression, continually innovating and improving as new materials and technologies were developed. Today, our reciprocating compressors, manufactured to stringent specifications, boast an outstanding record for performance, efficiency, reliability, and low maintenance in the most demanding upstream, midstream and downstream process applications.

    COMpREhENsIVE COMpREssOR sOLUTIONs, EXTENsIVE CLIENT sUppORTWe offer a complete line of reciprocating compressors, built to strict API and ISO standards, and all backed by a global network of service and support centers. We supply our reciprocating compressors from state-of-the-art facilities in Painted Post, New York, USA; Peterborough, UK; and Naroda, India. This global presence allows Dresser-Rand to provide the most flexible and responsive service, regardless of your location.

    MAXIMIzE yOUR EffICIENCIEs wITh sINGLE-sOURCE ACCOUNTAbILITyWe can engineer, manufacture, procure, test, deliver, install, operate, and maintain your entire compressor system. Our extensive application experience with all major drive systemsincluding motors, engines and turbinesallows us to precisely match the drive train to the compressor for maximum efficiency and reliability.Our equipment is ready for modular installation, with compressor drive, lubrication, coolant, pulsation dampening, and control systems. This integrated approach simplifies ordering,

    delivery and installation; reduces your coordination time and expense; lowers your engineering and construction costs; and provides single-source accountability.

    wE ENsURE pROCEss AND OpERATIONAL EXCELLENCEOur project management expertise and systems ensure compliance with specifications, shortest delivery cycles and on-time shipment. All components custom-

    engineered to meet your specific requirements, including cylinders and valves

    Available with up to 10 crank throws. Our design flexibility does not limit the frame to an even number of crank throws. Dresser-Rand uses its variable crank angle design to offer a compressor that requires the minimum number of cylinders.

    Factory-tested for critical clearances and dimensions

    sERVICEAt Dresser-Rand, we apply our state-of-the-art technology and total solution capabilities to all makes and models of installed reciprocating processors. It is the same technology we use to design and build our new equipment. No matter the manufacturers nameplate, our dedicated professionals are ready to keep it running with responsive, reliable technical support 24 hours a day, anywhere in the world.

  • 3Dresser-Rand reciprocating compressors meet stringent regulatory requirements and have an outstanding

    record for performance, efficiency, reliability, and low maintenance in the

    most demanding upstream, midstream and downstream applications.

  • 4a customized solution for your process application.

    CrankshaftsConstructed of high-tensile-strength alloy steel forgings, fully stress relieved, heat treated. Bearing surfaces are ground and polished to a fine finish. Generous proportions provide a wide margin of safety.

    *Alloy steel proprietary tungsten carbide coated (TC3) Illustration and descriptions are typical of large compressors.

    BearingsPrecision main bearings provide maximum support to ensure reliability.

    Precision SpacersPrecision spacers and rugged tie rods above each main bearing provide rigidity to prevent distortion.

    Connecting RodsDie-forged steel and rifle-drilled for positive crosshead pin lubrication.

    CrossheadsAvailable on the HHE-VG and larger frames, the flanged crosshead designs allow easy vertical/horizontal adjustment of the piston rod (eliminates the need to re-shim the crosshead). Benefits include reduced maintenance costs and downtime.

    An inside look At our Process reciProcAting comPressors. dresser-rand

    offers a complete line of reciprocating compressors built to strict APi and iso standards

    for a variety of applications in refining, petrochemical, chemical, gas transmission and

    storage, enhanced oil recovery (eor), and heavy industry.

    Crosshead Extensions On BDC-12H and larger units, separate crosshead extensions simplify frame transportation and installation.

  • 5a customized solution for your process application.

    External Bolting External bolting maintenance accessibility allows for proper tensioning.

    Pistons and RodsAlloy steel piston rods with rolled threads provide reliability (proprietary TC3 optional*). All pistons have non-metallic trim materials for prolonged service life of the piston, rider and packing rings, which increases maintenance intervals.

    O-Ring Valve CoversOffer improved sealing over gasketed center bolt cover designs and are more easily maintained.

    CylindersA complete line of efficient, reliable and application-proven cylinders results in precise matching of components to meet each application. Available for lubricated and non-lubricated service.

    Capacity ControlFixed or variable systems are available. Our variable capacity control systems allow operators to match compressor capacity to demand, reducing operating costs.

    Distance PiecesSingle- or two-compartment distance pieces with large gas-tight access covers provide maintenance accessibility.

    Visit www.dresser-rand.com/products/recip/ for more information on our line of process reciprocating compressors.

    O-Ring Face SealsEliminate oil leakage and provide fugitive emissions control.

  • 6Unloader Rod

    Gland Sweeping Purge

    Gland

    O-Ring

    Cylinder Wall

    Valve Cage

    Operator

    Operator Return Spring

    Cover

    Gland Vent

    Sleeve-type Unloader Valve

    Unloader Guide

    Partial Compressor Valve

    CAPCON SUITE APPLICATION MAP

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    CAPCON SUITE APPLICATION MAP

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    DIsCRETE sTEp CApACITy CONTROL Unloaders are used to deactivate one or more cylinder ends for starting or for capacity control. This reduces the throughput and power consumed by that cylinder approximately 50 percent. By unloading both ends of a double-acting cylinder the capacity is reduced to zero for start-up.

    Port, Plug and Clearance Pocket UnloadersThese rugged devices require only a minimal force to close the unloader sleeve. The unloader piston rod is sealed and vented. The air housing is completely sealed against the process environment. An indicator rod shows the unloader load or unload position. Air-to-load (shown) and air-to-unload versions are available.

    VARIAbLE CApACITy CONTROLReduce Operating Costs with Variable Capacity ControlDemand for variable load control is growing because of the increase in driver sizes and the cost of power. Variable capacity control dates back to the 1950s, when Ingersoll Rand developed a pneumatic hydromechanical infinite step controller (ISC) that held the suction valve open and provided variable end unloading. The variable volume clearance pocket (VVCP) concept was also developed during this time.

    Variable End Unloading with ISC The ISC technology proved successful with integral gas engines through the 1970s, but wasnt actively pursued in the process market until more recently. In the late 1990s, Dresser-Rand began using electronic controls on gas engines and later adapted this technology for variable capacity control of reciprocating compressors for process applications and modernized the original ISC system.

    The Dresser-Rand ISC system allows compressor capacity to be varied between 30 and 100 percent of maximum capacity within a wide variety of operating conditions. The ISC control panel receives a capacity, torque or pressure set-point signal from a local controller or the clients plant control system. Using this input, the ISC generates an unloader timing signal that is distributed to the ISC unloaders, holding the suction valves open for a precise portion of the compression stroke. This process delays the beginning of compression in the cylinder, thereby reducing compressor capacity.

    Plug Unloader

    ISC curve

    compressor capacity controlUnloaders improve operating efficiency.

  • 7Upgrade to high-reliability, high-efficiency valves.

    Magnum ValvesValve performance and reliability are key to compressor performance. By paying careful attention to reliability in every aspect of the design, weve created a valve that can run more than 50% longer than other valves before needing service. We proved it in thousands of hours of tests, many at high speeds and high temperatures, with a wide range of gases. A high-strength thermoplastic, PolyEtherEtherKetone (PEEK), is used to produce low-mass sealing elements that withstand the high impact velocities that occur during operation. It also handles high temperatures, is compatible with most gas applications and resists dirt, corrosion and liquid swelling. The PEEK sealing element provides reliable performance in demanding conditions, while the streamlined flow path optimizes the effective flow area.

    CompressorValves

    Visit www.dresser-rand.com/products/recip/valves/magnum.php for additional information on Magnum valves.

    ISC Unloader

    Hydraulic variable volume clearance pocket

    Variable Volume Clearance with HVVCPIn addition to our standard fixed volume pockets, we offer the ability to control capacity with our hydraulic variable volume clearance pocket (HVVCP). The HVVCP clearance pocket can be applied to virtually any reciprocating gas compressor. Mounted in the outer head, it controls capacity of the head end of the cylinder by adjusting the clearance volume. The HVVCP system allows compressor capacity to be varied between 55 and 100 percent of maximum capacity within a wide variety of operating conditions. The HVVCP is an economical solution when the process operating range is not wide enough to require an ISCsystem.

  • 8preassembled for faster installation, to reduce installation and start-up times.

    Four-throw HHE-VL package loaded for shipment.

    Two-throw HHE-VL compressor packages loaded for shipment.

    Bringing energy and the environment into harmony.

    Preparation for shipment of compressor frame for block-mounted compressors greater than two throws.

    IMpROVED pERfORMANCE RIGhT OUT Of ThE bOX Your Dresser-Rand reciprocating compressor is fully engineered and preassembled to the extent possible prior to shipment to reduce construction and engineering costs.

    When size permits, we can ship an entire base platemounted package, with auxiliaries and piping in place, to ensure a simple and timely installation.

    If the unit size exceeds shipping limitations, after complete assembly and tests, we can ship large subassemblies. Special closures are provided for protection during shipment and easy on-site reassembly.

    Our complete packaging capabilities mean that field welding, cylinder alignment, and other costly field assembly times will be minimized. We evaluate the best delivery method to save you both time and money.

    With Dresser-Rand as your single-source supplier, you will derive the most in efficiency, convenience, reliability, and durability from your compression system.

  • 9Two-throw HHE-VB package.

  • 10

    Forged Steel Billet with Tail Rod

    processcylinders

    The industrys most

    comprehensive line of

    compressor cylinders.

    Each compressor service varies by capacity, pressure, temperature, and gas type. With decades of experience, we have developed the industrys broadest line of compressor cylinders.

    With such a wide selectionfor both lubricated, and when required, non-lubricated servicewe have the ability to offer the precise combination of components to best meet each clients operating conditions.

    Cylinder materials include cast iron, ductile iron, cast steel, and cast stainless steel.

    enhanced cold cylinder supportOur cylinders are supported from the foundationnot by piping. This allows for a solid, adjustable support arrangement.

    Dresser-rand Distance piecesWe offer distance pieces suitable for the applicationoil-lubricated cylinders, non-lubricated cylinders, corrosive gases, flammable or explosive gases, toxic gasesfor optimal protection and to prevent contamination of the process gas and/or the crankcase oil.

    Distance pieces are standard in all of our process compressors. The distance pieces are vented,

    or purged, as the application requires.

    Long, single-compartment, API type B distance pieces are provided as standard. When two-compartment distance pieces are required, API type C or D double-distance pieces are substituted.

    All distance pieces feature large openings for unequaled packing box access. For maximum strength under the cyclic loads, studs with rolled threads secure distance pieces to the frame and cylinders.

    Divided Forged Steel Billet Forged Steel Billet

    Forged steel cylinder with two-compartment distance pieces

    and frame extension for 3,000 psi refinery service.

    Cast cylinder with two-compartment distance pieces and frame extension

    for refinery service.

  • 11

    With the largest installed base of any original equipment manufacturer (OEM) in the industry, Dresser-Rand has the resources to deliver reliable compressor solutions anywhere in the worldquickly, efficiently and cost-effectively. Our services include:

    Local technical support by qualified engineers Revamping existing or out-of-service compressors (Dresser-Rand and

    other nameplates) Expert compressor and component repair by factory-trained

    technicians Replacement and upgraded compressor parts Around-the-clock field service Installation assistance to turnkey installation On-the-job training at your facility or ours

    sTRATEGICALLy LOCATED fOR sEAMLEss REspONsEDresser-Rand has employees around the globeeach with access to the experience and vision to create the best solution for your energy conversion needs. They also have access to engineering and manufacturing expertise to achieve those solutions on time and on budget. Currently, we have three major locations on three continents dedicated to reciprocating compressor manufacturing and service operations.

    tHe aMericas: painted post, nYCertified for ISO 9001:2008 and ISO 14001, this facility measures 650,000 ft2 active manufacturing space. We use more than 500 machine tools, including more than 70 computer numerically controlled (CNC) tools, to more accurately build our compressors to stringent specifications. The facility features: Teams dedicated to enhanced

    quality performance Dedicated high-efficiency

    cylinder machining center Comprehensive in-process

    inspection of all manufactured cylinders

    europe: peterborough, uKThis modern, multi-product facility is certified for ISO 9001 and 14001. The facility provides global project management and engineering for reciprocating process compressors.

    Peterborough also offers gas turbine repair, as well as maintenance and service agreements on CHP units, together with a wide range of aftermarket services for Dresser-Rand and other OEM equipment.

    asia: naroda, indiaCertified for ISO 9001:2008 and ISO 14001: 2004, this facility has supplied more than 3,000 reciprocating gas compressors for both local and global markets.

    Naroda specializes in packaged units, but in all respects, follows Dresser-Rands single global engineering standard for the product and its subsystems.

    services, operations and Maintenance

    Dresser-Rand reciprocating

    compressors: built right,

    backed right.

  • 12Bringing energy and the environment into harmony.

    For more than 50 years, Dresser-Rand has been designing and manufacturing reliable, state-of-the-art control systems for process reciprocating compressors. Our team continually strives to provide advanced control technologies that are reliable, intuitive and easy to operate. All phases of design, manufacturing, installation, training, and documentation are coordinated to ensure effective performance and dependability of these systems. We also provide upgrades and complete replacement of existing control systems.

    ENVIsION CONDITION MONITORING sOfTwAREWe are proud of our reputation for providing the most efficient and mechanically sound equipment for the oil, gas and petroleum industry. To ensure the highest level of safety and reliability, all of our units should be augmented

    with condition monitoring systems such as the Envision suite. This software enables operators to better assess the health of their equipment and schedule maintenance before failure occurs.

    The Envision suite provides a uniquely differentiated value proposition that allows process control and condition monitoring within a single computer platform. Unlike older systems that use separate control and monitoring tools, it delivers unprecedented insight into a units performance and mechanical health.

    pULsATION ANALysIsDresser-Rand was the first compressor manufacturer to provide clients with comprehensive pulsation analyses. We have more than 3,500 successful compressor installations of all sizes, and at pressures up to 60,000 psi.

    Our process consists of complete pulsation analysis of the compressor/dampener/piping system, including cylinder gas passages. When necessary, modifications are made to this system to avoid potential pulsation-related vibration, excessive power consumption or valve reliability problems.

    This is followed by a comprehensive review of the piping system and its supports to guard against mechanical resonance matching up with acoustic excitation. Digital pulsation analysis can be combined with valve dynamics and system mechanical analyses to predict the response of the entire compressor/piping system.

    pARTs AND sERVICE AROUND ThE CLOCk AND AROUND ThE wORLDOur commitment to quality does not end when we deliver your equipment. With more than 80 sales, service, manufacturing, and parts-stocking locations around the world, we are always in your neighborhood. It extends to providing you professional service and rapid delivery of our genuine spare parts.

    In the majority of cases, we ship spare parts within 24 hours. We can closely monitor your spare parts usage and create a customized stocking, service and maintenance program based on your needs.

    controls and condition Monitoring

    Ensure the health and

    performance of your

    compressors.

    Visit www.dresser-rand.com/products/controls/ for more information on our controls and condition monitoring systems.

  • 13

  • 1414Bringing energy and the environment into harmony.

    DREssER-RanD REcipRocaTing coMpREssoRs aRE aT woRk RighT now in ThEsE applicaTions:

    refiningHydrogen and hydrocarbon mixtures are compressed to produce clean gasoline, jet and diesel fuels, heating oils, lubricants, asphalt, and other related refinery products. in addition, dresser-rand compressors are used to help collect and separate toxic gases which otherwise may be harmful to our environment.

    PetrocHemicAlthousands of products, ranging from plastic to shampoo, are created by the compression of various gaseous mixtures in many different chemical processes.

    nAturAl gAs, H2, And co2 trAnsmission dresser-rand compressors provide an efficient means to compress gases of all types along pipeline networks.

    gAs inJectionour units compress carbon dioxide, hydrocarbon gas or acid gas to high pressures (sometimes > 15,000 psi/1,000 bar) for injection into oil wells to increase oil production or reduce environmental impact.

    BDC-18H3 Up to 16-inch stroke 2, 4, 6, 8, or 10 throws, up to 45,000 hp (33.6 MW)

    HHE-VL Up to 16-inch stroke 1 to 10 throws, up to 22,500 hp (16.8 MW)

    HHE-VG Up to 15-inch stroke 1 to 10 throws, up to 9,450 hp (7.0 MW)

    BDC-12H Up to 12-inch stroke 2, 4, or 6 throws, up to 8,225 hp (6.1 MW)

    HHE-VB Up to 12-inch stroke 1 to 6 throws, up to 5,000 hp (3.7 MW)

    HHE-FB Up to 12-inch stroke 2 or 4 throws, up to 2,250 hp (1.7 MW)

    HSE Up to 11-inch stroke 2 or 4 throws, up to 1,000 hp (750 kW)

    PHE 7-inch stroke 2-throw, up to 250 hp (200 kW)

    11-ESH/V 11-inch stroke single-throw, up to 250 hp (200 kW)

    5/7-ESH/V Up to 7-inch stroke single-throw, up to 75 hp (60 kW)

    a reciprocatingcompressorfor everyapplication.

    We custom engineer each unit by designing each cylinder and valve, and select other components to meet your specific operating requirement. Our factory experts check critical clearances and dimensions, and perform inspections and tests to facilitate installation. The result is a reciprocating compressor that meets and often exceeds client specifications, while delivering unmatched efficiency and reliability.

    NOMENCLATURE: ESVStraight Line Vertical ESHStraight Line Horizontal PHEPhillipsburg Horizontal Electric HSEHorizontal Straight Line Electric HHE-FHeavy Horizontal Electric (fixed crank) HHE-VHeavy Horizontal Electric (variable crank) BDCBalanced Direct Connected (fixed crank) S XHHE-VY-Z NL

    S: Stroke (inches or mm)

    X: Number of frame throws

    Y: Model number (for HHE compressor model)

    Z: Number of stages (multiple services separated by -)

    NL: designates non-lubricated cylinder construction (if applicable)

    Example: 15" 4hhE-Vl-3-1

    15", 4 throw, hhE-Vl frame, with 3

    stages (make-up) & 1 stage (recycle)

    coMpREssoR TypEs:

  • Model of a typical block-mounted compressor installation.

  • Bringing energy and the environment into harmony.

    2013 Dresser-Rand. All rights reserved. DRESSER-RAND is a registered trademark of Dresser-Rand Company. Printed in U.S.A.

    This brochure comprises a general overview of the Dresser-Rand products described herein. It is solely for informational purposes, does not represent a war-ranty or guarantee of the information contained herein, and is not to be construed as an offer to sell or solicitation to buy. Contact Dresser-Rand for detailed design and engineering information suitable to your specific applications. Dresser-Rand reserves the right to modify its products and related product information at any time without prior notice.

    For a complete list of products and services, visit www.dresser-rand.com or contact the following:

    Dresser-ranD corporate HeaDquarters Dresser-Rand West8 Tower, Suite 100010205 Westheimer RoadHouston, Texas 77042Tel: (Intl +1) 713-354-6100Fax: (Intl +1) 713-354-6110

    Dresser-Rand 112, Avenue KleberCedex 16Paris 75784 FranceTel: (Intl +33) 156 26 71 71Fax: (Intl +33) 156 26 71 72

    Email: [email protected]

    regional HeaDquarters The AmericasWest8 Tower, Suite 100010205 Westheimer RoadHouston, Texas 77042Tel: (Int'l +1) 713-354-6100Fax: (Int'l +1) 713-354-6110

    EMEA (Europe, Middle East, Africa)Dresser-Rand S.A.31 Boulevard Winston ChurchillCedex 7013Le Havre 76080, FranceTel: (Int'l +33) 2-35-25-5225Fax: (Int'l +33) 2-35-25-5366/5367

    Asia-PacificDresser-Rand Asia Pacific Sdn BhdUnit 9-4, 9th FloorBangunan Malaysian Re17 Lorong DungunDamansara Heights50490 Kuala Lumpur, MalaysiaTel: (Intl +60) 3-2093-6633Fax: (Intl +60) 3-2093-2622

    Manufacturing operations Dresser-Rand Painted Post, NY, USATel: (Intl +1) 607-937-2011Fax: (Intl +1) 607-937-2905

    Dresser-Rand Company Ltd.Peterborough, CambridgeshireUnited KingdomTel: (Intl +44) 1733 292200Fax: (Intl +44) 1733 292300

    Dresser-Rand India Pvt. Ltd.Naroda (Ahmedabad), IndiaTel: (Intl +91) 79 2280 0800Fax: (Intl +91) 79 2280 4555

    Form 85264

    Complete list of local offices and service centers can be found on our website at: www.dresser-rand.com/contactUs.php