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SC and TP Series: Process-engineered Centriugal Compressors

Atlas Copco Gas and Process



Publication Data

Gas and Process Division

Atlas Copco Energas GmbH

Am Ziegeloen 2

50999 Cologne

Germany

Phone: +49 (0) 2236 9650 – 0

Teleax: +49 (0) 2236 9650 – 899

[email protected]

www.atlascopco-gap.com

Editor-in-Chie: Petra Jacob

Phone: +49 (0) 2236 9650 –750

Published by Threeview GmbH or Atlas Copco Energas GmbH.

Additional photography credits: Hansi Herbig, Munich

Illustrations: Andrew Irving, Munich

Printed in Germany – 2008

© Atlas Copco Gas and Process Division.

All data are without warranty. No guarantee is given or the correctness o the inormation contained in this newsletter.

Articles may be reprinted ree o charge on condition that a copy o the publication is orwarded to and approved by the publisher

(Atlas Copco Energas GmbH). Reproduction o photographs only with written agreement o the communications agency/publisher.



Table o Contents

Overview

Advancing Compressor Technology 4

Your Application

Fuel Gas Boosting Applications 6

Oxygen Service Applications 8

Hydrocarbon Applications 9

Technical Features

Innovations For Your Superior Productivity 10

Seal System Options 14

Twin-pinion Gearbox Conguration 16

Three-pinion Gearbox Conguration 17

Operating Control System 28

Capacity Control Options 29

Quality Management

API Options 20

Quality Standards 21

Products and Applications at a Glance

SC/TP 22



4

Overview

With more than 125 years o interaction with customers

engaged in a broad range o processes, we’ve learned

the importance o meeting the unique requirements each

industry segment demands o our compressors and our

services. That’s why we build a close relationship with

each customer – to better understand their processes,

their turbomachinery applications and how we can bestserve their needs.

We know that process industries require machines to

API specications plus rigorous testing and documenta-

tion. Customized Atlas Copco process compressors are

uniquely capable o meeting all o your requirements,

including packaging with application-specic accessory

systems.

Advancing Compressor Technology



5

To ensure that each compressor is exactly right or the job,

we’ve assembled dedicated application/engineering

management teams with specialized experience in key

industries. For applications in the petrochemical, chemical,

and oil and gas industries, our API team will prepare

quotes and manage the project through assembly, test and

commissioning o your compressor to API standards.

In all types o process applications, Atlas Copco engineers

have clearly demonstrated that our integrally geared cen-

triugal compressors are very competitive in range and

perormance when we work closely with a customer on

the proper scope o supply and when the long-term

benets o high-quality equipment are considered.

At a Glance:

SC/TP-Series compressors are engineered or your

toughest process applications.

Here’s an overview o our SC/TP-Series

compressor technology:

With our technology, we serve the petrochemical,•

chemical, and oil and gas industries, among others

Oered in various congurations, meeting numerous•

and very specic needs

Developed and advanced by the world’s number-one•

company or integral-gear technology

Dedicated to boosting your productivity•

Thousands o reerences worldwide•

Process application

capabilities include:

Hydrocarbon processes•

Hydrogen compression•

Oil and gas processing•

Fuel gas boosting•

Pulp and paper manuacturing•

Desulphurization•

Oxygen production•

Air separation•

Petroleum rening•

Wastewater treatment•

Power generation•

Food processing•

Pharmaceutical manuacturing•



6

Your Application – Fuel Gas Boosting Applications

Centrifugal gas compressor for fuel gas boosting

“Complete on-skid packaging o uel gas

boosting compressors and ancillaryequipment reduces costs.”

When you speciy Atlas Copco integrally geared centriugal

compressors or uel gas boosting, you eliminate the

elaborate and costly system congurations and

oundations that are typically required by reci-

procating compressor systems. The compact

package includes the inlet gas separator, com-

pressor, drive motor, scrubber and PLC controls

installed and completely piped on a single

column-mounted or slab-mounted skid. There is no

pulsation, so maintenance is minimized.

Since they are inherently oil ree, integrally geared

centriugal compressors eliminate the risk o oilcontaminating the uel gas. There is no need or

downstream ltration as would be required by

lubricated compressors.

Dry-gas Sealing System

Atlas Copco dynamic dry-gas seals are especially well

suited to uel gas applications, since they minimize

leakage and ensure positive sealing at shut-down. They

utilize a ltered process gas buer support system. Seals

can be applied in single, double or tandem congurations.

Fuel Gas Boosting Applications



7



8

Your Application – Oxygen Service Applications

Oxygen Service Applications

Atlas Copco meets the specialized requirements o oxygen compression or both internal and external

processes. In either application, special seals, shrouds

and liner materials, as well as other materials, are used

to ensure sae operation. Optimum purity o the gas

stream is maintained because the integrally geared

centriugal compressors are inherently oil ree.

Availability o higher pressure and fow ranges and fow

ranges has made the SC/TP-Series popular or oxygen

applications in the chemical industry, reneries

and steel production. Lower initial purchase cost,

lower installation costs, smaller ootprint and

lower maintenance costs have made thesemachines the ideal choice or oxygen service.

Atlas Copco engineers have extensive experience

with high-pressure oxygen that requires maximum

cleanliness and saety.

“Atlas Copco leads the industry in experience

with centriugal compressor designsor oxygen service.”

6-port buffered labyrinth sea



9

Your Application – Hydrocarbon Applications

Hydrocarbon Applications

Compression o hydrocarbon gases has similar character-

istics as the oxygen service and requires the use o

buered labyrinth seals or dry-gas seals to ensure a sae,

oil-ree process operation.

Integrally geared centriugal compressors have demon-

strated signicantly lower initial capital cost or

hydrocarbon applications when compared to

single-shat compressors. Long-term operating

and maintenance costs are also signicantly lower.

Dry-gas Seal Support System

The compact, on-base dry-gas seal support system

is typically installed outboard o the compressor

base rame where it can be easily accessed or

maintenance.

“Our expertise with high pressure/hazardous

processes benefts your hydrocarbon applications.”

TP 6/6 two-stage compressor



10

Technical Features

Application-specifc compressor

case selections

Compressor casings oered include cast scroll, olded

volute and case or abricated plenum congurations.

The design o the inlet section o each casing makes it

easy and inexpensive to adjust working clearances or

reliable operation in severe-duty applications.

Compressor case materials are designed based on the gas

to be handled as well as the operating pressure. Casings

can be cast rom nodular iron, steel and stainless steel.

Fabricated casings can be supplied or lower operating

pressures. All casings are hydrostatic tested to 150% o

the maximum working pressure.

Innovations For Your Superior Productivity



11

90º

100

100

45º

70º

50º

% RELATIVE FLOW

% R

E L A T I V E H E A D

Confgurations accommodate

piping requirements

SC/TP-Series compressors are custom built or the

characteristics o your specic process by combining

eld-proven components. This ensures mechanical

integrity and permits more ecient packaging. The

compressor, driver, lubrication system, controls and

instrumentation are completely actory packaged on a

common base. Connection o utilities and system

piping is normally all that is required to complete

installation at your site.

Precision-balanced rotor assembly

or smooth operation

SC/TP-Series rotor assemblies combine precisely matched

and balanced pinion shat, high-speed gear and impeller.

Impellers are selected rom standard geometrically

similar impeller groups with unique fow coecients

to meet the dierent requirements o the compressor

fow range. Impeller geometries have been thoroughly

tested by Atlas Copco R&D and proven by practical

application experience.

The unique Atlas Copco impeller design combines good

turndown capability with high head and eciency. Eachimpeller will have a basic operating characteristic as

shown in the graph.

Each impeller is dynamically balanced and overspeed

tested beore assembly. Dynamic balance o the complete

rotor assembly is checked ater all components are

assembled to the shat.



12

Technical Features



13

Horizontally split gearbox acilitates inspection and maintenance

o gearing and horizontally split seals and bearings.

Optional adjustable inlet guide vanes

provide ecient control at a constant

speed over a broad capacity range.

High-perormance impellers conorm to

your fow and pressure requirements.

Open backward-leaning blade designs

provide maximum eciency.

Extensive shat seal selection enables the one best

solution or your specic process application.

Low-speed coupling. (High-speed coupling not required.)

Casing material appropriate or your process

gas requirements.



14

Technical Features

Labyrinth seals

Used when leakage o process gas

into the atmosphere can be tolerated.

The number o labyrinths used and

clearances are determined by the

application.

Labyrinths can be combined with

multiple chambers to allow injection

o a buer gas or more positive seal-

ing. The easily replaced labyrinths

are made o light metal, brass or

other corrosion-resistant material

and installed on the shat sleeve.

Dynamic dry-gas seals

Minimize leakage and ensure positive

sealing at shut-down. They eliminate

oil-lm seals and expensive seal

support systems. Seals can be

applied in single, double or tandem

congurations. They are recommened

when leakage can be hazardous and/or

costly, and when no buer gas sys-

tem is available.

Seal System Options

The right seals minimize leakage to your process.

Buer gas injection

Floating oil seal

Carbon ring

Seal cartridge

Vent, Flare, ect.

Bearing

Floating oil seal Oil drain

Oil drain

Vent to atmosphere

Bearing

Ventinlet, ect

Matingring



15

For oxygen service

Six-port buered labyrinth seals are

used. Monel shat sleeves and bronze-

coated silver mating ring are used

with a compatible buer gas.

During operation, pure oxygen is

vented to the compressor inlet rom

the rst chamber. Buer gas and a

small portion o oxygen are vented to

a sae area rom the second chamber.

Buer gas is introduced at the third

chamber, and the ourth chamber

vents the buer gas to atmosphere.

The last chamber is an atmospheric

opening only. Chambers one and our

are controlled by pressure dierential

transmitters to ensure proper direc-tional fow through the seal.

Floating carbon ring seals

Used or minimum leakage applica-

tions, they can be combined with two

or three chambers and can operate

dry or buered with gas.

Vent or buered port

Floating oil seal

Vent

VentRegulated buer gas

Atmosphericopening

Bearing

Vent to compressor inlet

Oil drain to reservoirOil seals

Vent, Flare, ect.

Bearing

Carbonring sealcartridge



16

Technical Features

Second stage

First stageFixed diusers

Single helical integral gearing counterbal-

ances aerodynamic thrust load. Gears are

designed by Atlas Copco and manuactured

to meet AGMA Q-13 (DIN 5/6) specications.

Groove cut into gearbox accommo-

dates O-ring to eliminate oil leaks.

Optional adjustable inlet

guide vanes.

Gear drives oil pump to

ensure ecient lubrication.

Twin-pinion Gearbox Confguration

This cross-section shows how easily the gearing, bearings and seals can be accessed when the top o

the split compressor gearbox is removed.



17

Second stage housing First stage housing

Third stage cross section

Removing the top hal o the horizon-

tally split gearbox at the second split

line provides access to the rst and

second compressor stages.

Horizontally split gearbox top enables

access to gearing, seals and bearings in

the third compressor stage without

removing the entire upper gear cap.

Three-pinion Gearbox Confguration

This cross-section shows how the gearbox is confgured to accommodate the third pinion, retaining the

compact compressor gearbox design and small ootprint.



18

Technical Features

Operating Control System

Commercially available PLCs are used to monitor and

control processor operation enabling you to obtain

hardware rom a local source. All system programming

is done by Atlas Copco engineers who have expertise in

both compressor and control sotware technology to

optimize perormance.

The customized control system continuously monitors

temperature, pressure and vibration data, and automati-

cally adjusts or controllability. All relevant settings can

be programmed to your requirements.

Surge anticipation system

An optional surge anticipation system is oered to

operate the compressor beyond the surge limit while

maintaining maximum possible turndown under

varying inlet conditions.

Remote compressor control and sequencing

SC/TP-Series compressor control systems can be linked toyour central control system via RS232C, RS485 or other net-

working systems or ecient remote monitoring and control.

USER PLANT

SYSTEM HEADER

CUSTOMERSPROCESSCONTROL

SEQUENCER

S Y S T E M 1

S Y S T E M 2

LCP = LOCAL CONTROL

= EL. SIGNAL

= DATA LINKAGE

Turbocompressor

CompressorControl

ProcessComputer

Driver

Relay

Service Terminal

Optional Terminal



19

0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4

1.4

1.2

1.0

0.8

0.6

0.4

0.2

-80.00 closed

α = Inlet guide vanes position

= 1.0

0.980.95

0.90

20.00 open

α = 0.00

η

ηA

RELATIVE VOLUME FLOWV

1

V1A

R E L A T I V E P R E S S U R E R A T I O

P P A

0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4

1.4

1.2

1.0

0.8

0.6

0.4

0.2

α = -20.00 closed

= 1.02

1.0151.0

0.95

0.90

α = 20.00 open

α = 0.00

η

ηA

RELATIVE VOLUME FLOWV

1

V1A

R E L A T I V E P R E S S U R E R A T I O

P P A

α = Inlet guide vanes/discharge guide vanes position

Perormance characteristic or adjustable diuser vanes.

Perormance characteristic or adjustable inlet guide vanes.

Capacity Control Options

Because the compressor is an integral part o a process,

SC/TP-Series compressors are oered with capacity con-

trol options that make it possible to adapt the compressor

to changing process conditions (e.g. discharge pressure

and volume) or maximum fexibility and eciency.

Adjustable inlet guide vanes combined with adjustable

diuser vanes are recommended or applications with

very high pressure ratios, steep pressure variations and

medium operation ranges – a good choice or o-design

perormance in a wide control range.

Simultaneous control o inlet guide vanes and diuser

vanes oers maximum capacity control with minimum

power consumption.

P R E S S U R E R A T I O

BROAD PERFORMANCE RANGE FOR EVERY APPLICATION

40:1

12:1

10:1

3.5:1

ACFMx1000 .3 .6 .9 3 6 10 30 60

m3/hx1000 .5 1 1.5 5 10 17 51 102

S C - 6

T P

- 1 4 / 1 0 / 6

T P

- 1 0 / 1 0 / 6

T P

- 1 0 / 6 / 6

T P - 6 / 6 / 6

T P

- 1 4 / 1 4

T P

- 1 4 / 1 0

T P

- 1 0 / 1 0

T P

- 1 0 / 5

T P

- 6 / 6

S C - 1 0

S C - 1 4

S C - 2 0

S C - 2 8

SC-32

SC-40

Standard SC-Series centriugal compressors handle fows rom 680 to

110,000 m3 /h (400 to 68,000 ACFM). Standard TP-Series models handle

fows rom 680 to 20,400 m3 /h (400 to 13,000 ACFM). For fows and pressures

greater than those shown here, consult our GT-Series brochure.



20

Quality Management

API Options

Atlas Copco has many years o experience supplying

integrally gearing centriugal compressors designed and

built with minimum deviation to API specications. This

includes API-672 and API-617 with oil systems to API-614.

When compared to traditional API-617 ‘’between bearings’’

compressors, the Atlas Copco integrally geared machine is

the reliable, maintenance-riendly and cost-eective option.

Material

In accordance to ASTM with equal or better characteristics

than specied. Threads, bolts, struts, pipes, fanges and

instruments in accordance to equivalent standards ISO,

DIN and CENELEC.

Lube Oil System

Integrated to the main equipment package. Lube oil supply

with mechanical drive, main oil pump and auxiliary

motor-driven pump. Option to API-614.

Gear

Integrated helical gear designed to AGMA Q-13 (DIN 5/6).

Option to API-613. Bearing housing is part o the

gearbox casing.

Rotor Dynamic

Options: Shop verication test with unbalance. Residual

unbalance check.

Bearings

Radial bearing tilting pad design. Thrust bearing tapered

land type. Tilting pad Kingsbury-type thrust bearings are

available as an option.

Vibration Limits

Per API-617 or API-672. Torsional analysis.

Coupling

Flexible multi-disc coupling. Option API-671

Casing

Plenum, scroll or older volute. 2DFE analysis.

“API capabilities includes applications in

chemical and gas process industries.”



21

Quality Standards

High quality standards, rom design through commis-

sioning, are undamental to every Atlas Copco project.

The eectiveness o our quality management protocols

is evidenced by our certication to ISO 9001 standards.

Dedicated quality assurance programs are enhanced by

detailed data and project management control, CAE/CAD

databases and application programs. Our adoption o the

metric SI-Systems helps ensure interchangeability o com-

ponents and local availability o more common parts – an

important consideration in an emergency situation.

Quality assurance includes complete acceptance testing at

operating pressures and speeds in compliance with ASME

PTC 10. All specied operating conditions are simulated

and perormance o all compressor components is mea-

sured and recorded prior to nal approval.

“We promise you a commitment to quality

products and prompt, responsive service.”

ISO 9001A consistent quality earned

us the industry’s leadership

and the customer’s trust.



22

Products and Applications at a Glance

SC-6 single-stage compressor

Used or hydrogen compression in

Thailand.

SC/TP-Series integrally-geared

centriugal compressors are oered

in single and multi-stage designs

(1-5 stages) to handle all gases at

fows rom 250 - 110,500 m³/h (150 to

65,000 cm) at a discharge pressure

up to 55 bar (a) / 800 psia.

TP6/6 two-stage compressor

Engineered or hydrocarbon services.

Standard TP-Series models handle

fows rom 680 to 20,400 m³/h (400 to

13,000 ACFM) and eature completely

assembled process gas piping andon-base PLC control system in NEMA

4 enclosure to meet Class 1, Group C

& D, and Division II area classication.



23


Is integral to the desulphurization

process or a diesel uel producer.

SC/TP-Series integrally-geared

centriugal compressors are oered

in single and multi-stage designs

(1-5 stages) to handle all gases at

fows rom 250 - 110,500 m³/h (150 to

65,000 cm) at a discharge pressure

up to 55 bar (a) / 800 psia.


Installed on skids with auxiliary

equipment or uel gas boosting.

Flow rates are 90.000 Nm3 /h (56,000

scm) at an inlet pressure o 24 bar

(350 psi), and a discharge pressureo 40 bar (580 psi).



ItalyGianranco Marinelli

Phone: +39 02 61 79 94 50

Fax: +39 02 66 01 18 90

[email protected]

JapanMichael Shaer

Phone: +81 3 57 65 78 24

Fax: +81 3 57 65 31 97

[email protected]

NordicHeikki Alanko

Phone: +358 8 51 67 64

Fax: +358 8 51 68 24

[email protected]

RussiaDaniil Korobko

Phone: +7 495 933 55 50

Fax: +7 495 933 55 60

[email protected]

South AfricaWayne Jacobs

Phone: +27 11 821 91 24

Fax: +27 11 821 91 06/7

[email protected]

SpainRaael Cañete

Phone: +34 91 276 91 54

Fax: +34 91 671 31 16

[email protected]

South KoreaSeungHoon Yang

Phone: +82 2 21 89 40 80

Fax: +82 2 522 19 79

[email protected]

Our Points o Contact Worldwide

Headquarters


Am Ziegeloen 250999 Cologne, Germany

Phone: +49 2236 96 50 0

Fax: +49 2236 96 50 899

[email protected]

www.atlascopco-gap.com

Application Centers

Europe, Middle East and AfricaAxel Teschner

Phone: +49 2236 96 50 618

Fax: +49 2236 96 50 899

[email protected]

North and South AmericaNasser Sadeghzadeh (Comptec)

Phone: +1 518 765 58 38

Fax: +1 518 765 33 57

[email protected]

Randy Dirlam (Maf-Trench Company)

Phone: +1 805 928 57 57 275

Fax: +1 805 925 38 61

[email protected]

Far East

Sander van SpijkPhone: +86 21 62 55 13 31

Fax: +86 21 62 55 19 63

[email protected]

IndiaS.S. Vasan

Phone: +91 20 39 85 23 09

Fax: +91 20 27 14 59 48

[email protected]

Customer Centers

Alpine/Balkan StatesPeter von Graenried

Phone: +41 61 731 37 00

Fax: +41 61 733 94 40

[email protected]

BahrainEmile Bado

Phone: +973 17 22 15 33

Fax: +973 17 22 95 11

[email protected]

BeneluxJan Hop

Phone: +31 64 620 37 30

Fax: +31 33 299 95 06

[email protected]

BrazilRoberto G. Becker

Phone: +55 11 34 78 87 11

Fax: +55 11 41 95 70 90

[email protected]

FrancePatrick Coupel

Phone: +33 1 39 09 31 60

Fax: +33 1 39 09 30 51

[email protected]

Germany

Axel Teschner

Phone: +49 2236 96 50 618

Fax: +49 2236 96 50 899

[email protected]

Great BritainIan Mather

Phone: +44 1442 22 23 35

Fax: +44 1442 84 05 06

[email protected]

IranAli Rakhshani Moghaddam

Phone: +98 21 66 93 77 11 322

Fax: +98 21 66 92 73 14

[email protected]

©

A t l a s C o p c o 0 7 / 2 0 0 8 P r i n t e d i n G e r m a n y .

B 0 5 / 0 0 4 / 2 4 / 0 8 0 8


Gas and Process DivisionAm Ziegeloen 2 . 50999 Cologne, Germany

Phone: + 49 2236 96 50 0 . Fax: + 49 2236 96 50 899E-Mail: [email protected]

www atlascopco-gap com

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