Professional Documents
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Centrifugal Compressors
SRL
g
Contents
Centrifugal Compressors for 4
Air and Process Gas
Compressor Components 6
Auxiliaries 9
General 10
Global Services 12
Air/CO2 Compressors 13
Process Gas Compressors 14
(Single Stage - Directly Driven)
Process Gas Compressors 15
(Integrally Geared)
Steam Compressors 16
Installations 18
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SRL Centrifugal Compressors
for Air and Process Gas
GE Oil & Gas started production of overhung-impeller The custom-built compressors in this line are
centrifugal compressors (SRL) in 1966. The first unit individually engineered to meet each customer’s
with an integral gear was completed in 1979. specific needs using proven standardized
With their simple, compact structure and excellent components. SRL compressors combine the
reliability, SRL compressors are especially suited to advantages of custom-built machines (maximum
a wide range of heavy duty applications with air, efficiency, layout flexibility, materials selection etc.)
steam and other gases such as those employed in and standardization (proven, reliable components;
the Petrochemical Industry. availability of spare parts).
The high efficiency, reliability and operational flexibility The SRL compressor series comes in a range of sizes.
of the SRL line of compressors is the result of the For each size the baseplate, gearbox, stage volutes,
advanced centrifugal compressor design achieved cooler shells, oil and gas piping, and auxiliaries are
through: standardized.
• extensive experience with machines in service Machines can be produced to meet the individual
all over the world requirements of each application through the
• continuous improvement of the aerodynamic appropriate selection of key design factors including:
and mechanical design
• use of sophisticated computer design codes - Number of stages
• advanced manufacturing processes - Shaft rotational speed
• innovative R&D programs. - Diameter of impellers
Customers benefit from GE Oil & Gas’s advanced - Exchange surface of coolers
technology through improvement in plant
productivity.
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Advantages of SRL Compressors Package concept
Simplicity of Installation
• Unit prepackaged and tested at factory SRL compressors are usually mounted on a single
• No special foundations required base together with all auxiliaries such as oil pumps,
oil reservoir and control instruments, and are
Superior Operation delivered fully assembled and tested. Outstanding
• High efficiency and reliability reliability, ruggedness, low installation and
• High compression ratio operating cost, plus ease of maintenance are
• Wide range of flow rate the key features of these packages, which are
• Optimum rotor balance for low vibration especially designed for heavy-duty continuous
level service.
The packages are usually installed outdoors
Advanced seal system options available and can be fully automated for remote control.
• Absence of lube oil in process gas
Ease of Maintenance
• Designed for maintainability Compressor sizes
• Accessibility of components
Casing sizes and number of impellers are indicated
in the compressor designation by the digits
following the compressor model. For example,
SRL 808 is the designation for a eight stage
SRL design options compressor, size 800. The letter D before the
• Single or multi-shaft models compressor designation indicates a double flow
• Direct or gear (integral or separate) driven configuration (DSRL).
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SRL Compressor Components
Casings
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Inlet guide vanes
The Inlet Guide Vane (IGV) system allows wide
capacity control of the compressor with reduced
energy losses.
IGVs consist of a row of aerodynamically shaped
blades placed at the inlet of the stage.
The blades can rotate around their aerodynamic
center in order to give the suction flow a pre-swirl
that guarantees an optimum incidence angle with
the impeller’s leading edge even at reduced flows,
minimizing inlet losses. Support casing with shaft
Shafts
Unless the compressor is integrally geared, the shaft
is machined from a single forging of 40NiCrMo7
(AISI 4340). The impeller can be overhung mounted
at the end of the shaft by means of a frontal Hirth
coupling, by a flange (for high speed applications),
or hydraulically fitted with a tapered coupling.
Thrust collars can be either replaceable or
non-replaceable.
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Integral gearbox
The integral gearbox consists of a bull gear and Thrust bearings: The thrust bearings are designed
high speed pinions, with a single-helical gear mesh. for equal thrust capacity in both directions, and are
sized for continuous operation under all specified
Casing: The gearbox casing is horizontally split.
conditions including all external forces transmitted
The lower part is fixed to the baseplate and the
by the couplings or by the gear mesh. The thrust
compressor stages are fixed to it. The gearbox
bearings of high speed shafts can be the thrust
casings can be either cast or fabricated.
collar type (standard for multi-stage compressors)
Gear meshing: The gear unit can be rated in or the tilting pad type for single impeller shafts
accordance with AGMA or with API Codes. The with high axial thrust. Thrust bearings of low speed
toothed portion of pinions is integrally forged with shafts are generally the hydrodynamic tapered
the shaft. The bull gear is shrunk on the low speed land type (a tilting pad arrangement can be
shaft. supplied on request).
Shafts: The shafts are sized to transmit the gear
rated power within the stress limits of AGMA
Codes. They are made of one-piece, heat treated
forged or hot-rolled alloy steel, and the entire
Shaft arrangement
length of the shaft is machined. GE Oil & Gas will With Integrally Geared compressors, many shaft
take complete responsibility for the lateral and arrangements are possible in order to suit the required
torsional analysis of the entire train. duty. In particular, the bull-gear can be driven directly by
an electric motor (standard solution) or by a turbine (gas
Radial bearings: The radial bearings are of the
or steam); the number of pinions can vary (depending
hydrodynamic fluid film, tilting-pad type for the
on the size of the stage casings) from one to four.
high speed shaft and fixed profile type for the low
speed shaft.
The bearings are split for ease of assembly,
equipped with anti-rotation pins and are firmly
secured in the axial direction.
The bearing design suppresses hydrodynamic
instabilities and provides sufficient damping to limit
rotor vibrations while the compressor is operating,
loaded or unloaded at the specified operating
speed.
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Auxiliaries PDAH
PDISH
6 6
7
PCV
FG
TO
RESERVOIR
8
LSL
LG
PAL
LAL
PALL
5 5 TO
COMPRESSOR
4 4
PI PI
LAL
compressor operation.
It generally consists of:
FROM
TSHL COMPRESSOR
1
LG
• oil reservoir
TI
PI
5 5
Typical lube oil system
• twin oil filter allowing cartridges to be changed
diagram in accordance
during operation TI
PCV
4 4
PI
PI
G
SEAL GAS
FOR START UP
gas to the dry gas seals at the correct pressure. The FO PCV
L3
PDAH I
PDIT PDIT PDI
The Control Panel implements the compressor start/ • process data monitoring (pressure, temperature, level)
stop sequence logic, alarm annunciator sequence • alarm display
logic, capacity control logic etc. • shutdown display
The PLC is programmed prior to shipment and includes • surge controller monitoring
a serial communication interface RS422, with Modbus • hour meter
protocol, for connection to a supervision and control • event recorder.
system (ie, DCS, PC, telemaintenance etc.). If field instrumentation includes analogue signals from
The Control Panel front includes a video terminal pressure and temperature transmitters, the operator
connected to the PLC, which provides the following interface can perform additional functions:
functions, organized in pages: • operating parameter display
• top level diagram • PLC set point adjustment
• unit controls to start / stop and control the • trend recording of process data.
compressor, auxiliary motors and heaters (with The compressor vibration monitoring system is also
status display) located on the Control Panel.
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General
Operation control Dynamic simulation
The following methods are available to control flow Dynamic simulations ranging from a single loop
and suction or discharge pressures under varying to a more complete process configuration are
process conditions: possible to define anti-surge valves, hot by pass
compressor speed variation: this method is requirements, piping optimization for improved
utilized when a compressor is driven by a variable compressor protection and starting conditions
speed driver for electric motor drives.
discharge throttling: a valve is fitted in the discharge
piping so that pressure at the compressor outlet
nozzle may increase while maintaining the normal
Test facilities
value downstream of the valve
Centrifugal compressors are carefully tested throughout
suction throttling: a valve is fitted in the suction the manufacturing process in order to guarantee a
piping so that suction or discharge pressure can be perfect match to their design criteria and to assure
regulated according to the process requirements long lasting, continuous operation.
The following tests are typically carried out on
adjustable inlet guide vanes: these vanes alter
components and assembled machines:
the gas flow direction, as it enters the impeller,
- casing: hydraulic pressure test
thus varying the pressure ratio and flow of the
- impellers: ultrasonic and dye penetrant liquid tests;
compressor. These guide vanes can be placed
over speed testing
before each compression stage.
- impellers/rotors: over-speed testing
- mechanical run test
Optional tests may be performed based on the specific
Anti-surge protection and process job requirements. For example:
control - performance tests (with air or other gases in an
open or closed loop)
Anti-surge control algorithms implemented within
- full load - performance tests (including flammable
the integrated control system are based on the
gases) to check rotor stability and the performance
knowledge acquired through our expertise as a
of the machine
leading compressor manufacturer and experience on
- mechanical string test.
thousands of applications. Different control strategies
Numerous indoor and outdoor test beds together
are available to meet the needs of the application.
with a sophisticated system for data acquisition and
All provide both closed and open loop controls to better
processing of test results distinguish the Florence,
react to small and large process disturbances. Different
Massa and Le Creusot facilities.
process control and load bearing functions can be
We have the largest and most complete testing
provided.
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Air/CO2 Compressors
General Drivers
These compressors are used in air separation, Drivers for this type of compressor are generally
synthetic fiber and fertilizer plants as main process electric motors, but it is also possible to use steam
gas compressors and in all industrial plants as and gas turbines (either as a direct driver or
service air compressors, and for the compression of through an intermediate gearbox).
CO2 in CCS/EOR applications.
Package arrangement
Technical data
In multi-stage compressors, coolers are located
The inlet flow for such machines can vary from below the compressor in order to obtain a very
10,000 to 200,000 m3/h (6,000 to 120,000 cfm), with compact arrangement of the unit. The lube oil
a max. discharge pressure of up to 200 bar (2900 psi). system is supplied separately; the main lube oil
pump can be either shaft driven or electric motor
driven.
Main characteristics
These compressors are generally multi-shaft, Applicable codes and standards
integrally geared type, single or multi-stage (up
to 8 stages). Compressors are modularized in order Compressors may be designed either according
to meet varying customer needs. to API 617 or API 672, or customized to the
High compression efficiencies are achieved by using customer’s specific requirements.
3-D impellers especially designed for this service.
Inlet Guide Vanes are available for each compression
stage, permitting extremely large compressor turndown
with high efficiencies throughout the range. Seals
are generally labyrinth type (single, dry gas type for
last stages of high pressure applications). Multi-stage
compressors are equipped with inter-coolers with an
integral condensed water separator.
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Process Gas Compressors
(Single Stage - Directly Driven)
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Process Gas Compressors
(Integrally Geared)
Technical data
Package arrangement
Flows can vary from 500 to 50,000 m3/h (300 to
30,000 cfm), with discharge pressure up to 100 bar The baseplate generally accommodates both
(1,500 psi). the compressor and its driver. The lube oil system
can be either integrated with the main machine
baseplate or manufactured as a separate console.
Main characteristics
Several configurations are available to cover all Applicable codes and standards
applications for this type of machine.
Impellers are 3-D or 2-D, backswept semi-open or Generally designed according to API 617, or
closed type, overhung mounted on the shaft. The customized to Customer’s specific requirements.
SRL 253 dichloromethane compressor SRL 254 natural gas booster compressor
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Steam Compressors
General Drivers
Rising energy costs have led to a demand for high Drivers for this type of compressor can be either
efficiency machines for energy recovery. electric motors, or steam turbines (as a direct driver).
Steam compressors are employed in various sectors,
such as the agriculture-food Industry, chemical
industry, paper industry and desalination plants.
Another application of SRL compressors is in Package arrangement
geothermal power stations to extract non-condensable
gases from the steam turbine condensator. The baseplate generally accommodates both
the compressor and its driver. The lube oil system
can be either integrated with the main machine
baseplate or manufactured as a separate console.
Technical data
Flows can vary from 5,000 to 250,000 m3/h (3,000 to
150,000 cfm), with discharge pressure up to 10 bar
(150 psi).
Main characteristics
Steam compressors are of the integrally geared type,
single or multi-stage (up to 6 stages) machines.
The compressors are modularized, for flexibity in
meeting customer requirements.
High pressure ratios together with high compression
efficiencies are reached by using 3-D open impellers
specially designed for this service.
Inlet Guide Vanes are available for each compression
stage to provide a large turndown for the compressor
with high efficiencies throughtout the range.
Labyrinth type seals are always used.
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SRL 904 centrifugal compressor
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Installations
SRL 601 SRL 601
- PROJECT: EO/EG PLANT – - PROJECT: COPOLIMEROS
RECYCLE COMPRESSOR - CUSTOMER: REPSOL QUIMICA S.A.
- CUSTOMER: PRALCA - COUNTRY: SPAIN
- COUNTRY: VENEZUELA - SERVICE: POLYPROPYLENE PLANT RECYCLE
- SERVICE: RECYCLE FOR EO/EG PLANT
SRL 603
SRL 454 - PROJECT: GEEL NO.3 PTA
- PROJECT: H-OIL - CUSTOMER: AMOCO
- CUSTOMER: PEMEX - COUNTRY: BELGIUM
- COUNTRY: MEXICO - SERVICE: OFF-GAS COMPRESSOR
- SERVICE: PSA TAIL GAS
SRL 801
- PROJECT: ACIDE NITRIQUE
- CUSTOMER: ENG. D’AMBES
- COUNTRY: FRANCE
- SERVICE: NITRIC ACID PLANT
SRL 903
- PROJECT: MONTEVERDI 2
GEOTHERMAL POWER STATION
- CUSTOMER: ENEL
- COUNTRY: ITALY
- SERVICE: GEOTHERMAL POWER STATION
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SRL 454
- PROJECT: CAPROLACTAM
- CUSTOMER: SINOPEC
- COUNTRY: CHINA
- SERVICE: PROCESS AIR
2 SRL 801
- PROJECT: TIANJIN ETHYLENE
- CUSTOMER: SINOPEC TIANJIN
PETROCHEMICAL CORPORATION
- COUNTRY: CHINA
- SERVICE: RECYCLE - ETHYLENE OXIDE
6 SRL251
- PROJECT: JBEL ALI
- CUSTOMER: ENEL POWER FOR DUBAI
ELECTRICITY & WATER AUTHORITY
- COUNTRY: DUBAI
- SERVICE: FUEL GAS COMPRESSOR
SRL 806
- PROJECT: GT DEVELOPMENT LAB. AIR
- CUSTOMER: GENERAL ELECTRIC
- COUNTRY: CINCINNATI (OHIO)
- SERVICE: AIR
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GE Oil & Gas
Global Headquarters
Via Felice Matteucci, 2
50127 Florence, Italy
T +39 055 423 211
F +39 055 423 2800
E customer.service.center@ge.com
www.ge.com/oilandgas