GE Oil & Gas

Positive Displacement Compressors

Oil-free rotary screw

Oil-free rotary screw

For applications where process gas conditions and gas composition may vary, oil-free rotary screw compressors offer the best of both worlds the reliability and rotary motion of centrifugal compressors plus the surge-free performance of positive displacement (reciprocating) compressors. Screw compressors are also the best choice for applications in which no other compressor can operate economically. They can easily handle dirty, polymerforming process gases and process gases with entrained liquids.

Single-source solutions
GE integrates its extensive line of oil and gas products and services to provide customers with single-source access to a full array of comprehensive solutions: Upstream wellhead & production Midstream transportation & storage Downstream refineries & petrochemicals Industrial Plants turnkey design of integrated industrial applications Global Services installation, startup and aftermarket services including: Conversions, Modifications & Uprates (CM&Us); Contractual Service Agreements (CSAs); Multivendor Solutions; Reliability, Availability, Maintainability (RAM) Engineering and e-Services Advanced engineering We provide top-quality engineering talent, resources and advice from project start to finish. Our engineering teams work to meet your needs with cost-effective, creative expertise. Every one of our compressors is carefully designed to ensure its suitability for your specific application and operating conditions. Our experienced engineering staff carefully review every specification. World-class production cycle time We provide personal service that concentrates on your needs and deadlines. Fast-track projects are not a problem. Single-source responsibility A single project manager is responsible for your entire project, minimizing the demands on your time and resources. This individual coordinates all of the design/build work and helps you put the system into operation. Complete testing and review From our computer-based project management system to our aggressive component testing program, quality is our priority. Help you can rely on Experienced field service technicians are available to supervise the installation and start-up of your unit, and to provide maintenance instruction and training. We can also support your operation with the highest quality replacement parts and repairs.

Designed for long-term durability and dependability

For more than 40 years, GE engineers have worked closely with customers to build cost-effective, high quality equipment. Many companies in the petrochemical, refining and natural gas industries rely on our compressors and compressor systems to provide strong, dependable performance in a variety of demanding long-term applications. Our systems are designed and manufactured in-house using the most advanced computerized design tools, drafting systems and numerically controlled machine tools. Our people are specialists in the systems and equipment we build, and our customers have come to depend on our knowledge and professional support.

How it works
Compression is achieved by the intermeshing of a male and a female rotor. As the rotors turn, the location of the intermeshing of the rotor lobes moves from the suction port to the discharge port; correspondingly, the gas in the rotor pockets - contained by the intermeshing - is compressed and expelled. Oil-free rotary screw compressors rely on tightly controlled rotor-to-rotor and rotor-to-casing clearances to prevent internal recirculation of the compressed gas from discharge to suction. Timing gears synchronize rotation of the male and female rotors preventing metal-tometal contact and eliminating the need for oil injection.

1 Precise rotors and shafts Machined from carbon steel forgings or special-use rotor materials Optimized rotor profile Critical internal clearances maintained by seal strips machined on each rotor lobe tip Dynamically balanced rotors 2 Shaft seals that isolate and protect Each of four journal bearings is isolated from the compression chamber Seals prevent outward leakage of process gas and inward leakage of lubricant Space for floating carbon ring, labyrinth, dry gas or mechanical contact seals (with or without buffer) Seals are carefully selected to properly handle the type/quality of gas to be compressed at the process operating pressures 3 Dependable thrust bearings Positive axial rotor position ensured Thrust loads transmitted to tilting-pad thrust bearings via hardened steel, removable thrust collars Tapered-land bearing faces on the inactive side 4 Timing gears designed for consistent clearances Synchronized rotation of rotors Proper rotor-to-rotor clearances maintained Single helical gears, precision ground, AGMA Class 12 quality Separate female rotor gear and hub controls pitch line run-out and timing clearance in the assembly

5 Choice of flange locations Top inlet with top discharge for installation on grade Top inlet with bottom discharge to maximize casing drainage 6 Zero leakage drive shaft seal Labyrinth design prevents bearing housing oil leaks Air buffering capabilities 7 Heavy-wall radial bearings for extra support Pressure lubricated, sleeve bearings support radial loads on rotors 360 type with heavy-wall construction, steel backing and babbitted rubbing surface Computer analysis dictates bearing design (oil film thickness and operating temperature are evaluated when selecting proper lateral and torsional rotor stiffness) Pivoted-shoe radial bearings are available for maximum rotor stability in applications with relatively low radial loads 8 Strong, stable compressor frame Vertically split, two-piece cast construction for dimensional stability Water-jacketed housing castings for high temperature operation For erosive or corrosive gases cast stainless steel is standard Special application materials available

5 Detail view of shaft seals which isolate and protect bearings and prevent leakage of process gas.

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Engineered for top performance and low maintenance

Oil-free rotary screw compressor features

Standard Design Parameters Multiple internal volume ratios: 1.34, 1.64, 2.19, 2.69, 3.16 Pressure differential: L models, 10 to 150 psi; 0.7 to 10.3 bar S models, 10 to 250 psi; 0.7 to 17.2 bar Casing design pressure: Cast steel, 225 to 300 psig; 15.5 to 20.7 barg Molecular weights: 2 to 140 Inlet temperature: -50 to 250F; -45.5 to 121C Maximum temperature: 550F; 288C Rotor tip speed: 150 to 550 ft/s; 45 to 168 m/s Optional design parameters Multi-staging compressor frames can increase overall pressure ratios to more than 25:1 Parallel operation of compressor frames offers multiple capacity increases without sacrificing plant performance Liquid injection can flush gas streams contaminated with polymers, or cool gases where discharge gas temperature is critical Alternate materials of construction ensure long life in erosive or corrosive gas applications

Custom designed. Precision built.

GEs products are built to meet each users unique system and specification requirements. Compressor packages Oil-free screw compressor packages include a steel baseplate with machined mounting pads to precisely align all rotating components. Baseplate options include continuous nonskid decking and a perimeter drip-rim with low point drain Driver is typically an electric motor or steam turbine, with or without speed changing gear. Gas turbines, gas expanders or reciprocating engines are available for special applications Non-lubricated guarded couplings connect the compressor and driver Local or gauge-board mounted instrumentation, with tubing and electrical wiring between the instruments and on-skid sensing points, ensures reliable performance Header piping for lubrication oil, seal oil, buffering gas, cooling water and liquid injection is connected to convenient interface connection points at the edge of the baseplate Oil systems Designed to exacting standards as an integral part of each compressor package, the oil system provides clean, cool, pressurized lubricant to the compressor and drive bearings. The same system can also provide oil to the seals. Pulsation dampeners Multi-chamber silencers meet API-619 specifications, as dictated by process conditions. The lagging material is mounted externally, away from the process gas stream, and is covered with a metallic jacket. Control panels Panel enclosures typically include instrumentation designed to integrate the compressor into the specific installations operating process. Monitoring equipment measures shaft vibration and bearing temperature to provide continuous protection. Push-button controls govern local start and emergency stop. Real-time condition monitoring equipment Vibration and Axial Position Detectors monitor radial vibration and the axial position of the rotors. All probes are noncontacting and may be adjusted externally. Bearing Temperature Detectors are embedded below the surface of the radial and thrust bearings to sense bearing metal temperature. A variety of thermocouples or RTDs are available.

Equipment designed for the demands of your industry

Successful in the most demanding applications

With 12 basic models and a range of flow and pressure configurations, GEs oil-free screw compressors are the top choice for hundreds of the most demanding compression applications. The screw compressor combines the advantages of positive displacement (like a reciprocating compressor) with the rotary motion of a centrifugal compressor to provide a wide range of operating capabilities. Oil-free rotary screw compressors are designed for maximum reliability and efficiency in challenging operating conditions. Their rugged design allows them to operate reliably in harsher conditions than other compressor types. The following guide identifies applications for which screw compressors are ideally suited.

Typical applications
Chemical, petrochemical and refining industries: Pollution control and energy industries:
Flare gas recovery Fuel gas boosting Natural gas boosting Coal gasification Flue gas recovery Steam recompression Tank farm vapor Geothermal energy recovery Styrene Butadiene Acetylene Isoprene ethylene Propylene Polypropylene Synthetic gas Urea Soda ash Alkylation Hydrogen recycling Ammonia Nitric acid Maleic anhydride Phthalic anhydride Vinyl acetate Vinyl chloride Phosgene (TDI) Acrylonitrile Normal paraffins Phenol Delayed coker

Application guide
When variations exist in the process gas or operating conditions Without the surge limit typical of centrifugal compressors, the oil-free rotary screw easily provides the desired process flow at the required discharge pressure. When the process gas is polymer or tar forming No risk of imbalance with high speed impellers or fouling of diffusers or scrolls No fouling of piston rings or valves Polymer or tar buildup reduces internal clearances and actually increases compressor efficiency Rotors are less sensitive to imbalance because of their high weight-to-speed ratio Liquid solvent may be injected during operation to remove excessive polymer buildup When the process gas is beyond saturation (free liquid) or includes particulate matter Many process screw compressors are liquid-injected to control discharge temperature and to prevent polymer and tar formation at elevated temperatures. When the process gas must be 100% oil-free The compression chamber is completely oil-free, eliminating the possibility of recirculation of contaminated or corrosive oil. Environmental issues associated with the disposal of contaminated oil are also eliminated with oil-free rotary screw compressors.

Steel industry:
Coke oven injection Recycle gas Process gas Process air

Clean gas applications:

Hydrogen peroxide Cryogenic processes Oxidation Fermentation Helium Enzyme production Food and drug Argon processing

High reliability in applications where other compressors fail

Unique characteristics of oil-free screw compressors

Process control The design of the screw compressor can accommodate for run-in on air or nitrogen. For practical purposes, aside from small changes in volumetric and adiabatic efficiencies, the flow of an oil-free screw compressor is proportional to speed. Installation flexibility Discharge connections are located vertically on the casing and may be arranged in an up or down position. When both connections are in a vertically up position, the compressor/driver may be located on grade, reducing foundation costs and facilitating service access. In the vertically down position, casing drainage is maximized. With its rotary motion, the screw compressor does not exhibit the shaking forces of the reciprocating compressor, making foundation requirements less rigorous. Meets the most demanding standards To give you the quality and reliability you need, our oil-free screw compressors meet the requirements of API Standard 619, Rotary-Type Positive Displacement Compressors for Petroleum, Petrochemical and Natural Gas Industries. In fact, we not only comply with API, we helped develop the specification. Designed for easy maintenance and servicing Despite being used in the most severe applications, the oil-free screw compressor has a history of high availability and low maintenance costs similar to centrifugal compressors. All major wearing parts may be inspected without disturbing the main compressor casing joint. These include radial bearings, thrust bearings, shaft seals and timing gears. Complete access to the rotors and inner casing is possible through a single vertical casing joint. Proven experience, proven applications GE products are hard at work around the world. Industry leaders depend on the cost-effective quality of our equipment. For more than 40 years, our oil-free screw compressors have met the toughest demands of a wide variety of industries.

Typical installations

Aniline reactor recycling in petrochemical plant Model: 105L Volume: 2,136 ACFM/3,629 m3/h Speed: 6,720 rpm Inlet: 72.5 psia/5.0 bar a Discharge: 140.7 psia/9.7 bar a Driver: 1,250 hp/932 kW

Butadiene recycling Model: 200L Volume: 7,822 ACFM/13,290 m3/h Speed: 2,832 rpm Inlet: 19.5 psia/1.34 bar a Discharge: 86.4 psia/5.96 bar a Driver: 1,555 hp/1,160 kW

Styrene off gas Model: 250L Volume: 18,228 ACFM/30,971 m3/h Speed: 3,518 rpm Inlet: 4.0 psia/0.276 bar a Discharge: 27.0 psia/1.86 bar a Driver: 1,525 hp/1,138 kW

Petrochemical plant Model: 200L Volume: 7,439 ACFM/12,640 m3/h Speed: 3,596 rpm Inlet: 4.0 psia/0.276 bar a Discharge: 28.5 psia/1.97 bar a Driver: 631 hp/471 kW
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Comprehensive pre-installation testing ensures peak performance in the field

Rigorous testing to ensure field performance

Every oil-free screw compressor we manufacture must pass stringent testing and inspection procedures. Every component is thoroughly tested before assembly, then the entire assembled compressor goes through a comprehensive testing and inspection process. Rotating elements Each rotor is assembled with the timing gear and thrust collar subassemblies, then dynamically balanced to ensure top performance upon installation. Rotors Physical and chemical properties are verified prior to start of manufacture Full material traceability and unique identification for rotors Latest generation high efficiency rotor profile is available All rotor tooling is verified against design values on in-house coordinate measuring equipment Optimized rotor-to-rotor clearances are verified on precision rotor checking fixtures after machining Dye-penetrant or MPI check of all finish machined rotors Mechanical and electrical run-out is verified for each rotor Mechanical integrity ensured via API-619 mechanical run test

Casings Two-piece rugged cast construction provides dimensional stability, with water-jacketed housing castings for high temperature operation. ASTM A216 WCB cast steel is standard, with other materials available, including cast stainless steels for erosive or corrosive gas applications. In every case, our engineers carefully review the composition of the process gas to select materials which optimize initial cost versus service life. Testing Every compressor is fully assembled and mechanically tested Full string or complete unit testing is available Compressor performance testing is available per PTC-9 and ISO 1217 All operational data is recorded and provided to the purchaser for future reference

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Oil & Gas Global Services

Our Global Services teams provide a complete spectrum of services for the oil and gas industry from installation to maintenance, refurbishment and uprates. We support the entire product value chain from large gas and steam turbines to pumps and valves for both our own and multivendor equipment. We offer an extensive portfolio of proactive and interactive service products such as Conversions, Modifications & Uprates, Condition-based Maintenance and Contractual Service Agreements. These complement our traditional service product offerings of OEM-quality spare parts, repairs and field services. Our unique position gives us access to the world-class GE engineering organization and the advanced technology, design experience and manufacturing capabilities that ensure our customers the highest quality engineering know-how, spare parts, repair and field service, plus state-of-the-art product uprates. This same expertise is also applied for the repair, refurbishment and upgrading of third-party equipment. To protect our customers investment in equipment, we have developed the following set of Reliability, Availability and Maintainability (RAM) solutions that play an important role in optimizing plant operations and maintenance: Remote Monitoring & Diagnostics for proactive maintenance planning PILOT, a system for tracking availability and outage documentation Reliability Engineering, a process using field experience for continuous product improvement Finally, to simplify and streamline doing business together, we have implemented a Customer Service Center and a series of e-Service solutions.

Adaptability and diversity

Industries We offer a broad range of experience earned through meeting the varied needs of diverse industries such as: Chemical and petrochemical Oil and gas production Refining Distributed power Coal bed methane Power plants/utilities Waste water treatment Solid waste facilities Offshore oil and gas production Industrial refrigeration Applications We have a proven record of performance in applications as tough as: Hydrocarbon gas Vapor recovery Wet sour gas (up to 90% H2S) Acid gas Wellhead casing pressure Refrigeration Condenser vacuum reduction Synthetic fuels production Coal bed methane Landfill gas Digester gas Polymerizing gas Microturbine fuel gas Natural gas Cogeneration

Environmental GE takes great pride in helping meet environmental challenges through processes such as: Water purification Sewage treatment Recompression evaporation Solvent recovery Flare gas recovery

Quality and service for industries around the world

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Nuovo Pignone S.p.A. Via Felice Matteucci, 2 50127 Florence, Italy T +39 055 423 211 F +39 055 423 2800 GE Oil & Gas 1333 West Loop South, Suite 800 Houston, Texas 77027-9116 USA T +1 713 803 0900 F +1 713 803 0499 GE Oil & Gas Operations, LLC 3300 Medalist Drive Oshkosh, Wisconsin 54902 USA T +1 920 237 6000 F +1 920 237 6195

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Customer support 1 800 577 5155 24-hour emergency service 1 920 237 2200 The information contained herein is general in nature and is not intended for specific construction, installation or application purposes. GE reserves the right to make changes in specifications or add improvements at any time without notice or obligation. 2008 General Electric Company All Rights Reserved

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