Driving Centrifugal Compressor Technology Atlas Copco Gas and Process Solutions HANDLE THE PRESSURE Driving Centrifugal Compressor Technology 1 HANDLE THE PRESSURE We know you’re no stranger to pressure. Budget pressure. Time pressure. Performance pressure. Pressure challenges us, but it also pushes us to be better. At Atlas Copco Gas and Process, the pressures you face are what drive us to develop turbomachinery that assures reliability, improves efficiency and reduces cost. To us, pressure is innovation in progress. CONTENTS Turbocompressor overview 04 Markets served 06 Inside integral-gear technology 08 Inside multi-stage single-shaft technology 10 Inside single-stage single-shaft technology 12 Gears 14 Impellers 16 IGVs 18 vDGVs 20 Seals 22 Bearings 24 Compander 26 Standardized compressors 27 Product matrix 28 Engineering expertise 30 Production cycle 31 Frequently asked questions 32 2 Driving Centrifugal Compressor Technology 3 TURBOCOMPRESSOR OVERVIEW ADVANCED COMPRESSOR SOLUTIONS FOR YOUR CRITICAL DEMANDS Over the past few decades, Atlas Copco Gas and Process has built close relationships with customers around the globe. In doing so, we have pursued one goal: providing our customers with sustainable productivity — regardless of process, application or market. ATLAS COPCO GAS AND PROCESS Supporting you every step of the way Reliability & availability There’s no time for downtime. That’s why critical applications in more than 180 countries rely on Atlas Copco Gas and Process’ industry-leading turbomachinery technology to keep them up and running around the clock. Our broad range of centrifugal compressors, including both integrally geared and non-geared designs, provides innovative ways to handle the pressures you face 8 000 + MACHINES every day. running in process gas applications worldwide. With 99.8% reliability and Get the flexibility you need for all your processes with our fully customizable compressor solutions and standardized designs for 99.7% availability, our centrifugal low-CAPEX, fastturnaround projects. Our standardized compressors include customizable aerodynamics to optimize performance compressors are the industry’s and provide maximum efficiency. From project concept through commissioning — and beyond — Atlas Copco Gas and Process is most trusted. here to support you every step of the way. Our compressor range 650 000 Flexibility & efficiency (382 000) Non-geared for air (RT) 45 000 480 000 kW max. power 10–15% (283 000) 7bar(a) max. (60 000 hp) efficiency increase, thanks to pressure (102 psia) Gas: Air / N 2 exceptional design and state-of-the-art 400 000 process cooling capability, as well (235 000) as process flexibility shown in our (cfm) Compander combined service and /h 3 multi-section compressors. 80 000 Non-geared (47 000) for polyolens (T) Integrally geared kW8 max.000 power for process gas (GT) 43bar(a) max. (10 700 hp) pressure 37 000 (630 psia) Gas: all kW max. power 205bar(a) max. (50 000 hp) Custom aero, 10 000 pressure standard package (5 800) (3 000 psia) Gas: all 250 (150) 0 CAPEX & OPEX 1 2 3 4 5 6 7 8 0 STAGE STAGES STAGES STAGES STAGES STAGES STAGES STAGES savings with our standardized solutions that offer optimized aerodynamics and pre-engineered package components. 4 Driving Centrifugal Compressor Technology 5 MARKETS SERVED ATLAS COPCO GAS AND PROCESS CENTRIFUGAL COMPRESSORS, THE PERFECT FIT Our integrally- geared GT-series compressors and radial single-shaft T- and This product showcase is only a portion of our total compressor RT-series compressors cover a wide range of applications, across many product line and just a few of the numerous applications it covers. FOR YOUR PROCESS important markets. From gas processing and LNG to petrochemicals, supercritical power cycles and beyond, our compressors provide the most efficient, space-saving and reliable solutions. Hydrocarbon Processing Hydrocarbon Processing Power Generation Industrial Gases Gas Processing LNG Olefins / Polyolefins Syngas / Methanol Refineries Fertilizer Refrigeration gas – GT-series Boil off gas / Large scale and Cycle / Recirculation gas – Refrigeration gas – GT-series Refrigeration gas – GT-series CO – GT-series Fuel gas boosting – Main air – GT-series, AeroBlockTM TM 2 CLNG – GT-series PolyBlock GT-series, TurboBlockTM Residue gas – GT-series Reliquefaction – Compander Recycle gas – GT-series Syngas - GT-series PSA tailgas – GT-series Nitric acid – Compander Supercritical CO2 power cycle – Main air – RT-series GT-series Regeneration gas – GT-series Mixed refrigerant / SSLNG – Propylene oxide production Regeneration gas – GT-series Flue gas desulphurization – Carbon monoxide / GT-series (HPPO) – Compander GT-series HyCO plants See what we can do for your process. Contact an Atlas Copco Gas and Process product specialist at: www.atlascopco-gap.com/contacts See how our centrifugal compressors can bring more efficiency, reliability and performance to your compression processes. 6 Driving Centrifugal Compressor Technology 7 GIVE YOUR PROCESS A CLEAR INTEGRALLY - GEARED COMPRESSORS – GT-SERIES ADVANTAGE Integrally- geared compressor features WITH INTEGRAL • Higher efficiency versus other rotating compression technologies • Compact design saves space and simplifies transport and setup As the industry’s most efficient and compact compressor design, GEARING integral gear technology is the go-to solution for numerous applications. • Multi-speed capability for optimal performance at each stage Through its optimized aerodynamics, superb process control and • Optional interstage cooling for boosting isothermal efficiency interstage cooling capabilities, integral gearing provides the efficiency, reliability and performance that are vital to your process. • Improved process flexibility handling different process gases via combined service and multi-section • Easy access for inspection and maintenance Integral gearing basics 8 1) As the name suggests, in integrally geared 1 Variable inlet and diffuser 5 4 compressors (IGCs) multiple compressor stages are guide vanes (IGVs/vDGVs) mounted onto one gearbox. Variable IGVs guide and control flow sent to the impellers, 2) A driver, such as a motor, is coupled to a bull providing accurate process gear that drives several pinions. Integrally geared control and efficient operation. compressors deliver multiple-speed capability by They are standard on all Atlas Copco Gas and Process placing impellers on separate pinions ( , ). centrifugal compressors. Variable DGVs are used for larger 3) Each compression stage runs at the optimum 1 2 turndown and varying mole speed for high efficiency. weight applications, providing wider control range and 8 flexibility in operation. 4) The optimal aerodynamic performance that IGCs can obtain at each stage translates into higher 3 7 per-stage pressure ratios. The result is that fewer 7 2 Bull Gear compression stages are necessary to reach a target 8 Necessary compression power is supplied by the outlet pressure. 5 4 driver and transmitted to 6 impellers via a gear set – a bull gear and pinions. The bull gear rotates at the driver speed and drives the 3 rotating pinions by helical Optional interstage cooling gears with a high gear ratio. Gas temperature rises during the compression process. To improve compression efficiency, interstage cooling 3 Impellers can be easily accommodated between any (compressor wheels) of the compressor stages. Impellers impart kinetic energy to the gas, which is turned into pressure To control gas temperatures, we can supply in the diffuser and then coolers and aftercoolers. Water-cooled or the volute. Well-designed air-cooled interstage impellers play a major role in overall compressor efficiency. 8 Bearings 7 Seals 6 Rotors 5 Shafts 4 Pinions / pinion gears A combination of axial Our compressors are available Each rotor has one or two Robust shafts, high-speed gears A helical gear mesh (tapered land / tilting with several shaft seal options: impellers (stages), a seal for each and thrust bearings/collars guarantees smooth power pad) bearings and radial dry gas, floating carbon ring, and stage and two bearings for each are precisely machined and transmission from bull tilting pad bearings ensure labyrinth seals in single, tandem, rotor. The geared pinion sets the balanced. Our shafts use proven gear to pinion and optimal pinion mechanical stability or double-acting arrangements. rotor speed. microspline connections or Hirth speed for each compression stage. and reliability. serration for impeller mounts. 8 Driving Centrifugal Compressor Technology 9 OUR ROBUST SINGLE-SHAFT MULTI-STAGE SINGLE-SHAFT COMPRESSORS – RT-SERIES DESIGN Single-shaft compressor features • Efficient impeller and stage design for excellent performance To provide high flow capability, our single-shaft centrifugal air compressor is built on a sturdy frame with proven compressor stage aerodynamics • Proven modular design for all components and interstage cooling. Designed for higher capacity, the single-shaft • Reduced number of parts for machine robustness and compressor is tailored to the needs of the air separation industry for accelerated setup efficiency, higher reliability, minimal maintenance and faster installation. • Possibiity of interstage cooling design for low air approach temperatures • Local packaging options available around the world 2 Bearings Shaft bearings are split-tilting type bearings with five pads Drive train flexibility per bearing. Babbitt-faced Single-shaft RT-Series compressors represent our unique steel construction