Post on 01-Jan-2017
Fuel Gas Booster Compressors
2< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
MDT fuel gas booster compressors
are of integrally-geared design to API 617 Chapter 3
3< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster CompressorsTypical Gas Turbine Requirements and Compressor Configurations
Large gas turbines require fuel gas pressure levels such as:
• 45…50 bar, typical for Trent, GT24 and GT26 gas turbines
• 33…36 bar, typical for 9FA/B and Siemens gas turbines
•40…46 bar, typical for MHI gas turbines
• < 30 bar for Ansaldo gas turbines and older models or small size GTs
With gas pipeline pressure levels ranging from max. 80 to as low as 3-4 bar, many installations require fuel gas booster compressors.
Depending on the overall power plant concept, typical combinations are:
• 1x100% gas compressor for backup service w/ usually high pipeline pressure
• 2x100% for maximum availability
• 3x50% for multiple unit power stations
•any other combination as the case may be (such as 5x100%)
4< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
MDT gas booster compressors are of integrally geared design as per API 617 chapter 3
They are arranged as single lift packages on a steel base frame with externally installed gas cooler
All on skid piping and wiring is brought to skid edge for easy connections
Integrally geared compressors
5< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
MDT’s integrally geared type compressor range
1- to 6-stage gear-type compressors for up to 60 bar discharge pressure
and beyond for other applications
Single stage gas compressor package for a power plant in Al Jubail, Saudi Arabia
6-stage gas compressor for gas transport in Canada, oil sands
Fuel Gas Booster Compressors Product Range
6< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
1-, 3- und 5-stage compressor packages for different
configurations and applications
Other Examples
7< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
Coupling shaft
Bull gear
Compressor casing / volute
Inlet guide vanes(IGV)
IGV actuator
Gearbox casing
Pinion shaft
Impeller
3D sectional view
8< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
The gear is a single helical type with thrust collars on the pinion shafts.
Gear
9< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
The compressor casing (volute) is of cast steel
Stationary parts - Casing
10< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster CompressorsRotating parts - Impellers
Impeller designs range from milled open type to milled and brazed closed impellers of 2D or 3D type
11< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
The Hirth toothing is a form-fitted connection with a high repeatability precision of 0.0001 mm.
No repeated balancing required after re-assembly.
Rotating parts - Impeller to shaft assembly
12< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
Assembled shaft with two impellers after balancing
Rotating parts - Shaft assembly
13< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
PROCESS ATMOSPHERE
Clean Buffer GasLeakage Inert Buffer Gas
Inert Buffer Gas
Source: Flowserve
The compressor stage(s) will be sealed towards the atmosphere by dry gas seal cartridge(s), tandem type with intermediate labyrinth
Seals
14< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
Compressor Design Data
(Input for Compressor Design)
15< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
Typically, integrally geared gas compressors are characterized by relatively low flow and high head (high pressure ratio) combinations.
Basic design data for the fuel gas compressors:
• configuration, e.g. …x 100%
• rated flow = … Nm³/h
• inlet pressure = xx – yy barg (min. / max., yes/no suction pressure control)
• inlet temperature = xx – yy °C
• outlet pressure = xx barg
• max. allowable gas temperature (for cooler arrangement)
• gas composition = mol-weight xx kg/kmol, estimate or analysis
• contaminations, such as H2S, mercaptans, etc. (NACE design)
• driver preference and control mode options (VFD, inlet guide vanes, throttle)
Design Input Information
16< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
Compressor Type Selection
(Design Output Data)
17< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster CompressorsPerformance Map (pressure vs flow)
Design point
Operating range (IGV)Surge control line
18< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster CompressorsPerformance Map (power vs flow / IGV angles)
Design point
Rated motorpower
19< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
High efficiencyintegral gearaxial inflow to each stageoptimum flow coefficients (speed selection)small hub/tip ratiosadjustable inlet guide vanesintercooling after each stage
Low investment
Wide application rangeshrouded / unshrouded impellers etc.connects the benefits of high- and low-speed trains
Advantages of Integrally Geared Compressor Design
20< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
Design details
21< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
The process conditions suppose a single-stage integrally geared design compressor to API 617 7th edition.
Mechanical design limits (mainly power vs. speed) are considered in the design of the gearbox and its bearings.
Combination of pinion shaft speed and max. power are well within the experience limits.
The compressor casings (volute) will be made of cast steel G20Mn5.
Impeller material will be X13CrMoV, alternatively aluminum may be used for rotor-dynamic reasons.
The impeller will be milled design, open type.
Proposed design: integrally geared compressor
22< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
Typical 3-stage gas compressor package
Base frame w/ integrated oil reservoir
Stage 1 inlet flange
Oil system piping
Seal gas rack
Motor
23< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
Typical 3-stage gas compressor package
Stage 3 outlet flange
Inter-stage pipe spools
Oil heater
Seal gas piping
Double oil filter MV motor terminal box
24< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
Hamburg
BerlinOberhausen
Zürich
Manufacturing, packaging and testing in Oberhausen:Axial compressors Large centr. compressorsSteam turbinesGas turbinesScrew compressorsAll kind of testing
Manufacturing and packaging in Berlin:Small centr. compressorsManufacturing of all radial compressor stages
Testing of compressors in Zürich:Compressor packages are scheduled to be tested in the Oberhausen test center, with back-up capacity in the Zurich test fields
MDT’s European turbo manufacturing facilities
25< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
Package Examples
26< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster CompressorsExamples (1)
27< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
This picture shows a packaged 3-stage compressor ready to go to site.
Examples (2)
28< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
Installation Examples
29< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
Buidling for 2 gas compressors and auxiliary equipment in Castejon, Spain.
Installations (1)
30< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
Shelter for 2 gas compressors and auxiliary equipment in Boehlen, Germany.
Installations (2)
31< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
Outdoor installation with completely enclosing outdoor noise hoods in St. John, Canada
Installations (3)
32< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
Maintenance
33< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
This means operators can expect 5 years uninterrupted operation!
Maintenance requirements
34< >MAN Diesel & Turbo Fuel Gas by MDT - Athens 2014 02.10.2014
Fuel Gas Booster Compressors
All data provided in this document is non-binding. This data serves informational purposes only and is especially not guaranteed in any way. Depending on the subsequent specific individual projects, the relevant data may be subject to changes and will be assessed and determined individually for each project. This will depend on the particular characteristics of each individual project, especially specific site and operational conditions.
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