AP1 618 Reciprocating Gas
Compressors
Peter Brotherhood Ltd
solutions World class engineering
Peter Brotherhood Ltd has been designing and manufacturing precision engineered machinery since 1867. The company’s expertise covers a wide range of industries and Peter Brotherhood equipment is operating in more than 100 countries around the world.
The company combine world-class skills in design and manufacture with practical industry experience to provide technically-sound and cost-effective engineering. Brotherhood Process & Energy specialise in the design and manufacture of AP1 618 reciprocating gas compressors as complete packages incorporating the prime mover, gas processing plant, instrumentation and controls. The company’s experience covers a wide range of gas mixtures, including corrosive and hazardous gases. The company has worked with customers in the oil and gas industry both offshore and onshore throughout the world. Peter Brotherhood accept total engineering co-ordination and project management on every contract undertaken. Highly experienced engineers provide comprehensive services from design through to on site commissioning, as well as after sales support and on-site maintenance. Frame 2D1 gas compressor, supplied to Fluor Daniel
Frame 4D3+R gas compressor installed at Dalian Petrochemical plant in China
Reciprocating Compressors
Peter Brotherhood reciprocating gas compressors are designed and manufactured to comply with the latest edition of API 618. They are designed to operate at slow to medium running speeds with variable strokes to give maximum reliability, smooth operation and low wear, ensuring a minimum service life of 20 years. The machines are designed in accordance with the company’s design criteria ARM (Availability, Reliability and Maintainability). This ensures that, during the service life of the compressor, the availability for service will exceed 95 per cent. The compressors are designed and constructed to give at least three years uninterrupted operation between overhauls, thus providing maximum reliability. Particular attention is also paid to maintainability. All standard components have been developed over the years with ease of maintenance being one of the main design criteria.
This frame 4B2 gas compressor, mounted on concrete foundations, is one of two machines supplied to a refinery in Thailand
Reciprocating compressors are well suited to a wide range of offshore and onshore applications. They offer benefits of economy in terms of both low capital cost and low power consumption at full and part load operating conditions. The reciprocating design provides inherently flexible capacity control and the ability to handle ‘off design’ gas conditions, providing an assurance of economy and reliability over a wide operating envelope. The reciprocating compressor is also inherently quieter than fixed capacity rotating machines and is simple and economical to maintain, with procedures that are easily understood by operating personnel.
Frame Data
Peter Brotherhood gas compressors are rated for piston rod loads from 100 kN to 700 kN and strokes varying from 130 mm to 460 mm. The maximum speeds quoted are those which give a nominal mean piston speed of 4.6 m/s for machines with lubricated cylinders and 3.6 m/s for machines with non-lubricated cylinders. The company has developed a number of compressor frame sizes to cover all applications within its power and capacity range. Six frames, designated M, A, B, D, E and F in ascending order of allowable loads and power, form the core of the company’s range.
Frame
*M
*A
B
D
E
F
2-6
2-6
Number of cranks
-
1-2
1-6
1-6
2-6
Maximum absorbed shaft power
kW
1,800
3,500
6,500
11,500 20,000 34,000
Maximum speed lubricated
rpm
1,000* 750*
560
450
375
327
Maximum speed non-lubricated
rpm
800*
450
360
300
260
compressors 600
* The company consider speeds of 750 rev/min and above to be outside the scope of AP1 618. However, they are included here to show that the M and A Frames have this capability.
design CAD model of a 4D3 gas compressor
Compressor Design
Peter Brotherhood reciprocating gas compressors are designed specifically for handling a wide range of process gases. Machines for this type of application are fundamentally different from air compressors and Peter Brotherhood’s machines are built solely for gas compression duties. The company is therefore able to offer many features not found on gas compressors derived from machines originally designed for air compression. These all add to safety and reliability and lower the ‘life-time’ cost of purchasing, installing and operating the compressor. This design approach ensures that all Peter Brotherhood reciprocating compressors can match the exacting requirements of the API 618 standard. The company remains at the forefront of compressor technology and invest heavily to allow customers to benefit from new materials and components.
Frame 4D3 gas compressor during assembly
Reliability
Reliability is being improved with the use of materials such as PTFE, which is now used to extend the life of piston rings, and ceramic coatings to reduce wear on piston rods. Efficiency is being improved through better design of valves. Power saving control systems are based on control of suction valves to save power when the load changes. Although Peter Brotherhood utilise standard, service-proven components and designs to the fullest possible extent, each individual compressor is tailored to meet a customer’s precise requirements.
Research & Development
The compressor design team combines decades of practical experience with the latest computer technology to speed up and enhance the process, ensuring that the most effective design is produced. CAD/CAM, finite element analysis (linear, non-linear and multi-physics), piping stress analysis and an advanced process simulation package are just some of the tools used to optimise the compressor design. The company’s design system performs rating and sizing calculations to ensure the most economic sizing of the compressor in terms of power and performance under all running conditions. This wealth of software, as well as feedback from hundred’s of machines in services over many years, allows the company to design using ‘virtual master model’ approach. Designs are continuously optimised to improve both product capability and reliability. This methodology minimises the time taken to implement new developments and maximises Peter Brotherhood’s responsiveness to customer needs.
Frame 2A1 reciprocating gas compressor for a UK oil refinery
Caltex Oil / Foster Wheeler South Africa ordered a 2A2 make-up hydrogen compressor and a 2B2 membrane booster. The 2A2 compressor compresses hydrogen from 19.8 bara to 64 bara and is fed into the Hydrotreater. The compressors were ordered as part of the South African clean fuels programme
Refining Experience
Brotherhood Process & Energy have supplied compressors to many different refineries and process plants around the world. They are used in a wide range of processes and for production of a variety of substances including: ● ● ● ●
Crude distillation Hydrocracking Hydrodesulphurisation Isomerisation
● ● ●
Naptha treatment Residual desulphurisation Resid refining
Frame 4B2 reciprocating gas compressor for South Africa
In 1990 Brotherhood Process & Energy designed and manufactured 14 reciprocating gas compressors for Mossel Bay GTL Onshore Project in South Africa. The gas to liquid process plant required 14 compressors up to 1.4 MW to compress hydrogen and hydrogen with hydrocarbons in a highly corrosive marine environment. More recently Foster Wheeler has purchased 2 more units to recycle hydrogen gas through the hydrogenation reactor.
3.8 MW reciprocating gas compressor for Changling Oil Refinery
A number of Chinese refineries are investing in a new hydrofining capacity to meet customer demand for lower-sulphur fuels. Brotherhood Process & Energy have supplied a number of compressors to China. Each package is based around what appears to be a typical four-cylinder reciprocating compressor, but two cylinders of each machine handle hydrogen make-up gas whilst the other two simultaneously handle recycling gas for diesel fuel hydrofining. The compressors range up to a maximum of 3.8 MW. Lukoil, a Russian oil company, needed to upgrade the Volgograd refinery to produce ‘sulphur-free’ diesel oil. They turned to engineering contractor SNC-Lavalin of Canada to design and install new refinery equipment. SNC-Lavalin placed the contract with Brotherhood Process & Energy (an order worth more than £8 million) to supply 9 reciprocating gas compressors ranging up to 1.7 MW each with their own drive motor, control panel and oil and water systems.
490 kW compressor for Lukoil
refining
petrochem Petrochemical Experience
Brotherhood Process & Energy have supplied compressors to many different petrochemical plants around the world. They are used in a wide range of processes and for production of a variety of substances including: ● ● ● ● ● ● ●
Frame 4D3 reciprocating gas compressor for Sasol Technology South Africa
Aromatics Butane Ethanol Ethylene HDPE LLDPE Methanol
● ● ● ● ● ●
MTBE Olefins Oxo-alcohol Syngas Urea 2-ethyl hexanol
Sastech Engineering, a division of Sasol Technology, required a compressor company that could deliver a cost effective option of providing compressed hydrogen for an eighteen month period and ensure the compressor was flexible enough to be used on other processes after this period. They turned to Brotherhood Process & Energy to provide a reciprocating gas compressor. The compressor is fed by hydrogen, which used to be flared. The recovered gas is firstly cleaned by scrubbers then piped to the compressor. This raises the pressure to match the Sasol Hydrogen gas network system which feeds the gas to various customers on the plant for differing synthetic fuel uses. The 2.1 MW system operates at 24 bara and is one of the biggest compressors of its type installed in South Africa. Brotherhood Process & Energy have supplied four reciprocating gas compressors to Nanjing Petrochemical Plant in China to boost and recycle hydrogen. The four reciprocating compressors are non-lubricated and skid mounted with pulsation vessels and have a combined safe area control panel with programmable logic controller (PLC). The system also incorporates knock-out pots, local gauge board and 580 kW and 150 kW drive motors with a Bently Nevada 3500 system. Two frame 4A3 reciprocating gas compressors (865 kW and 430 kW) have been installed at ICI Wilton on the ethylene liquefaction plant, North Tees site. The compressors were replacement flash gas units packaged to client specifications using a specially designed lifting beam to allow partial assembly of the compressors before installation.
One of two Frame IMHI, 150 kW reciprocating gas compressors for China
Frame 2D2 reciprocating gas compressor for Air Products
Gas Processing / Fuel Gas Booster Experience Brotherhood Process & Energy has experience in the following gas processes: ● ● ● ● ● ● ● ●
Boil-off Gas Carbon Dioxide Carbon Monoxide Ethylene Storage Flare Gas Recovery Gas Injection Gas Lift Gas Processing
● ● ● ● ● ● ● ●
Gas to Gasoline Gas Transport Gas Treatment - ‘Selexol’ Helium Production LNG Oxygen Production Special Process Synthesis Gas
Two Brotherhood compressors were supplied to Air Products for a gas blending station at Rozenburg in the Netherlands. The compressors boost the pressure of the incoming nitrogen from 17.8 bara to 72.2 bara and are driven by 1,050 kW electric motors.
Reciprocating compressor for British Gas
The gas processing facilities at the British Gas liquefied natural gas (LNG) terminals at Dynevor Arms and Avonmouth in the UK use the Selexol process to remove CO2 and other impurities from the gas before it is stored in tanks. British Gas selected two-stage, two-crank compressors from Brotherhood Process & Energy to undertake gas compression as part of the process. The Chiyoda Corporation in Japan have 3 reciprocating gas compressors installed in Oman that are used to feed pre-treated or regeneration gas into the process train. This LNG is reprocessed to improve its purity and the overall efficiency of the system. Each machine produces approximately 3.3 million tons per year and operates at a power of 400 kW. A 925 kW reciprocating gas compressor has been installed in a gas processing plant in Kuwait. Sour and corrosive gases are being compressed in a special process. The 2B1 compressor has stainless steel cylinders and vessels.
925 kW compressor for KNPC
gas processing
offshore Offshore / FPSO Experience
Brotherhood Process & Energy has extensive experience of working with customers in oil and gas industries offshore. The company has supplied compressors for a wide range of different applications including:
● ● ● ● ● ● ● ●
Fuel gas boosting Gas export Gas handling Gas lifting Gas re-injection Gas storage Gas treatment Vapour recovery
150 kW compressor for Amoco
Brotherhood Process & Energy supplied Amoco with a vapour recovery gas compressor for the Central Area Transmission System (CATS), one of the UK’s biggest undersea pipeline projects. The compressor takes natural gas, which would otherwise be flared, and re-injects it into the process stream to main compressors in the North Everest field. The 150 kW system operates at 64 bara. Two reciprocating gas compressors were supplied to BHP Petroleum in Australia for installation in the Jabiru Venture, a floating production, storage and off-loading (FPSO) facility producing oil in the Timor Sea off Northern Australia. The two identical reciprocating gas compressors deliver natural gas up to 140 bara. The compressors are each driven by a 630 kW electric motor. In addition to the compressors Brotherhood Process & Energy supplied a 2.2 MW steam turbine. 1,850 kW reciprocating gas compressor for Chevron Petroleum
A 205 kW fuel gas reciprocating package incorporating a frame 2A2 fuel gas compressor for the Shell Auk Alpha oil platform
A 120 tonne compressor package was supplied to Shell Auk Alpha oil platform in the North Sea. It was built on a large underbase which was then attached to the platform as a cantilevered deck unit. In addition to a twostage reciprocating gas compressor the module incorporates a fuel gas treatment unit to cool the gas and then filter and dry it. Overall the package measures 14 metres in length, 7 metres in width and 5 metres in height.
The Jabiru Venture FPSO vessel, which has two frame 2B2 gas compressors and a steam turbine installed onboard
Frame 2B1 + BL installed at Mobil’s Coryton refinery
Compressor Packages
Peter Brotherhood can design and install a wide range of auxiliary equipment on compressor packages, including:
Forced lubrication systems and water consoles complying with API 618 standards. ● Capacity control systems including suction valve unloaders, volume clearance pockets (manually or pneumatically operated), automatic by-pass systems and stepless capacity control systems. ● Pulsation dampeners designed to attenuate pressure pulsations in process pipework. In addition to supplying the bottles the company offers both digital and analogue computer analysis of the acoustic and mechanical interaction of the vessels and associated piping systems. ● Gas intercoolers and aftercoolers of shell and tube, air blast, plate type or other design. ● Free-standing or in-line moisture separators, which can be supplied complete with all associated level control instrumentation and liquid disposal systems. ● Separators and heat exchangers (free-standing or in-line) designed and constructed in accordance with customer specifications and recognised codes, including British Standard, ASME, Stoomwezen, TEMA, etc. ● Interconnecting gas and water pipework, pre-fabricated and tested in the company’s factory, designed to ASME B31.3 and relevant customer specifications. ● Instrumentation comprising either a local free-standing gauge board or a complete control and instrumentation panel which might contain PLC control systems, annunciator systems and specialised equipment. Peter Brotherhood supply complete instrumentation packages to meet specific customer requirements. The panel connections may be either piped and wired by the contractor on site or, in the case of a packaged compressor, fully installed and tested at the company’s facility. ● A full range of protection systems and safety features such as monitors for vibration, rod drop and gas valve temperature and detection systems for gas leakage and fire. ●
A gas compressor driven by a gas engine - part of a complete package supplied to the Heera platform in the Bombay High natural gas field in the Indian Ocean
230 kW reciprocating gas compressor packaged for Shell Carrington, UK
Packages are tailor-made to the customer’s specification
packages
compresso Section through a typical compressor
1
19
17
18
2
3
16
Connecting rods & bolts
4
15
Crosshead
5
14
6
7
8
9
13
Piston, piston rod & hydraulic nut attachment
Key 1 2 3 4 5 6 7 8 9
Distance Piece Piston Rod Piston Rod Oil Wiper Packing Crosshead Explosion Relief Valve Connecting Rod Bolt White Metal Bearing Crankcase & Distance Piece Connecting Rod
10 11 12 13 14 15 16 17 18 19
Suction Valve Unloader Cylinder Valve Piston Crankshaft Balance Weight Piston Rod Nut Intermediate Packing Piston Rod Packing Piston & Bearing Rings Cylinder
Piston, rod packing
or Cast Iron cylinder
2
Piston rods are generously proportioned and have rolled threads as standard to give the maximum possible fatigue strength. They are manufactured from various materials depending on the service, ranging from AISI 4140 to 17/4 PH, and are flame or induction hardened to a minimum of 50 HRC in the packing areas. For more arduous duties they can be hard coated with a variety of materials using high velocity surface coating techniques with give a typical hardness of 70 HRC.
4
All crossheads are manufactured from cast steel for maximum strength and have separable shim adjustable slippers with white metal rubbing faces. Each slipper is separately force lubricated through the distance piece, to ensure negligible wear.
9
Connecting rods are machined from high tensile drop forgings, designed for maximum strength and minimum weight. Lubricating oil is pressure fed to the small end bearing via a bored hole through the centre of the connecting rod shank.
11
The cylinder valves are generally of the Hoerbiger design. Valves are manufactured from carbon steel as standard, with stainless and other alloy steels offered as options. The plates can either be either metallic or nonmetallic. All the design parameters, such as valve lift and spring rates, are individually calculated to give the optimum valve performance for the specified duties.
12
Pistons are individually designed to meet the specified process requirements. They can be cast, forged or fabricated in materials selected to suit the process conditions. Where aluminium piston are used, to give optimum balance, they are hard anodised over the entire outer surface.
15
In line with the latest compressor technology, the company has designed a hydraulically actuated piston rod nut which is primarily for the crosshead end but can be used at the piston end. It ensures that any operator, using simple hydraulic tools, can ensure a pre-tension accuracy and repeatability of better than 5 per cent.
17
The selection of the correct materials for the wearing parts is critical. Materials are selected on the basis of experience to achieve the maximum period between changes of the internal components. Where particularly hazardous gases are involved, the latest techniques for minimising leakage are utilised. Packing case materials are selected depending on the process gas being compressed. Packings may be cooled if the pressures and temperatures require it.
19
Cylinders are individually designed to meet the specified process requirements and are not just selected from a ‘standard’ range to give the nearest option. They can be supplied in grey cast iron, SNG, cast steel, cast stainless steel, forged steel or more exotic materials depending on the process gas conditions and operating pressures.
10
12
11
Piston, & bearer rings
Forged cylinder
components Cylinder valves
Brotherhood Process & Energy Specialists in the design and manufacture of equipment to meet the needs of the process and energy industries. Reciprocating gas compressors are supplied as packaged units incorporating the prime mover, gas processing plant, instrumentation and controls. The company has produced gas compressor packages which help refinery, petrochemical and offshore installations protect the environment. Peter Brotherhoods experience covers a wide range of gas mixtures, including corrosive and hazardous gases. The company has worked with customers in the oil and gas industries both offshore and onshore throughout the world. In addition to reciprocating gas compressors, the company also specialises in the design and manufacture of steam turbines, packaged CHP systems, special purpose machinery and gearboxes. In all its activities, from design to commissioning, Peter Brotherhood works to ISO 9001:2000 quality assurance standard and ISO 14001:2004 environmental management standard.
Brotherhood Process & Energy A business unit of
Peter Brotherhood Ltd
RGC 02/06
Peter Brotherhood Ltd Werrington Parkway Peterborough PE4 5HG United Kingdom
Peter Brotherhood Southern Africa (Pty) Ltd PO Box 1819 Halfway House 1685 Midrand South Africa
Telephone: +44 (0)1733 292200 Fax: +44 (0)1733 292300 E-mail:
[email protected] Website: www.peterbrotherhood.co.uk
Telephone & Fax: +27 (0)11 805 2850 E-mail:
[email protected]
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