modern rotating equipment technologies for up- / mid ... · for gas turbine and low speed electric...

Modern rotating equipment technologies

for up- / mid- / downstream applications

2 < > MAN Diesel & Turbo E Enghardt / K. Olesevich MTTP Working Group / IBC conference, Florence (final) 30.01.2018 MDT-Rus

Agenda

1 MAN Diesel & Turbo - Portfolio

2 Upstream Applications

3 Midstream Applications

4 Downstream & Process Industry Applications

5 Modernizations – “State of the Art”

6 Conclusion


MAN Diesel & Turbo A worldclass Product Portfolio

Power Plants Turbomachinery Engines & Marine Systems

Two-stroke and

four-stroke

engines for

marine

applications

Propellers and

complete

propulsion

systems incl.

fuel gas

systems

Turbochargers

Compressors,

gas and steam

turbines,

expanders

Complex

machinery

trains

Chemical

reactors

Service: MAN PrimeServ

Worldwide

network of

service hubs:

24/7 OEM

service around

the globe

Two-stroke

and four-

stroke

engines for

stationary

applications

Diesel and

gas power

plants


MAN Diesel & Turbo Comprehensive applications in diverse industry areas


Upstream Applications Screw Compressor Portfolio

Horizontal split casing

Volume flows:

4,000 – 100,000 m³/h

Discharge pressure:

≤ 16 bar

Vertical split casing

Volume flows:

200 – 20,000 m³/h

Discharge pressure:

≤ 52 bar

Vertical split casing

Volume flows:

1,180 – 17,000 m³/h

Discharge pressure:

≤ 40 bar CPO400

CPO252

CPO200

CPO160

SKUEL816

SKUEL643

SKUEL510

SKUEL408

SKUEL321

CP320

CP252

CP200

CP160

CP128

CP100

CP80

100 1000 10000 100000

CP series

SKUEL series

CPO series

oil-f

ree

oil-i

nje

cte

d


Upstream Applications Screw Compressor Examples

Offshore Unit,

Preassembled

at the workshop &

ready for dispatch

“mobile unit” with

air cooled oil system,

designed to be moved

in between wells


Upstream Applications Subsea Gas compression for the Åsgard field

MAN has developed the first subsea gas compressor directly installed on the seabed,

already in successful, remotely controlled operation for more than 1 year !!!


Midstream Applications HOFIM™

Application 2:

Natural Gas Transport

Medium Head / High Flow

Power Range (per train):

~ 4 .. ~ 18 MW

(5‘300 .. 25‘400 bhp)

Application 1:

Natural Gas Storage

High Head / High Flow

Flow / Nm3/h

Pre

ss

ure

Ra

tio

8

4

2

1

For serial and parallel operation


Midstream Applications World Wide References

2013

1

2

2

7 32

11

3

8

20

11 2

11

2

2

4

TOTAL: 111 High speed compressors installed world wide


Conventional Compressor

Series RV Sealed Compression

Technology MOPICO®

between-bearing-design

1-6 impellers

horizontal nozzles, heavy duty casing

oil lubricated bearings

dry gas seals

for gas turbine and low speed electric

motor drivers

hermetically sealed unit

high speed electric motor driver

2 overhung impellers

axial inlet

magnetic bearings

Midstream Applications


Downstream & Process Industry

Applications

Horizontally split casing

Suction flow rates up to

660,000 m3/h

Max. discharge pressure up to

50 bar

Refinery processes Refrigeration Chlorine HCL Wetgas O-Gas Olefins

Vertically split outer casing

(barrel type)


325,000 m3/h


1,000 bar

Refinery processes Refrigeration Gas Gathering Gas Injection Gas Lift Methanol / Syngas

Integrally geared

Compressor

Suction flow rates up

to 350,000 m3/h

Max. discharge

pressure up to 225 bar

CO2 CO Nitrogen Refrigeration Vapor Syngas


Axial Compressor


1,500,000 m3/h

Main Air Blower

FCC

Flexicoker

Axial Expander

Single stage & Multi stage

up to 30 MW

power generation &

integrated compressor train

Power recovery train

Hot Gas

Flue Gas

Singe stage Compressor


350,000 m3/h

Max. discharge pressure up

to 225 bar

PRU

ERU

Heat Pump

Cx Splitter


Applications



Applications

Steam Turbines

Power Output up to 160 MW

Inlet Pressure up to 140 bar

Inlet Temperature up to

540°C

Refinery processes

Refrigeration

Methanol / Syngas

Refinery Train Package


28,000 m3/h


205 bar

Refinery processes

Hydrotreating

Hydrocracking

Maren Steam Turbine

Power Output up to 10 MW

Inlet Pressure up to 65 bar

Inlet Temperature up to 460°C

Refinery processes

Hydrotreating

Hydrocracking


Development of a new gas turbine

range

Expansion of the production

program for power generation

and mechanical drives

Two-shaft and single-shaft

references with more than 40 000

operating hours are available

Industrial gas turbines MGT6000 - development

MGT6000

single-shaft

MGT6200–

Maintenance

concept

MGT6000

two-shaft


Service and Customer Benefits:

- Enhance the efficiency and reliability of the

equipment

- Available for all types of turbomachinery

regardless of the OEM

- The current status of the machine will be

calculated and compared with the original

performance map

- Possible causes for large deviations will be

identified and conclusions drawn

- Allows the operator to improve operation

with the actions recommended

- Early recognition of possible risk potential

e.g. potential damage, etc.

- Identification of potential energy saving

- Easy to understand condition evaluation

report on a regularly basis

Modernizations – “State of the Art” Performance Check / Changed Operating Conditions


Modernizations – “State of the Art” Performance Check / Changed Operating Conditions

• Flash Gas Compressor Trains

• Transport-Container • Gearboxes Speed Increase

• Gear Wheel Sets Speed Increase

• New Motors 5360KW

• LP Coupling Motor to Gearbox

Long-term Service Agreement: Outstanding Reliability Performance,

confirmed by the customer


Modernizations – “State of the Art” Relocations

Gas turbine: THM 1304-10N

Power output: 11,5MW

Compressor: RV050-02

Power input: 11,2MW => to be kept

Speed: 8000rpm

Volume flow rate: 1.011.405 Nm³/h => only slight change

Inlet temp. / pressure: 20°C / 52,82barg

Outlet temp. / pressure: 48°C / 73,98barg => 99,1Bar

=> Configurations & Casing (even of compressors)

shall be kept, allowing optimizations for engineering

(time & costs)


Modernizations – “State of the Art” Reverse Engineering

sca

nn

ing

Wo

rkpie

ce

pre

pa

ratio

n

Piont cloud

Mesurement of:

dimensional and

geometrical tolerances,

sections, diameters

Reverse Engineering

sections

NURBS-

surface

Construction 3D-model



Compressor Scan

(rotor pre-assembled /

in situ) t a site in Spain

Reverse engineered

rotor / impellers with

design improvements

Impellers have been exchanged 1 year after the scan at site reusing the shaft;

some years of damage free operation already completed!


Compressor room

half dismantled Old Inner bundle

dismantles

Existing compressor

casing used for

reverse engineering

Compressor on the test stand at

MAN in Oberhausen New Inner Bundle – set of rotor and

stator parts ready for transfer

Successful delivery and re-commissioning


New parts / bundle


“We aim to be

our customers

preferred business

partner”

Conclusion


Your Contacts

Kirill Olesevich

Head of Sales Turbomachinery

Russia and CIS

Landline: +7 (495) 258-36-70 , ext. 308

Cell: +7 (905) 751-5284

Email: [email protected]

Enrico Enghardt

Managing Director MDT-Rus

Head of CIS

Landline: +7 (495) 258-36-70 , ext.200

Cell: +7 967 201 8544

Email: [email protected]

modern rotating equipment technologies for up- / mid ... · for gas turbine and low speed electric...

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