GE Oil & Gas Overhung Centrifugal Compressors D Series Single-Stage
D Series Single-Stage Compressors Overhung, single-stage centrifugal compressors are designed for lower pressure, high volume applications, including mechanical vapor recompression, sulfuric acid plants, chlorine, combustion air, process gas boosters and many more. With different combinations of materials, seal designs, and impeller configurations, D Series compressors are capable of handling a wide range of gases and processes. Packages can be tailored to meet specific customer specifications as well as API and other industry standards. How they work Gas enters the compressor axially and is accelerated by the rotating impeller. At the impeller exit, the kinetic energy of the gas is converted into pressure energy in the parallel wall diffuser and the compressor volute or collecting ring. Whether controlled by adjustable inlet guide vanes or by variable speed operation, the compressor can meet a wide range of varying flow and pressure requirements. This simple compressor design, incorporating a single overhung impeller with a shaft mounted on two tilting-pad radial bearings, provides many years of dependable service. Downstream Technology Solutions GE Oil & Gas is a highly-experienced industry partner. We work closely with our customers in the downstream industry to help them operate more efficiently and profitably. Local expertise and global capabilities As today s projects become more complex, difficult and remote, localization is vital to success. Our global footprint is localized to speed and improve delivery of services, technologies, and expertise - to be closer to our consumers. We continuously strive to improve our local presence working closely with our customers to fully understand their unique project requirements while simultaneously bolstering our global presence to make projects of any size, at any location a reality. The oil and gas industry is driven by technology and technology is driven by people. Every day at GE Oil & Gas we invest in developing the right expertise in the right places. Our Field Service Engineers (FSEs) are not only highly experienced and highly knowledgeable, they can leverage GE s vast technical knowledge base, consisting of thousands of experts covering tens of thousands of units. So, when an FSE arrives on site, our customers have direct access to an entire global technical network. Differentiated products and services Over the years, we have developed cutting-edge technologies and world-class capabilities to support our customers as they execute increasingly challenging projects. Our portfolio includes an extensive range of proven industry standards gas and steam turbines, centrifugal and reciprocating compressors, expanders, pumps and more. We design, manufacture and service equipment to meet individual plant requirements and offer the advantage of multi-product integrated solutions. We are committed to continually supporting our products with our technical knowledge, over their entire operating life. Operational excellence Reducing costs while operating safely, reliably and efficiently represents a huge challenge for downstream operators. Therefore, we are focused on defining and managing the scope of projects as well as searching out opportunities for modularization and simplification to help control expenditures. At GE s Downstream Technology Solutions, we work to anticipate our customers needs by being timely and responsive from the initial project phases through to installation and commissioning. We drive operational excellence through proper and integrated project planning to allow on-time and on-budget execution. Standard maintenance Every equipment design decision draws on our extensive engineering experience and informed considerations of industry best practices for your plant. No other company can provide this level of expertise for your equipment. Highly qualified, wellplanned maintenance is fundamental to getting consistently high performance and long life from your rotating equipment. Our expert services teams can be mobilized quickly to deliver the highest quality service anywhere in the world. GE genuine parts incorporate our latest technical improvements, advanced materials and innovative designs. These advantages are unique to our parts and contribute to their superior performance and durability, even under the most extreme operating conditions. Time-tested, tough performance For over 0 years, we have built single-stage compressors that deliver consistent, reliable service in heavy-duty industrial applications. This success is the result of a single, focused objective: to manufacture and service top-quality compressors that work better, last longer and meet or exceed every customer s specifications. For low pressure, high volume applications, our single-stage overhung compressors offer a compact design, wide-ranging flexibility and long service life. With a variety of models and seal options, we can tailor a system to meet your specific needs, and our quality management system helps ensure trouble-free operation and short lead times. 2 3
1 Heavy-duty casings 7 2 Cast iron standard, other materials available depending on application Low point drain on all casings nozzles Removable Cast iron standard, other materials available depending on application 8 Variety of shaft seals Configurations available to suit specific applications including: - multiple labyrinth type - segmented carbon ring type - dry gas seals Rotating elements Designed to boost uptime, simplify maintenance 1 2 6 7 8 9 10 3 4 6 Optional inlet guide vanes Creates infinite array of performance characteristics Maximizes efficiency in variable operating conditions Power savings of up to 1% possible Increases turndown, broadening operating range Pneumatic, electric or manual operators Variety of housing materials to suit customer needs Standard vanes made of 316 stainless steel Efficient impellers Milled, fabricated or cast Available in a variety of materials and configurations Absence of shroud ring reducesparticle accumulation O-rings Ensure tight fit to avoid contamination or leakage Ease disassembly and reassembly of compressor Exclusive balance ring on back of impeller Permits trim balancing while compressor remains in place No removal of process piping or inlet nozzle required Reduces downtime 9 10 Shaft and impeller assembled and balanced as a unit Entire element can normally be removed and installed without removing impeller from shaft Integral thrust collars Selection of bearings Full line of pivoted-shoe radial bearing packages Tilt-pad, double-acting thrust bearings Interchangeable shoes for each bearing size Horizontal split housing and bearing eases inspection and maintenance High speed couplings Unlubricated couplings Include spacers and guards 4 3 Outstanding features designed for top performance and minimal maintenance 4
Single-stage compressor details Frame sizes Backplate support: D8 to D36 Centerline support: D42 to D72 Impeller options 12-80 diameter One-piece milled impeller, forged hub/welded blades or cast impeller Material options - AISI 4140 alloy steel - 410 stainless steel (to 1,000 fps) - 17-4 stainless steel (to 1,400 fps) - Milled titanium (above 1,400 fps) - Other materials available for specific applications s: 1,000 to 20,000 rpm Shaft Single-piece bar stock or forging Integral thrust collar Tapered impeller fit, no key required or hydraulic removal, if specified Coupling fit to meet specific requirements - Keyed cylindrical fit - Tapered hydraulic fit Renewable stainless sleeve in seal area Typical installations Casing Cast iron for lower working pressure Smaller machines go to 200 psig/13.8 bar g with steel casing Other materials available for specific applications nozzle Cast iron Nickel plated for steam applications Other materials available Backplate Fabricated steel or cast iron Other materials available guide vane assembly Cast iron housing, steel and stainless steel available Nickel plated housing for steam applications One-piece 316 stainless steel vanes Teflon bushings at vane shafts Other materials available for specific applications Sulfuric acid production D42JR 100,300 ICFM/170,400 m3/hr 3,91 rpm 11.63 psia / 0.8 bar a 20.4 psia / 1.41 bar a 4,700 hp /3,06 kw Mechanical vapor recompression D42JR 90,000 ICFM/12,900 m3/hr 4,42 rpm 1.0 psia /1.03 bar a 21.6 psia / 1.49 bar a 3,00 hp /2,611 kw Air blower in fertilizer plant D48JR 124,040 ICFM/210,70 m3/hr 3,40 rpm 14.2 psia /0.98 bar a 24.0 psia / 1.6 bar a 6,360 hp /4,74 kw Main air supply for wind tunnel facility 6 D4JR 240,000 ICFM/407,760 m3/hr 3,600 rpm 8.3 psia /0.7 bar a 14.9 psia /1.03 bar a 7,00 hp /,9 kw 7
Support systems manufactured to meet specific requirements Because each system s operation depends upon unique requirements, GE offers a variety of factory assembled accessory packages. s Most drivers are electric motors or steam turbines, with or without speed change gears. For special applications, gas turbines, gas expanders or reciprocating engines are available. Lubrication Console Designed to exacting standards as an integral part of each component, a lubrication console provides clean, cool, pressurized lubricant to the equipment bearings. Bearing package Bearing packages Seal packages Sound attenuation To ensure reliable service, pivoted-shoe radial bearings and tilt-pad, double-acting thrust bearings are used exclusively on all heavy-duty, single-stage centrifugal compressors. The oil-flooded radial bearings feature five pivoted-shoe pads, equally spaced around the base of a horizontally split bearing body. Each shoe is self-aligning to compensate for shaft angularity. A separate oil wedge is formed between each shoe and the shaft journal. This design eliminates shaft instability caused by oil whirl, a common problem with lightly loaded sleeve bearings. Buffered labyrinth For easy inspection and maintenance, the bearings and housing are split. The bearing can be removed without disturbing the shaft. Shoes for each bearing size are completely interchangeable, shoe-to-shoe. Should parts replacement become necessary, only the affected parts must be replaced, not the entire bearing. Carbon ring A custom designed sound attenuation blanket can be affixed to the exterior of the compressor casing. Each segment of the blanket is comprised of a heavy lead sheet surrounded by layers of fiberglass mat encased in an oil-resistant covering. Segments are individually marked and form-fitted around the casing. A stainless steel wire hook-and-loop system facilitates installation and removal. This design reduces the calculated sound level by as much as 2 db from the compressor s unprotected sound pressure levels and can dramatically reduce the exposed temperatures in hot applications such as vapor recompression. Buffered labyrinth seal package Carbon ring seal package Designed for corrosive, dirty and toxic gas or steam use where some buffer gas consumption is permitted, these seals contain a buffering port for gas or steam. Sealing touchpoints located on either side of the buffering port prevent the process gas from leaking into the atmosphere. The seal is horizontally split and bolted to the backplate from the bearing side, providing accessibility for inspection or removal of the seal. Used where more positive sealing is required and only a small amount of buffering gas usage is acceptable, these segmented carbon rings are held in position by two garter springs and antirotation stops. Carbon rings are stacked in the chamber and fastened in place by an end plate bolted to the seal housing. The entire seal housing is horizontally split and bolted to the backplate from the bearing side, providing accessibility for inspection or removal of the seal. Other seal options Control panels Panel enclosures typically include instrumentation designed to integrate the compressor into the specific installation s operating philosophy. Monitoring equipment measures shaft vibration and bearing temperature to provide continuous protection. Pushbutton controls govern local start and emergency stop. Other options may include antisurge and performance controllers or other specific components to meet customer specifications. For applications requiring zero leakage of buffer gas to the process, dry gas seals with a buffer system can be provided. Other seal arrangements are available. 8 9
Comprehensive testing Every single-stage centrifugal compressor we manufacture must pass stringent testing and inspection procedures. Each component is thoroughly tested individually, then the entire assembled compressor goes through a comprehensive testing and inspection process. Shafts Full magnetic particle inspection is conducted on the shaft. Other tests include complete sonic inspection, dimensional checks, and tests for electrical and mechanical run-out and concentricity. Rotating elements To ensure top performance at installation, the shaft and impeller are assembled and balanced as a unit in our facility. Both static and dynamic balancing are conducted. Impellers Hub-disc forgings undergo complete sonic inspection. Physical and chemical properties are verified as well. After preliminary machining, full magnetic particle inspection or dye-penetrant tests are run. Impeller blades undergo full magnetic particle inspection or dyepenetrant tests, and physical and chemical properties are verified. Fully welded impellers pass magnetic particle inspection or dye-penetrant tests of all welds. A full radiograph inspection is conducted on cast impellers. All impellers are statically and dynamically balanced. Mechanical integrity is assured through over-speed tests, followed by final magnetic particle inspection or dye-penetrant tests and dimensional checks. Casings Each casing undergoes hydrostatic testing to 10% of maximum application pressure. Physical and chemical properties are verified as well. guide vanes Dye-penetrant tests are conducted on all vanes. Assembled units are also bench tested. Assembled compressors Every compressor is fully assembled and mechanically tested with the same clearances required for field operation. All operational data is recorded for future reference. To confirm that design standards have been met, vibration, bearing performance, oil temperatures, as well as oil flows and pressures are checked and confirmed. GE Oil & Gas 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 multi-vendor equipment. We offer an extensive portfolio of proactive and interactive service products such as Conversions, Modifications & Uprates (CM&Us), Condition-based Maintenance and Contractual Service Agreements (CSAs). These complement our traditional 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 can also be called upon 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, Maintainability (RAM) solutions, all of which 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 the way we serve our customers, we have implemented a Customer Service Center and a series of e-service solutions. Industries Our service teams have acquired a broad range of expertise through meeting the varied needs of such diverse industries as: Chemical and petrochemical Petroleum Refining and production Food processing Pulp and paper Military Natural gas Applications We have a proven record of performance in applications as tough as: Sulfuric acid production Brine concentration Mechanical vapor recompression Chlorinated hydrocarbons Sulfur removal/recovery Chlorine Combustion air Tail gas Exhauster Cogeneration Synthetic fuels production Fluidized bed Environmental GE takes great pride in helping meet environmental challenges through processes such as: Water purification Sewage treatment Recompression evaporation Solvent recovery Peak performance 10 11
geoilandgas.com Nuovo Pignone Via Felice Matteucci, 2 0127 Florence, Italy T +39 0 423 211 F +39 0 423 2800 customer.service.center@ge.com Nuovo Pignone S.p.A. Nuovo Pignone S.r.l. GE Oil & Gas 4424 West Sam Houston Parkway North Houston, Texas 77018 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. GE, the GE Monogram, and imagination at work are registered trademarks of the General Electric Company. 2016 General Electric Company. All Rights Reserved. GE_DSeries_brochure-112216