GE Oil & Gas - Cobey

1 Reciprocating CompressorsGE Oil & GasPerformance, reliabilityand 618 Design4 API 618 Features 6 API 11P High Speed Reciprocating Compressors14 Packaged Pre-assembled Units16 Inspection and Testing16 Quality Assurance17 Research and Development17 Global Services18 Training19 Applications20 Frame Ratings22 IntroductionThe current range of GE reciprocating compressors is backed by a full century ofexperience. In addition to the original Nuovo Pignone product line, designed andmanufactured in Florence, Italy, the GE product portfolio also includes machines thatbegan as the Gemini brand of high speed reciprocating compressors, currently built inOshkosh, Wisconsin, , GE is a world-leading manufacturer, with a complete line of technologicallyadvanced and work-proven API 618 and API 11P machines. Over 20,000 reciprocatingcompressors have been installed worldwide, wherever reliability and long life are essentialto business success. Process applications include refineries, petrochemicals, fertilizers,LDPE, boil-off, refrigeration, and air.

2 Natural gas applications include wellhead gasgathering, vapor recovery, gas re-injection, gas lift , pipeline gas transmission, gasstorage, and fuel gas , the API 618 compression systems are engineered and offered directly by GE sOil & Gas business, while high-speed API 11P units are available through a network ofauthorized packagers and distributors that provide complete cost-effectivecompression packages including a driver (often a direct coupled reciprocating gasengine) and all necessary auxiliaries. The success of the current generation of process compressors is the result of constanttechnological innovation that draws on the global resources and unmatched experience ofGE. For example, an ethylene hyper-compressor rated for continuous duty with deliverypressure of up to 3500 bar requires the rigorous application of both modern designtools and proven product experience. These capabilities and technologies are employedthroughout our lines of reciprocating compressors to provide greater efficiency, reliability,and safety.

3 The modular construction of GE reciprocating compressors is based on the use ofstandardized, well proven components. Ease of maintenance is one benefit , fullcustomization at a reasonable cost is another. Our compressors are designed andmanufactured using the Six-Sigma Quality system to deliver products with the highestlevel of performance, reliability and availability. All of our reciprocating compressorsare backed by GE s Oil & Gas Global Services operation, which has a staff of expertsthat can provide installation, start-up and maintenance services anywhere in the 618 DesignPulsation BottlesPneumatic Valve Unloaders forCapacity ControlMain Oil PumpBearingsConnecting Rod(Die Forged Steel)Oil Wiper PackingPiston RodRod PackingPistonCylinder ValveCast CylinderForged CylinderDistance PieceBallast for Balancingof Inertia ForcesSliding BodyCrosshead(Steel)Crankshaft(Forged Steel) crankcase (Cast Iron)Counterweightfor Balancing6 CrankcaseThe compressor crankcases are single piece cast iron medium and high power frames and 4 or 6 cylinder small powerframes are equipped with tight-tolerance transverse spacers, fittedabove the bearing housings between the two sides of the solution creates an extremely stiff, closed body, with an evendistribution of stresses and strains.

4 Large openings are provided inthe crankcases, to cut the time and cost of maintenance ExtensionsCrosshead extensions are made of cast iron and machined toexacting tolerances, to ensure optimum alignment of crosshead,cylinders and piston assemblies. The crosshead extensions areintegral with the crankcase for the small OA, OC, HA, HB and all highspeed models, while in larger frames they are separate crankshafts are single-piece steel forgings. All feature balancingcounterweights to minimize free inertia forces and of high-speed machines are integral with theshaft , while others are 618 FeaturesCrosshead extension before assembly on working extensions of HF crankcase with transverse spacers in design AI-Sn (Aluminum-Tin) bi-metallic main and bigend bearings are standard on all machines. They feature a muchhigher load capacity than the older tri-metallic bearings and donot require any adjustment at installation. The traditional centralcircumferential groove is replaced by two oil feeders positionedat 90 degrees with respect to the area where the maximum pinload occurs.

5 The main bearings are split in the vertical plane torelieve the most heavily loaded area of surface discontinuities,increasing load capability and reliability still can be replaced without removing the shaft: big endand frame main bearings are identical in all machines with anopen top rodThe connecting rods are made of die-forged steel. Small endbushings are of the tri-metallic type (steel shell, leaded bronzelayer, galvanic white metal flash). An internal axial channel throughthe rod ensures reliable lubrication at both big and small ends. CrossheadCrossheads are made of steel and equipped with amply-sizedreplaceable shoes. Specific loads are kept to a minimum, resultingin an extremely high working life. Shoes are completely machine-finished and interchangeable. They do not require any manualadjustment or bearing split in the vertical small-end 618 Features78 Hydraulic tightening devicesDepending on machine size, the main threaded connections (pistonto piston rod, piston rod to crosshead, connecting rod to big end tierods, frame crosspieces, anchor bolts, high pressure cylinder bolting)are hydraulically tightened.

6 This method has many advantagesincluding simple and safe operation, the highest resistance toloosening, simultaneous tightening of parallel tie rods,repeatability, and the absence of secondary bending or torsioneffects on pieceAll compressors are equipped with distance pieces between thecrankcase and the cylinders. The distance pieces are available inmany different configurations, among them single or double,pressurized or purged with inert gas, and vented to theatmosphere. The optimum configuration is selected inaccordance with the process needs and Customer lubricationThe crank gear is lubricated by a forced feed system. A mainmechanical pump driven by the compressor shaft and an auxiliaryelectric pump with similar flow are standard. On request , twinelectric motor driven pumps may be supplied. All lube oil filters areof the twin type with changeover valve, to allow filter maintenanceduring machine operation. Standard lube oil coolers are single,shell and tube; once again a twin arrangement or different typesof coolers may be supplied on request.

7 API 618 FeaturesHigher safety & reliability. Connecting rod hydraulic oil cylindersThe cylinders are designed to achieve the highest materials are cast iron, nodular cast iron, cast steeland forged steel to accommodate pressure and processrequirements. Key features include: Ability to house different types of valves for maximum efficiencyand life of valve internals. Wide gas passages to minimize pressure drop. Optimization of cooling passages to reduce thermal stressand distortion, and to control operating temperature. Replaceable liners, in a wide range of materials, for specificapplications. Cylinder valvesGE s proprietary valves are designed to hold power losses to aminimum, while ensuring the longest possible life for internalparts. PEEK is the standard material for rings up to 350 bar. Fingeror plug type valve unloaders are available on request . A dynamicsimulation of the behavior of cylinder valve rings is carried outfor each application; it takes into account all aspects of workingconditions, including piping pressure pulsations when required.

8 Theresults of this simulation provide direction for final valve trimming;a complete range of standard interchangeable valve internals isavailable for this steel cylinder before assembly of bore cylinder during 618 FeaturesSuction valve valve components includingPEEK rings and finger 618 Features10 Cylinder lube oil console divider block typewith a large capacity compartment piston rod packing with nitrogen rod packing and piston sealing elementsA complete range of state-of-the-art materials, including PEEK, isavailable to ensure the best performance under any condition,including non-lube applications or extremely high working packings above 25 bar and all non-lubricated packingsare cooled. Packing cups are made of stainless steel. The packingassembly may be configured with one or two gas recovery linesor with inert or sweet gas purging. A zero-leakage arrangementis available on request . Pistons are equipped with plastic rings and rider bands, usuallyof the same material used for the packing rings.

9 The proprietarydesign rider band grooves are eccentric with respect to the axisof the piston rod, so that there is a higher protrusion of the riderband in the bottom part of the piston. This feature has manyadvantages, among them a greater thickness available for wear,and a lower average rod run-out . Cylinder lubricationThe cylinder bore and stuffing box may be lubricated, mini-lubricated or non-lubricated, according to process needs andCustomer specification. Cylinder lubrication is of the forcedfeed type. Single pump to point , divider block or a combinationof the two systems may be supplied, as MaterialsA wide range of materials is available to suit specific example, compressors can be manufactured in accordancewith NACE standards for use in a sour gas environment . Differenttypes of surface hardening and hard coatings, including tungstencarbide, are available for piston rods and cylinder 618 and controlsProvision for installation of a complete set of control and monitoringinstrumentation (temperature, vibration, displacement etc.)

10 Isstandard on all compressors; pressure indicator taps are providedon all cylinders. Actual instrumentation systems follow Customerspecifications, and may range from single instruments to a completediagnostic system, enabling confident predictive maintenanceof the unit . A proprietary design control panel (SCENETRON ) is also availableon request , as is a wide selection of different step and/or continuouscapacity control systems. Among them are valve unloaders,additional clearance pockets, recycle systems, and variablespeed drivers. A special automatically and continuously operatedadditional clearance pocket has recently been developed tomake possible very precise capacity control with virtually novariation in thermodynamic efficiency. Piston rod drop 618 FeaturesAdvanced technology. Piston rod packing flange with roddrop gas engine driven reciprocatingcompressor for gas lift compressor for gas storage driven byGE PGT5 gas compressor with variable speed manifold screen shot.