Peter Brotherhood Ltd

CompressorsAP1 618 Reciprocating Gas

solutionsWorld class engineering Peter Brotherhood Ltd has been designing and

manufacturing precision engineered machinery since 1867. The company’sexpertise covers a wide range of industries and Peter Brotherhoodequipment is operating in more than 100 countries around the world.

The company combine world-class skills in design and manufacture withpractical industry experience to provide technically-sound and cost-effectiveengineering.

Brotherhood Process & Energy specialise in the design and manufacture ofAP1 618 reciprocating gas compressors as complete packages incorporatingthe prime mover, gas processing plant, instrumentation and controls.

The company’s experience covers a wide range of gas mixtures, includingcorrosive and hazardous gases. The company has worked with customers inthe oil and gas industry both offshore and onshore throughout the world.

Peter Brotherhood accept total engineering co-ordination and projectmanagement on every contract undertaken. Highly experienced engineersprovide comprehensive services from design through to on sitecommissioning, as well as after sales support and on-site maintenance.

Frame 2D1 gas compressor, supplied to Fluor Daniel

Reciprocating Compressors

Frame Data

Peter Brotherhood reciprocating gas compressorsare designed and manufactured to comply with the latest edition of API 618.They are designed to operate at slow to medium running speeds withvariable 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 criteriaARM (Availability, Reliability and Maintainability). This ensures that, duringthe 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 yearsuninterrupted operation between overhauls, thus providing maximumreliability. Particular attention is also paid to maintainability. All standardcomponents have been developed over the years with ease of maintenancebeing one of the main design criteria.

Reciprocating compressors are well suited to a wide range of offshore andonshore applications. They offer benefits of economy in terms of both lowcapital cost and low power consumption at full and part load operatingconditions. The reciprocating design provides inherently flexible capacitycontrol and the ability to handle ‘off design’ gas conditions, providing anassurance of economy and reliability over a wide operating envelope.

The reciprocating compressor is also inherently quieter than fixed capacityrotating machines and is simple and economical to maintain, with procedures that are easily understood by operating personnel.

Peter Brotherhood gas compressors are rated for piston rodloads 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 pistonspeed of 4.6 m/s for machines with lubricated cylinders and 3.6 m/s formachines with non-lubricated cylinders.

The company has developed a number of compressor frame sizes to coverall 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.

compressors

Frame 4D3+R gascompressor installed at Dalian Petrochemical plant in China

This frame 4B2 gas compressor, mounted onconcrete foundations, is one of two machinessupplied to a refinery in Thailand

Frame *M *A B D E F

Number of cranks

Maximum absorbedshaft power

Maximum speedlubricated

Maximum speednon-lubricated

- 1-2 1-6 1-6 2-6 2-6 2-6

kW 1,800 3,500 6,500 11,500 20,000 34,000

rpm 1,000* 750* 560 450 375 327

rpm 800* 600 450 360 300 260

* 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.

designCompressor Design

Reliability

Research & Development

Peter Brotherhood reciprocating gas compressors are designedspecifically for handling a wide range of process gases. Machines for this typeof 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 gascompressors derived from machines originally designed for air compression.These all add to safety and reliability and lower the ‘life-time’ cost ofpurchasing, installing and operating the compressor.

This design approach ensures that all Peter Brotherhood reciprocatingcompressors can match the exacting requirements of the API 618 standard.

The company remains at the forefront of compressor technology and investheavily to allow customers to benefit from new materials and components.

Reliability is being improved with the use of materials such as PTFE, which isnow used to extend the life of piston rings, and ceramic coatings to reducewear on piston rods. Efficiency is being improved through better design ofvalves. Power saving control systems are based on control of suction valvesto save power when the load changes.

Although Peter Brotherhood utilise standard, service-proven componentsand designs to the fullest possible extent, each individual compressor istailored to meet a customer’s precise requirements.

The compressor design team combines decades ofpractical experience with the latest computer technology to speed up andenhance the process, ensuring that the most effective design is produced.

CAD/CAM, finite element analysis (linear, non-linear and multi-physics), pipingstress analysis and an advanced process simulation package are just some ofthe tools used to optimise the compressor design. The company’s designsystem performs rating and sizing calculations to ensure the most economicsizing 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 inservices over many years, allows the company to design using ‘virtual mastermodel’ approach. Designs are continuously optimised to improve bothproduct capability and reliability. This methodology minimises the time takento implement new developments and maximises Peter Brotherhood’sresponsiveness to customer needs.

CAD model of a 4D3 gas compressor

Frame 4D3 gascompressorduring assembly

Frame 2A1reciprocating gascompressor for a UK oil refinery

refining

Brotherhood Process & Energy have supplied compressors tomany different refineries and process plants around the world. They are usedin a wide range of processes and for production of a variety of substances including:

In 1990 Brotherhood Process & Energy designed and manufactured 14reciprocating gas compressors for Mossel Bay GTL Onshore Project in SouthAfrica. The gas to liquid process plant required 14 compressors up to 1.4 MW to compress hydrogen and hydrogen with hydrocarbons in a highlycorrosive marine environment. More recently Foster Wheeler has purchased2 more units to recycle hydrogen gas through the hydrogenation reactor.

A number of Chinese refineries are investing in a new hydrofining capacity tomeet customer demand for lower-sulphur fuels. Brotherhood Process &Energy have supplied a number of compressors to China. Each package isbased around what appears to be a typical four-cylinder reciprocatingcompressor, but two cylinders of each machine handle hydrogen make-up gaswhilst the other two simultaneously handle recycling gas for diesel fuelhydrofining. The compressors range up to a maximum of 3.8 MW.

Lukoil, a Russian oil company, needed to upgrade the Volgograd refinery toproduce ‘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 (anorder worth more than £8 million) to supply 9 reciprocating gascompressors ranging up to 1.7 MW each with their own drive motor, controlpanel and oil and water systems.

● Crude distillation ● Naptha treatment ● Hydrocracking ● Residual desulphurisation● Hydrodesulphurisation ● Resid refining● Isomerisation

Refining Experience

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

3.8 MW reciprocating gas compressor for Changling Oil Refinery

490 kW compressor for Lukoil

Frame 4B2 reciprocating gas compressor for South Africa

petrochemPetrochemical Experience

● Aromatics ● MTBE● Butane ● Olefins● Ethanol ● Oxo-alcohol● Ethylene ● Syngas● HDPE ● Urea● LLDPE ● 2-ethyl hexanol● Methanol

Brotherhood Process & Energy have suppliedcompressors to many different petrochemical plants around the world.They are used in a wide range of processes and for production of a varietyof substances including:

Sastech Engineering, a division of Sasol Technology, required a compressorcompany that could deliver a cost effective option of providing compressedhydrogen for an eighteen month period and ensure the compressor wasflexible enough to be used on other processes after this period. They turnedto Brotherhood Process & Energy to provide a reciprocating gas compressor.The compressor is fed by hydrogen, which used to be flared. The recoveredgas is firstly cleaned by scrubbers then piped to the compressor. This raisesthe pressure to match the Sasol Hydrogen gas network system which feedsthe 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 biggestcompressors of its type installed in South Africa.

Brotherhood Process & Energy have supplied four reciprocating gascompressors to Nanjing Petrochemical Plant in China to boost and recyclehydrogen. The four reciprocating compressors are non-lubricated and skidmounted with pulsation vessels and have a combined safe area control panelwith programmable logic controller (PLC). The system also incorporatesknock-out pots, local gauge board and 580 kW and 150 kW drive motorswith a Bently Nevada 3500 system.

Two frame 4A3 reciprocating gas compressors (865 kW and 430 kW) havebeen installed at ICI Wilton on the ethylene liquefaction plant, North Tees

site. The compressors were replacement flash gasunits packaged to client

specifications using a speciallydesigned lifting beam to allow

partial assembly of the compressors before installation.

Frame 4D3 reciprocating gascompressor for Sasol Technology South Africa

One of two Frame IMHI, 150 kWreciprocating gas compressors for China

gas processing

Brotherhood Process & Energy has experience in the following gas processes:

● Boil-off Gas ● Gas to Gasoline● Carbon Dioxide ● Gas Transport● Carbon Monoxide ● Gas Treatment - ‘Selexol’● Ethylene Storage ● Helium Production● Flare Gas Recovery ● LNG● Gas Injection ● Oxygen Production● Gas Lift ● Special Process● Gas Processing ● Synthesis Gas

Two Brotherhood compressors were supplied to Air Products for a gasblending station at Rozenburg in the Netherlands. The compressors boostthe pressure of the incoming nitrogen from 17.8 bara to 72.2 bara and aredriven by 1,050 kW electric motors.

The gas processing facilities at the British Gas liquefied natural gas (LNG)terminals at Dynevor Arms and Avonmouth in the UK use the Selexolprocess to remove CO2 and other impurities from the gas before it is storedin tanks. British Gas selected two-stage, two-crank compressors fromBrotherhood Process & Energy to undertake gas compression as part of the process.

The Chiyoda Corporation in Japan have 3 reciprocating gas compressorsinstalled in Oman that are used to feed pre-treated or regeneration gas intothe process train. This LNG is reprocessed to improve its purity and theoverall efficiency of the system. Each machine produces approximately 3.3million tons per year and operates at a power of 400 kW.

Gas Processing / Fuel Gas Booster Experience

Frame 2D2 reciprocatinggas compressor for Air Products

Reciprocating compressor for British Gas

925 kW compressor for KNPC

A 925 kW reciprocating gascompressor has been installed in agas processing plant in Kuwait.Sour and corrosive gases are beingcompressed in a special process.The 2B1 compressor has stainlesssteel cylinders and vessels.

offshoreOffshore / FPSO Experience

● Fuel gas boosting● Gas export● Gas handling● Gas lifting● Gas re-injection● Gas storage● Gas treatment● Vapour recovery

1,850 kW reciprocating gascompressor for Chevron Petroleum

A 205 kW fuel gas reciprocatingpackage incorporating a frame 2A2 fuel gas compressor for the Shell Auk Alpha oil platform

The Jabiru Venture FPSO vessel, which has two frame 2B2 gas compressors and a steam turbine installed onboard

Brotherhood Process & Energy has extensiveexperience of working with customers in oil and gas industries offshore.The company has supplied compressors for a wide range of differentapplications including:

Brotherhood Process & Energy supplied Amoco with a vapour recovery gascompressor for the Central Area Transmission System (CATS), one of theUK’s biggest undersea pipeline projects. The compressor takes natural gas,which would otherwise be flared, and re-injects it into the process stream tomain compressors in the North Everest field. The 150 kW system operatesat 64 bara.

Two reciprocating gas compressors were supplied to BHP Petroleum inAustralia for installation in the Jabiru Venture, a floating production, storageand off-loading (FPSO) facility producing oil in the Timor Sea off NorthernAustralia. The two identical reciprocating gas compressors deliver natural gasup to 140 bara. The compressors are each driven by a 630 kW electricmotor. In addition to the compressors Brotherhood Process & Energysupplied a 2.2 MW steam turbine.

A 120 tonne compressor package was supplied to Shell Auk Alpha oilplatform in the North Sea. It was built on a large underbase which was thenattached to the platform as a cantilevered deck unit. In addition to a two-stage reciprocating gas compressor the module incorporates a fuel gastreatment unit to cool the gas and then filter and dry it. Overall the packagemeasures 14 metres in length, 7 metres in width and 5 metres in height.

150 kW compressor for Amoco

packages

Peter Brotherhood can design and install a wide range ofauxiliary equipment on compressor packages, including:

● 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 thecontractor 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.

Packages are tailor-made to the customer’s specification

Compressor Packages

A gas compressor driven by a gas engine - part ofa complete package supplied to the Heeraplatform in the Bombay High natural gas field inthe Indian Ocean

Frame 2B1 + BL installed at Mobil’s Coryton refinery

230 kW reciprocating gas compressor packaged for ShellCarrington, UK

● Forced lubrication systems and water consoles complying with API 618 standards.

● Capacity control systems including suction valve unloaders, volumeclearance 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 companyoffers both digital and analogue computer analysis

of the acoustic and mechanical interaction of the vessels andassociated 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 liquiddisposal systems.

● Separators and heat exchangers (free-standing or in-line) designed and constructed in accordance with customer specifications andrecognised codes, including British Standard, ASME, Stoomwezen,TEMA, etc.

compressoSection through a typical compressor

Connecting rods & bolts Crosshead Piston, piston rod & hydraulic nut attachment

10 Suction Valve Unloader11 Cylinder Valve12 Piston13 Crankshaft14 Balance Weight15 Piston Rod Nut16 Intermediate Packing17 Piston Rod Packing18 Piston & Bearing Rings19 Cylinder

1 Distance Piece2 Piston Rod3 Piston Rod Oil

Wiper Packing4 Crosshead5 Explosion Relief Valve6 Connecting Rod Bolt7 White Metal Bearing8 Crankcase & Distance Piece9 Connecting Rod

Key

1 2 3 4 5 6 7 8 9

13141516171819

Piston, rod packing

or

components

Cast Iron cylinder Forged cylinder

Piston, & bearer rings

Piston rods are generously proportioned and have rolled threads asstandard to give the maximum possible fatigue strength. They aremanufactured from various materials depending on the service, ranging fromAISI 4140 to 17/4 PH, and are flame or induction hardened to a minimum of50 HRC in the packing areas. For more arduous duties they can be hardcoated with a variety of materials using high velocity surface coatingtechniques with give a typical hardness of 70 HRC.

All crossheads are manufactured from cast steel for maximum strength andhave separable shim adjustable slippers with white metal rubbing faces. Eachslipper is separately force lubricated through the distance piece, to ensurenegligible wear.

Connecting rods are machined from high tensile drop forgings, designed formaximum strength and minimum weight. Lubricating oil is pressure fed tothe small end bearing via a bored hole through the centre of the connectingrod shank.

The cylinder valves are generally of the Hoerbiger design. Valves aremanufactured from carbon steel as standard, with stainless and other alloysteels offered as options. The plates can either be either metallic or non-metallic. All the design parameters, such as valve lift and spring rates, areindividually calculated to give the optimum valve performance for thespecified duties.

Pistons are individually designed to meet the specified process requirements.They can be cast, forged or fabricated in materials selected to suit theprocess conditions. Where aluminium piston are used, to give optimumbalance, they are hard anodised over the entire outer surface.

In line with the latest compressor technology, the company has designed ahydraulically actuated piston rod nut which is primarily for the crossheadend but can be used at the piston end. It ensures that any operator, usingsimple hydraulic tools, can ensure a pre-tension accuracy and repeatability ofbetter than 5 per cent.

The selection of the correct materials for the wearing parts is critical.Materials are selected on the basis of experience to achieve the maximumperiod between changes of the internal components. Where particularlyhazardous gases are involved, the latest techniques for minimising leakage areutilised. Packing case materials are selected depending on the process gasbeing compressed. Packings may be cooled if the pressures and temperaturesrequire it.

Cylinders are individually designed to meet the specified processrequirements and are not just selected from a ‘standard’ range to give thenearest option. They can be supplied in grey cast iron, SNG, cast steel, caststainless steel, forged steel or more exotic materials depending on theprocess gas conditions and operating pressures.

19

12

2

4

15

11

17

9

10

1112

Cylinder valves

Peter Brotherhood Ltd

Specialists in the design and manufacture ofequipment to meet the needs of the processand energy industries.

Reciprocating gas compressors are supplied aspackaged units incorporating the prime mover,gas processing plant, instrumentation andcontrols. The company has produced gascompressor packages which help refinery,petrochemical and offshore installationsprotect the environment.

Peter Brotherhoods experience covers a widerange of gas mixtures, including corrosive andhazardous gases. The company has worked withcustomers in the oil and gas industries bothoffshore and onshore throughout the world.

In addition to reciprocating gas compressors,the company also specialises in the design andmanufacture of steam turbines, packaged CHPsystems, special purpose machinery andgearboxes.

In all its activities, from design tocommissioning, Peter Brotherhood works toISO 9001:2000 quality assurance standard and ISO 14001:2004 environmental management standard.

Brotherhood Process & Energy

Peter Brotherhood LtdWerrington ParkwayPeterborough PE4 5HGUnited Kingdom

Telephone: +44 (0)1733 292200Fax: +44 (0)1733 292300E-mail: sales@peterbrotherhood.co.ukWebsite: www.peterbrotherhood.co.uk

Peter Brotherhood Southern Africa (Pty) LtdPO Box 1819Halfway House1685 MidrandSouth Africa

Telephone & Fax: +27 (0)11 805 2850E-mail: linton.lake@xsinet.co.za

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Brotherhood Process & EnergyA business unit of