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CENTRIFUGAL COMPRESSORS

COMPETITIVE ADVANTAGES

Scientificandtechnologicalpotential,uniquedesignandprocesssolutionssolutions;

Extensivemanufacturing,engineeringanddesigncapabilities;

Successfulexperienceinlocalizationofadvancedforeigntechnologies;

Productionofmodernenergy-savingturbo-com-pressorequipment;

Unifiedproductionmanagementsystem;

Allstagesofthemanufacturingcycle,fromdesigningtoservicing;

High

reliability

and

operational

readiness

of

the

units;

Automated

manufacturing

techniques;

Improved

environmental

measures.

THE HOLDING ENTERPRISES DESIGN

AND MANUFACTURE

JSC «REP HOLDING» IS A LEADING RUSSIAN POWER ENGINEERING COMPANY,

DESIGNER, MANUFACTURER AND SUPPLIER OF NEW-GENERATION POWER EQUIPMENT.

REP HOLDING

REP HOLDING. KEY COMPETENCE 3

CENTRIFUGAL COMPRESSORS PRODUCED BY REP HOLDING

REP HOLDING DEVELOPS AND MANUFACTURES NEW GENERATION CENTRIFUGAL COMPRESSORS WITH A HIGH-PERFORMANCE FLOW PASSAGE FOR ELECTRICALLY-DRIVEN AND GAS TURBINE GAS-PUMPING UNITS OVER THE POWER RANGE FROM 4,0 TO 32,0 MW.

4 REP HOLDING. CENTRIFUGAL COMPRESSORS

Based on the accumulated design experience REPHoldingdevelopshigh-performanceflowpassagesforcentrifugalcompressorsoverawideoperationrange.Thenewmodelshaveadvantagesover thepreviousgenerationcentrifugalcompressors,especially inthepolytropicefficiencyandcommonalityandstandard-ization of the compressor flow passage componentsandassemblies.

The impellers with 3D blades are developed usingmodels (model test bed). Stages with 3D impellerblades increase essentially the efficiency of the cen-trifugal compressor flow passage. The domestic ad-vanced engineering technologies used in the designof centrifugal compressors enabled REP Holding toprovidehighefficiencyoftheflowpassagesduetoin-creasedpolytropicefficiency.

REPHoldinghasitsownproductionofmagneticbear-ings (under the license from SKF). Active magnetic

bearings are successfully applied not only in electri-cally-drivengas-pumpingunits,butalsooncentrifugalcompressorsaspartsofthegas-pumpingunitsatthegas trunk line facilities and booster compressor sta-tions.

ADVANTAGES OF REP HOLDING COMPRESSORS WITH MAGNETIC BEARINGS:

Operatingcostsreduction;

Increasedservicelifeofthebearingscomparedwithoilones;

Higherefficiencyduetonomechanicallosses;

Feweradditionalequipmentisneeded;

Higherreliability;

Enhancedenvironmentalperformance

According to the program of GPA standardization(PJSC“Gazprom”)REPHoldingcompanyhasdevel-oped and manufactured a standardized centrifugalcompressorratedat16MWandwithpolytropiceffi-ciencynolowerthan87–88%.Standardizationofcen-trifugal compressors consists in the development ofuniversalelementsof the flowpassage,bearingandsealassemblies.Reductionoftheproductiontimeandcostsisoneoftheadvantagesofstandardizedcentrif-ugalcompressors.

VARIETY OF COMPRESSORS

CENTRIFUGAL COMPRESSORS FOR GAS TRANSFER UNIT

REPLACEABLE BUNDLE FOR PEPLACEMENT OF OPERATING

COMPRESSORS

VARIOUS TYPES OF COMPRESSOR PACKAGE CONTENT

REP HOLDING. CENTRIFUGAL COMPRESSORS 5

COMPRESSORS FOR UNDERGROUND GAS

STORAGE

COMPRESSORS FOR COMPESSIONS OF

ASSOCIATED OIL GAS

Replacementofcompessorsthat

reachedtheendoftheirservicelife

ReplacementduetoChangeof

CSMode

ElectricMotorDrive

(GasandSteam)TurbineDrive

Bearings

Oil Magnetic Oil DryGas

Sealings

CENTRIFUGAL COMPRESSORS FOR GAS INDUSTRY

405-21-1С

170-31-1С 300-21-1СМП

220-11-1СМП

200-21-1СМП 400-21-1С

CONFIGURATION

Compressorcasing;

Compressorpackagewithrotor;

Lubricationsystem;

Drysealssystem;

Toolkitforassemblyanddisassemblyofthecompressor;

Compl.setofoilbearings.

Compressor170-31-1СisusedaspartofGPA-4RM-03units and is designed to compress and transmitnatural gas via gas trunk lines. Efficiency – no lessthan0,85.

REP HOLDING. NATURAL GAS CENTRIFUGAL COMPRESSORS 7

TECHNICAL CHARACTERISTICS

Commercialcapacity,MMSCMD

5,25

Finalpressure,abs.,MPa

3,74

Pressureratio 1,7

Compressorrotorspeed,rpm

10300

CENTRIFUGAL COMPRESSOR 170-31-1С

POWER RATING

4 MW

CONFIGURATION

Compressorpackagewithrotor;

Compressorcasing;

Gasdynamicsealssystem(GDS);

Activemagneticbearingsystemfortherotor(compl.setofmagneticbearings)producedunderthelicensefromSKF(S2M);

Confuser,compl.setoftransducerstomeasuregasflowforoperationoftheanti-surgeprotectionsystemandprocessmeasurementoftheCCca-pacitywithanerrornomorethan4%;

Toolkitforassemblyanddisassemblyofthecom-pressor.

CENTRIFUGAL COMPRESSOR 220-11-1СМП

8 REP HOLDING. NATURAL GAS CENTRIFUGAL COMPRESSORS

POWER RATING

4 MW

TECHNICAL CHARACTERISTICS

Commercialcapacity,MMSCMD

1,25

Finalpressure,abs.,MPa

4,41

Pressureratio 1,26

Compressorrotorspeed,rpm

8200

CONFIGURATION

Compressorpackagewithrotor;

Compressorcasing;

Gasdynamicsealssystem(GDS);

Activemagneticbearingsystem(AMB)fortherotor(compl.setofmagneticbearings)producedunderthelicensefromSKF(S2M);

Confuser,compl.setoftransducerstomeasuregasflowforoperationoftheanti-surgeprotectionsys-temandprocessmeasurementoftheCCcapacitywithanerrornomorethan4%;

Toolkitforassemblyanddisassemblyofthecom-pressor.

CENTRIFUGAL COMPRESSOR 200-21-1СМП

REP HOLDING. NATURAL GAS CENTRIFUGAL COMPRESSORS 9

POWER RATING

6,3 MW

TECHNICAL CHARACTERISTICS

Commercialcapacity,MMSCMD

12

Finalpressure,abs.,MPa

5,49

Pressureratio 1,44

Compressorrotorspeed,rpm

8200

CONFIGURATION

Compressorpackagewithrotor;

Compressorcasing;

Gasdynamicsealssystem(GDS);

Activemagneticbearingsystem(AMB)fortherotor(compl.setofmagneticbearings)producedunderthelicensefromSKF(S2M);

Confuser,compl.setoftransducerstomeasuregasflowforoperationoftheanti-surgeprotectionsystemandprocessmeasurementoftheCCca-pacitywithanerrornomorethan4%;

Toolkitforassemblyanddisassemblyofthecompressor.

CENTRIFUGAL COMPRESSOR 300-21-1СМП

10 REP HOLDING. NATURAL GAS CENTRIFUGAL COMPRESSORS

POWER RATING

12,5 MW

TECHNICAL CHARACTERISTICS

Commercialcapacity,MMSCMD

22,1

Finalpressure,abs.,MPa

7,45

Pressureratio 1,5

Compressorrotorspeed,rpm

6500

CENTRIFUGAL COMPRESSOR 405-21-1С

REP HOLDING. NATURAL GAS CENTRIFUGAL COMPRESSORS 11

CONFIGURATION

Compressorpackagewithrotor;

Lubricationsystem;

Drygassealssystem;

Toolkitforassemblyanddisassemblyofthecompressor;

Compl.setofoilbearings.

THE MAIN ADVANTAGES

Commonalityofassembliesandelementsoftheflowpassage;

Efficiency–87,2%;

CompatibilitywithvarioustypesofGTU.

Centrifugalcompressor405-21-1Сisdesignedtotrans-mitgasviagastrunklines.Itscasingisverticallysplit,thecompressorisequippedwithdrygassealsandoilslidingbearings.Thecompressorprovidesapplicationofreplaceableflowpassageswithpressureratio1,35,1,44(1,5)and1,7forfinalpressure9,91MPa.

TECHNICAL CHARACTERISTICS

Commercialcapacity,MMSCMD

33,00

Finalpressure,abs.,MPa

7,45

Pressureratio 1,44

Compressorrotorspeed,rpm

5200

POWER RATING

16 MW

THE MAIN PARAMETER AND DESIGN FEATURES

Efficiencynolessthan0,85;

Pressureratio1,44;

Capacityreferredtotheinitialconditions505m3/min;

Compressorrotorspeed5550rpm;

ApplicationofvariousgeometryflowpassagesprovidinggasflowandcompressionrequiredbytheCustomer;

Applicationofforgedcasingsmakesitpossibletooperateatahigherfinalpressure,longerservicelife;replaceableflowpassagescanbereplacedonsite.

CENTRIFUGAL COMPRESSOR 400-21-1С

12 REP HOLDING. NATURAL GAS CENTRIFUGAL COMPRESSORS

Centrifugalcompressor400-21-1Сisdesignedtotrans-mitgasviagastrunklinesaspartofthegas-pumpingunitratedat32MW.

CONFIGURATION

Compressorcasing;

Compressorpackagewithrotor;

Lubricationsystem;

Drygassealssystem;

Toolkitforassemblyanddisassemblyofthecompressor;

Compl.setofoilbearings.

DELIVERY DESTINATIONS

ThecompressorissuppliedaspartofGPA-32“Lado-ga” to the compressor stations of gas trunk linesandforreconstructionandconstructionofthePJSC“Gazprom”facilities.

POWER RATING

32 MW

TECHNICAL CHARACTERISTICS

Commercialcapacity,MMSCMD

78,9

Finalpressure,abs.,MPa

11,86

Pressureratio 1,4

Compressorrotorspeed,rpm

5550

CENTRIFUGAL COMPRESSORS FOR OIL INDUSTRY

К320-131-1

DELIVERY DESTINATIONS

The equipment is supplied to the facilities of Gaz-prom Neft, LUKOIL, Rosneft, Russneft, SIBURHolding, Surgutneftegaz, Tatneft, TNK-BP Holding,AK“Transneft”,KazMunaiGas.

CENTRIFUGAL COMPRESSOR К320-131-1

14 REP HOLDING. CENTRIFUGAL COMPRESSOR TO COMPRESS OIL-ASSOCIATED GAS

Centrifugal compressor К320-131-1 is designed tocompressoil-associatedgasatgasprocessingplants.

The compressor and all its accessories are explo-sion-proof.Itcanbeoperatedinexplosion-hazardouspremisesofClassВ-1А,withexplosivemixtureof2Т-2categoryandgroup.

Thecompressoristwo-cylinder,two-section,13-stage.The compressor cylinder tightness is provided bymeansofoilendseals.Thelowpressurecylinderhasacaststeelcasinghorizontallysplit.Thehighpressurecylinderhasaforgedbarrel-typecasingwiththeendcover.

Compressor К320-131-1 has been designed for thefoundation dimensions of the К380-103-1 and К354-101-1 units, providing replacement of the old equip-mentatminimumcosts.

TECHNICAL CHARACTERISTICS

Commercialcapacity,MMSCMD

1,16

Finalpressure,abs.,MPa

3,1

Pressureratio 12,4

Compressorrotorspeed,rpm

10800

CENTRIFUGAL COMPRESSORS FOR METALLURGY

K5500-41-1М

DELIVERY DESTINATIONS

ThecompressorequipmentproducedbyREPHoldingis supplied to themetallurgicalplantsandenterpris-esinRussiaandabroad,includingIntegratedIronandSteel Works in Magnitogorsk , Novolipetsk, NizhniyTagil,Severstal,ironandsteelplants,suchasMechel,Evraz, Kazakhmys Corporation (Kazakhstan), Metin-vestGroup(Ukraine),BokaroSteelPlant,BhilaiSteelPlant,DurgapurSteelPlant(India),PaksteelIntegratedIronandSteelWorks(Pakistan)etc.

TECHNICAL CHARACTERISTICS

Commercialcapacity,MMSCMD

5000

Finalpressure,abs.,MPa

0,51

Compressorrotorspeed,rpm

3450

CENTRIFUGAL COMPRESSOR K5500-41-1М

16 REP HOLDING. CENTRIFUGAL COMPRESSORS FOR METALLURGY

Centrifugal compressor К5500-41-1М, with a capac-ity of 5200 m3/min, driven by a heavy-duty steamcondensing turbine rated at 23 MW, is designed tocompress atmospheric air and supply it to the blastfurnace (OJSC “NLMK”). It is incorporated into theТКА-5200/22turbo-compressorunit.

CENTRIFUGAL COMPRESSORS FOR CHEMICAL INDUSTRY

540-41-1

DELIVERY DESTINATIONS

The equipment produced by REP Holding is installedatchemicalindustryfacilities,suchasUnitedChemicalCompany“Shchekinazot”,“Akron”,“Kirovo-ChepetskyChemical IntegratedPlant”,“GrodnoAzot”,“Naftan”,“Nizhnekamskneftekhim”, “Kazanorgsintez”, “Ufaorg-sintez”,“EUROKHIM”,“FOSAGRO”,“Minudobreniya”,“GazpromNeftekhim”.

CENTRIFUGAL COMPRESSOR 540-41-1

18 REP HOLDING. CENTRIFUGAL COMPRESSORS FOR CHEMICAL INDUSTRY

Centrifugalcompressor540-41-1isdesignedtocom-pressnitrousgasintheproductionofweaknitricacid.

CONFIGURATION

Compressorwithabuilt-inturboexpander;

Speedincreaser;

El.motordrive;

Lubricationsystem;

Thermalmonitoring,control,protectionandalarmsystem

TECHNICAL CHARACTERISTICS

Commercialcapacity,MMSCMD

540

Finalpressure,abs.,MPa

0,41

Pressureratio 4,42

Compressorrotorspeed,rpm

8455

DELIVERY DESTINATIONS

The active magnetic bearing system is used as partof electrically-driven gas-pumping unit (EGPA) ratedat 4MW at “GazpromTransgazTomsk” compressorstations, 6,3 MW - at “Gazprom Transgaz Saint Pe-tersburg” compressor stations, “Gazprom TransgazUkhta”, 16 MW - at “Gazprom Transgaz Samara”,“Gazprom Transgaz Belarus”, “Gazprom DobychaNoyabrsk”.

REP HOLDING. ACTIVE MAGNETIC BEARING SYSTEM 19

ACTIVE MAGNETIC BEARING SYSTEM

CONFIGURATION

Bearings;

Electroniccontrolsystem.

ADVANTAGES:

Operatingcostsreduction;

Increasedservicelifeofthebearingassemblies;

Increasedefficiencyduetonomechanicallosses;

Reductioninthequantityoftheadditionalequip-ment;

Higherreliability;

Enhancedenvironmentalperformance.

REPHoldinghassetupatitsfacilitiesitsownproduc-tionofelectricdrivesandmagneticbearingsunderthelicense of SKF (S2M). The innovative production ofcentrifugalcompressorsusingmagneticbearingsanddrygasdynamicsealshasbeenlocalized.

Theactivemagneticbearingsystemprovidescontact-less rotation or the rotor in the controlled magneticfield.

REPLACEABLE FLOW PASSAGES

20 REP HOLDING. REPLACEABLE FLOW PASSAGES

Replaceable flowpassagesaredesigned to renovatetheoperatingcentrifugalcompressors.Thereplacea-ble flowpassagesare installed into theexistingcas-ings,withoutchangingtheoveralldimensionsofthestandardequipment.

REPHoldingproducesreplaceableflowpassageswithvarious design versions of seals (dry gas dynamicseals,oilseals)andbearings (magneticbearings,oilbearings). Up-to-date replaceable flow passages canbedesignedandmanufacturedforinstallationintothecompressorsmadebyotherManufacturers.

TherangeofREPHoldingproductsincludesreplacea-bleflowpassagesforboosterandlinecompressorsta-tions,gasundergroundstoragecompressorstations.

ThereplaceableflowpassagesmadebyREPHoldingundergoafullcycleoftestsatitsowntestingfacilities.

Thefull lifecycleofreplaceableflowpassagesusingactivemagneticbearingsisnolessthan20year.Therepairintervalis50ths.hours.

THE MAIN PARTS OF THE REPLACEABLE FLOW PASSAGES

Package(statorandrotorelementsoftheflowpassage);

Sealassemblies(ifnecessary);

Compl.setofbearings(ifnecessary);

Compl.setofreplacementparts;

Changingpartsandtools.

REP HOLDING. SERVICE MAINTENANCE 21

SERVICE MAINTENANCE

REPHoldingperformsawholepackageofservicesonerectionsupervisionandservicemaintenanceforthewholerangeoftheunitsproduced,includingroutinerepair and overhaul, and training of the Customer’spersonnel.AspecialsubdivisionofREPHoldingpro-videsservicemaintenanceandsupplyofsparepartsforthewholeperiodoftheunitoperation.

HighlyqualifiedspecialistsoftheInstallationandSer-vice Maintenance Department perform installation,pre-commissioningactivities,aswellaswarrantyandpost-warrantyserviceduringthewholelifetimeoftheunits.

ParticipationintheequipmentacceptanceattheCustomer’swarehouse

Erectionsupervision

Pre-commissioning

Stafftraining

Fullpackageofservices

Scheduledpreventiveinspection

Technicalsupervision

Diagnostics

Sparepartssupply

Engineeringsupport

Equipmentupgrade

WARRANTY PERIOD

SERVICE LIFE EXTENSION

POST-WARRANTY PERIOD

TESTING FACILITIES

22 REP HOLDING. TESTING FACILITIES

TheREPHoldingproductionsitesareequippedwithunique high-tech test beds. Mechanical, gas dynam-icand investigationstring testsof theproduced tur-bo-compressorequipmentareperformedatthesetestbeds.

Theproductqualityisassuredandcontrolledinaspe-cialsubdivisionofREPHolding–InterplantMetrology,TestsandInspectionLaboratory.

Thelaboratoryisequippedwithup-to-dateequipmentfromtheleadingforeignManufacturers:

Spectrometer–ARL3460Advantage;

Machinesforsamplepreparation–HerzogVNU300and grinding machine – Herzog HT 350, machinesforexpressanalysisofchemicalcompositionwhenmeltingsteelsandcastironinmeltingfurnaces;

Flawdetector–P920Magnaflux–formagneticpar-ticleinspectionoftherotorpartsandcastingsoftheturbineandcompressorcasingparts;

Equipment produced by Zwick company to deter-mine the mechanical properties of metal (strengthand viscosity) – testing machine Z250 and impacttestingmachineRKP450.

Awide rangeof investigations isperformed in thelaboratory: X-ray flaw detection, chemical, spec-trum, capillary analysis, magnetic particle inspec-tion,ultrasonictesting

Testbedforcentrifugalcompressors

Replaceableflowpassageonthetestbed(upto16МW)

3Dimpellerstestbed Schenkhigh-speedbalancingmachine

Replaceableflowpassageonthetestbed(over16МW)

Testingfacilitiestodefinethemechanicalperformancesforbladesmetal

Testbedforcompressor405-21-1С

DELIVERY DESTINATIONS

REP HOLDING. DELIVERY DESTINATIONS 23

Morethan40regionsofRussia

Morethan20neighboringcountriesandbeyond

Morethan180unitsofdifferenttypesinoperation

JSC “REP Holding”51, Let. AF, Obukhovskoy Oborony pr., Saint-Petersburg, 192029, RussiaTel.: +7 (812) 372 58 80, +7 (812) 372 58 81Fax: +7 (812) 412 64 84www.reph.ru