CENTRIFUGAL COMPRESSORSFOR PROCESS GASES

CENTRIFUGAL COMPRESSORSFOR PROCESS GASES

A Member of KNM Group Berhad

BORSIG ZM Compression GmbH

BORSIG ZM Compression GmbH is a member of the BORSIG Group, whose headquarter is

based in Berlin. The BORSIG Group offers customised solutions for compressors, pressure

vessels, heat exchangers, membrane technology, as well as comprehensive industrial services.

The compressors and compressor units are manufactured in Meerane/Saxony.

Meerane is situated in the centre of the economic area of Leipzig, Chemnitz and Zwickau –

which is well known as birth place of the composer Robert Schumann and the beginning of auto-

mobile industry in Saxony – in the highly industrialized German State of Saxony and has been

developing as a modern and efficient business location over the past few years.

Our experience is based on more than 170 years of company history. The resulting com-

petence enables us to successfully master all economic, technical and social challenges both

today and in the future.

BORSIG ZM manufactures centrifugal compressors for process gases for almost 50 years. The

BORSIG ZM “T-Jet” series comprises one- to four-stage integrally geared centrifugal com-

pressors which comply with the corresponding API design standards, such as API 617, API 672,

API 614.

BORSIG ZM Compression GmbH – innovative solutions, state-of-the-art technology, perfectly

trained specialists and comprehensive know-how are the basis for our position as a “single

source” supplier of leading technology.

BORSIG ZM Compression GmbH – your capable partner for the future.

Typical fields of application:

- Chemical and petrochemical plants

- Oil and gas industry

- Refinery plants

- Fuel gas delivery for gas turbine plants

- Various industrial processes

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Integrally Geared Centrifugal Compressors for Process Gases

Pressure ratio: 1.4 … 15; max. 4-stages

Capacity / flow1): 1,100 … 40,000 m³/h

Power1): 100 … 12,000 kW

1) referring to atmospheric conditions and air

Performance Range

The Impeller is the heart of the centrifugal compressor stage.

Impellers with backwards curved blades develop a considerab-

ly higher static pressure than impellers with radial blades. The

residual kinetic energy (moderate exit velocity) is converted into

additional pressure by a long parallel-wall diffuser and a pre-

cisely calculated volute channel. This results in high efficiencies.

The BORSIG ZM impellers are open types and designed with

highly sophisticated CFD tools and are able to reach a very high

efficiency.

Special materials for the impellers and volutes e.g. Stainless

Steel or Titanium, guarantee that the requirements of the pro-

cess industry will be met.

Impeller

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Control Performance Range

a) 1 IGV at stage 1

b) 4 IGV´s

c) speed variation

surge flow … % (surge flow …% Overload:

of design flow at turndown) …% of design flow

a) 64% 36% 104%

b) 60% 40% 107%

c) 69% 61% 112%

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The adjustable inlet guide vane device enables a stepless modification of the

volume flow.

The volume flow can be changed in a range from 60% to 115%. By the con-

struction of BORSIG ZM’s inlet guide vane, over the complete control range an

excellent efficiency can be accomplished.

The inlet guide vane is controlled by means of an electrical or pneumatically

driven shifting device. Furthermore the flow control is realized by speed variation

of the turbo drive.

Depending on the process requirements, the volute casing is cast in ductile iron,

cast iron or stainless steel. Special materials are possible, too.

It is designed with the newest techniques of aerodynamics in association with

CAD-tools and FEM. In accordance with the inlet guide vane and the impeller

highest levels of efficiency are reached.

Inlet Guide Vane/Volute Casing

State-of-the-Art Technology

Compact skid design

Effective inlet

guide vane

Aerodynamically shaped volute

Three-dimensionally curved impeller,

high efficiency

Stable gear with axial limitation by thrust collar

Sealing system

optimised according to process

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Drive / Gearbox

The drive unit of BORSIG ZM’s centrifugal compressors basi-

cally consists of electric motor, coupling and gearbox.

The gearbox is used to enable the required speed levels as well

as a multistage compressor design. It is a helical spur gear. The

axial forces of the compressor impeller and of the helical gea-

ring are transmitted via thrust collars at the gear to the driving

wheel and absorbed at lower rotational frequencies by the

impellent shaft. The bearing of the gear shafts is effected by

plain tilting pad bearings.

The oil supply of the bearings and the toothing is realized by a

pressure lubrication. The lubricating oil may be cooled alter-

natively by means of an oil/water cooler or oil/air cooler.

Oil System API 614 -Manufacturer´s Standard

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The oil supply system of BORSIG ZM’s centrifugal compressors

is designed either integrally with the base frame or as an in-

dependent system.

An integral oil system is characterized by a compact design of

the complete unit and will be delivered completely assembled.

Compared with this, the location of an independent system is

not predetermined which enables a better integration into

existing plants.

BORSIG ZM uses only high-quality and reliable components for

its oil supply systems and so achieves a high reliability which

may be further increased by means of main components.

The design of BORSIG ZM’s oil supply systems complies with a

range of standards, such as API 614.

Dry gas seals

Integrally geared compressors are high speed machines. The sealing of the compression

chamber towards the atmosphere is a matter of importance. In particular, when toxic or

explosive media are compressed, this sealing serves as protection from danger to life. Dry

gas seals are designed for special application and are adapted to the various process con-

ditions. There are appropriate sealing types available for the different requests and condi-

tions, such as:

Single seals:

Used in Air-, Nitrogen- or CO2-Compressors. Leakage towards the atmosphere is harm-

less. The radial shaft sealing protects the dry gas seal. To be connected to the flare or for

venting purposes, this sealing type can also be used as zero-emission model.

Tandem sealing with intermediate labyrinth:

This type is particularly recommended when leakage towards the atmosphere as well as

product contamination by sealing gases are not allowed. The process gases are toxic and/

or explosive. The gas pressure is relieved via the seal ring pair which is mounted on the

gas side. The entire leakage is discharged via the flare connection. The atmosphere side

sealing is pressurised under Nitrogen or air. The pressure of the sealing gas has to ensu-

re that the flow goes via the labyrinth to the flare. Thus, the process gas cannot get to the

atmosphere side pair of sealing rings.

Monitoring:

Each sealing is equipped with a monitoring system which controls the supply of purge gas,

sealing gas and separating gas. It also monitors the leakage gas. The monitoring system

is adapted to the specified statutory orders on hazardous incidents and to the safety requi-

rements of the operator.

Sealing and Supply System

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purgegas purgegas processgasflare flare

BORSIG ZM provides state-of-the art solutions for instrumentation according to national

and international standards.

The instrumentation devices follow a high safety standard and are available worldwide to

an advanced standard with application using high quality techniques. These requirements

are continuously controlled and adapted according to customer demands and along with

new developments.

BORSIG ZM provides centrifugal compressor units customized with field instrumentation

wired to junction boxes and machine monitoring / control systems installed in a unit con-

trol panel. For local operations, a local operating panel with start / stop buttons for com-

pressor and auxiliaries, signal lamps, ESD-button etc is provided.

Safety-relevant operating data such as oil pressure, oil temperature, bearing temperature,

vibrations and various process measurements are controlled, analysed and recorded. In

addition, the control system includes an anti surge control or a separate anti surge con-

troller as loose supply is provided.

The integration of the control system into a control centre will be realized in cooperation

with the customer.

Process Measuring and Control Technology

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BORSIG ZM’s Quality Management System is certified accor-

ding to DIN EN ISO 9001:2000.

In order to comply with the high quality demands made by

clients, BORSIG ZM has successfully undergone further certifi-

cation processes such as DIN EN ISO 14001- Environmental

Management Systems and the SCC (Safety Certificate

Contractors) for its service department.

A high product quality level is guaranteed when competent engi-

neer performance goes hand-in-hand with state of the art pro-

duction processes and a complete chain of quality control.

BORSIG ZM applies modern portable measurement techniques

such as FARO laser tracker, scanner, index arm etc.

The work of the Quality Assurance Team is based on appropri-

ate testing schedules, measurement equipment administration

and is linked to the production, planning and control system

(PPS). The team runs its tests and checkups completely inde-

pendent of manufacturing and production control. It guarantees

the compliance of processed material, manufactured compo-

nents, equipment, products and services in accordance with the

requirements of national and international standards, with regu-

latory and contractual requirements, and also with BORSIG

rules and policies.

As a leading manufacturer of compressors, BORSIG ZM offers

a comprehensive service from one source.

Quality

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The After Sales Service takes care of your concerns, whether you require service for a

BORSIG ZM product or for compressors made by other manufacturers. Competence

based on long-term experience in the field of compression and the high quality of the

services, BORSIG ZM offers the partner on which you can depend.

BORSIG ZM’s products are known worldwide for their reliability even under difficult con-

ditions. In order to keep this brilliant availability, a broad service is offered for various

types and ranges of compressor application systems.

BORSIG ZM provides its support throughout from the erection and commissioning of the

machine and equipment up to the point of revamp and remodelling based on its engi-

neering. To keep the system availability at a high level, a comprehensive maintenance

service is provided.

In emergency cases you can rely on prompt assistance by BORSIG ZM’s service staff.

A short-term supply of spare parts subject to high quality standards guarantees a mini-

mal downtime for your compressor.

Service

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BORSIG ZM Compression GmbH

Seiferitzer Allee 26

D-08393 Meerane/Germany

Phone +49 (0) 3764 / 5390-0 Fax +49 (0) 3764 / 5390-5090

E-mail info@zm.borsig.de http://www.borsig.de