Entechmach RPC - Aleksandr Liubimov.pdf

62
7/18/2019 Entechmach RPC - Aleksandr Liubimov.pdf http://slidepdf.com/reader/full/entechmach-rpc-aleksandr-liubimovpdf 1/62 Nitrogen+Syngas 2015 CRU Hilton Bomonti 26.02.2015 Istanbul, Turkey

Transcript of Entechmach RPC - Aleksandr Liubimov.pdf

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Nitrogen+Syngas 2015

CRU

Hilton Bomonti 26.02.2015Istanbul, Turkey

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Aleksandr Liubimov – leading specialist on compressors

Increase of Capacity by 35% andEfficiency Raise of the Technological Air

Centrifugal Compressor 101Jin Ammonia Production

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3

1. About us

2. Experimental and calculation methods

3. Examples of performed works (ammonia production)

3.1 Air compr. item 402 3.3 Syn-gas compr. item 103J3.2 Natural gas compr. item 102J 3.4 Ammonia compr. item 105J

4. Air compressor item 101J

4.1 Original compressor 4.3 1800 t/day Modernization4.2 1700 t/day Modernization 4.4 1950 t/day Modernization

5. Conclusion

Contents

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1 About us

Contents

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1 About us23 years on turbo-compressor market

Improving the efficiency and reliability of the turbo-compressor units - a priority of the company

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1 About usProduction

Manufacture takes place in 4 main production facilities withmodern machine tool equipment

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1 About us

Components and parts for turbo-compressor modernizations aremade on our own production facilities

New machine tools

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2 Experimental and calculationmethods

Contents

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2 Experimental and calculation methods

Good results of turbo-compressor flow part modernizations areachieved by an unique experimental data base.

Experimental method

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2 Experimental and calculation methodsExperimental gasdynamic characteristics of the model stage

0

0.2

0.4

0.6

0.8

1

0.1 0.15 0.2 0.25 0.3 0.35

      η      н  -    2 ,      η

      п      о      л ,

        ψ ,

        Ω ,

        ζ    2  -    4

φr2

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2 Experimental and calculation methodsCFD calculations

3. Choke2. Optimal1. Surge

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3 Examples of performed works(ammonia production)

Contents

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3 Examples of performed works (NH3)Entechmach RPC LLC has successfully completed a number of

compressor modernizations for large-scale ammonia productions.

Natural Gas

item 102J

Ammonia

item 105J

Synthesis Gas

item 103J

К 29

121 1

Air

item 101J

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3.1 Air compressor item 402

Contents

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3.1 Air compressor item 402

3  modernizations are already performed with increased capacity+21% and increased efficiency.

In 2014 – 2015 4 more modernization will be put into operation.

Air compressor item 402 (К1290-121-1)

Turbine

LPC

HPC

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3.1 Air compressor item 402Modernized rotors

LPC

HPC

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3.2 Natural gas compressor item 102J

Contents

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3.2 Natural gas compressor item 102J

3  modernizations are already performed with increased capacity+15% and increased efficiency.

In 2016 1 more modernization is planned to be put into operation.

Natural Gas compressor item 102J

Turbine

HPC

PC

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3.2 Natural gas compressor item 102JAfter the modernization

Turbine HPC

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3.3 Synthesis gas compressor item 103J

Contents

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3.3 Synthesis gas compressor item 103J

3  modernizations are already performed with increased capacity+30% and increased efficiency.

In 2015 1 more modernization will be put into operation.

Synthesis gas compressor item 103J

Turbine LPCPCPC

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3.3 Synthesis gas compressor item 103JModernized MPC and HPC rotors (1750 t/day)

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3.4 Ammonia compressor item 105J

Contents

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3.4 Ammonia compressor item 105J

1 modernization is already performed with increased capacity +30%and increased efficiency.

Ammonia compressor item. 105J

Turbine

PC

LPC

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3.4 Ammonia compressor item 105JThe LPC modernization was done on «Hitachi» (2MCL808+MCL806)

compressor in the existing cases with existing turbine.

TurbinePC

HPC

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4 Air compressor item 101J

Contents

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4.1 Original Compressor

Contents

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4.1 Original Compressor

11  modernizations are already performed with increased capacity+25% and increased efficiency and 1 with increased capacity +35%.

In 2016 2 more modernizations will be put into operation.

Air compressor item 101J

Turbine

LPC

HPC

l

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4.1 Original Compressor

Turbine LPC

HPC

l

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4.1 Original CompressorCompressor scheme

2   1

3 4

LPC

HPC

Turbine

atm.

atm.

O i i l C

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4.1 Original CompressorLPC cross-section

4 1 O i i l C

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4.1 Original CompressorHPC cross-section

C

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4.2 1700 t/day Modernization

Contents

4 2 1700 /d M d i i

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4.2 1700 t/day Modernization

In 2005 Entechmach RPC LLC worked on the 1st  air compressormodernization to raise its capacity to obtain 1700 t/d of ammonia.

8  modernizations are already performed with increased capacity+16% and increased efficiency.

1700 t/day Modernization

NamingHitachi

1360 t/day

Entechmach

1700 t/day

Performance at the discharge at normalconditions Qg, Nm3/h

52000 60500

Discharge pressure pк, kgf/sm2, a. 37,6 35,0

Rotor speed n, rpm: LPC/HPC5250

1070051509967

Overall shaft power Nshaft, kW 10260 11290

4 2 1700 /d M d i i

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4.2 1700 t/day ModernizationDesign features (1700 t/day)

LPC

HPC

4 2 1700 t/d M d i ti

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4.2 1700 t/day ModernizationModernized LPC rotor (1700 t/day)

LPC

4 2 1700 t/d M d i ti

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4.2 1700 t/day ModernizationModernized HPC rotor (1700 t/day)

HPC

HPC

4 2 1700 t/d M d i ti

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4.2 1700 t/day ModernizationThe intermediate cooler sections were changed to new ones with heat

exchange surface increased by 25%.

4 2 1700 t/d M d i ti

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4.2 1700 t/day ModernizationResults, 1800 t/day

Q

g

Capacity

N

 

Shaftpower    +    1    6    %

 

    +    1    0    %

 

C t t

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4.3 1800 t/day Modernization

Contents

4 3 1800 t/d M d i ti

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4.3 1800 t/day Modernization

In 2012 Entechmach RPC LLC worked on the 1st  air compressormodernization to raise its capacity to obtain 1800 t/d of ammonia.

3  modernizations are already performed with increased capacity+21% and increased efficiency.

1800 t/day Modernization

NamingHitachi

1360 t/day

Entechmach

1700 t/day

Entechmach

1800 t/day

Performance at the discharge atnormal conditions Qg, Nm3/h

52000 60500 63000

Discharge pressure pк, kgf/sm2, a. 37,6 35,0 35,0

Rotor speed n, rpm: LPC/HPC5250

1070051509967

520010035

Overall shaft power Nshaft, kW 10260 11290 11290

4 3 1800 t/d M d i ti

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4.3 1800 t/day ModernizationDesign features

LPC

1800 t/day

HPC

1700 t/day

New gearbox couple

New HPC

4 3 1800 t/da Moderni ation

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4.3 1800 t/day ModernizationExperimental data (1800 t/day)

0.65

0.7

0.75

0.8

0.85

120 140 160 180 200 220 240

   П  о  л  и  т  р  о  п  н  ы   й   К   П   Д  η  п  о  л

 

1.6

1.8

2

2.2

2.4

2.6

120 140 160 180 200 220 240

   О  т  н  о  ш  е  н  и  е  д  а  в  л  е  н  и   й  ε

Объемный расход по условиям всасывания Qвс, м3/мин

(2) -  n т

= 5200 об/мин;

(1) - nт = 5300 об/мин; (3) - nт= 5100 об/мин;

(4) - nт= 5000 об/мин;

Начальные условия:  R= 289,0 Дж/(кг·К);  z = 1,0;  k  = 1,4;  t н = 49,0 C

- режим работы по ТЗ

0.55

0.6

0.65

0.7

0.75

0.8

0.85

60 70 80 90 100 110 120

   П  о  л  и  т  р  о  п  н  ы   й   К   П   Д  η  п  о  л

 

1.4

1.6

1.8

2

2.2

2.4

2.6

60 70 80 90 100 110 120

   О  т  н  о  ш  е  н  и  е  д  а  в  л  е  н  и   й  ε

Объемный расход по условиям всасывания Qвс, м3/мин

(2) -  n т

= 5200 об/мин;

(1) - nт = 5300 об/мин; (3) - nт= 5100 об/мин;

(4) - nт= 5000 об/мин;

Начальные условия:  R= 289,0 Дж/(кг·К);  z = 1,0;  k  = 1,42;  t н = 49,0 C

- режим работы по ТЗ

0.65

0.7

0.75

0.8

0.85

0.9

800 900 1000 1100 1200 1300 1400 1500 1600

   П  о  л  и  т  р  о  п  н  ы   й   К   П   Д  η  п  о  л

800 900 1000 1100 1200 1300 1400 1500 1600

 

1.6

2.0

2.4

2.8

3.2

3.6

800 900 1000 1100 1200 1300 1400 1500 1600

   О  т  н  о  ш  е  н  и  е  д  а  в  л  е  н  и   й  ε

Объемный расход по условиям всасывания Q вс, м3/мин

(2) -  n т

= 5150 об/мин;

(1) - nт = 5300 об/мин; (3) - nт= 5000 об/мин;

(4) - nт= 4850 об/мин;

Начальные условия:  R = 289,0 Дж/(кг·К); z = 1,0;  k  = 1,4;  t н = 29,5 C

- режим работы по ТЗ

 

0.65

0.7

0.75

0.8

0.85

0.9

300 350 400 450 500 550 600

   П  о  л  и  т  р  о  п  н  ы   й   К   П   Д  η  п  о  л

 

1.7

1.9

2.1

2.3

2.5

2.7

2.9

3.1

3.3

3.5

300 350 400 450 500 550 600

   О  т  н  о  ш  е  н  и  е  д  а  в  л  е  н  и   й  ε

Объе мный расход по условиям всасыв ания Qвс, м3/мин

(2) -  n т

= 5150 об/мин;

(1) - nт = 5300 об/мин; (3) - nт= 5000 об/мин;

(4) - nт= 4850 об/мин;

Начальные условия:  R= 289,0 Дж/(кг·К); z = 1,0;  k  = 1,401;  t н = 49,0 C

- режимработы по ТЗ

LPC (1700 t/day) HPC (1950 t/day)

4 3 1800 t/day Modernization

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4.3 1800 t/day ModernizationResults, 1800 t/day

Q

g

Capacity

N

 

Shaftpower    +    2    1    %

 

    +    1    0    %

 

Contents

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4.4 1950 t/day Modernization

Contents

4 4 1950 t/day Modernization

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4.4 1950 t/day Modernization

In 2013 Entechmach RPC LLC worked on the 1st  air compressormodernization to raise its capacity to obtain 1950 t/d of ammonia.

1 modernization is already performed with increased capacity +35%and increased efficiency.

1950 t/day Modernization

NamingHitachi

1360 t/day

Entechmach

1700 t/day

Entechmach

1800 t/day

Entechmach

1950 t/day

Performance at the discharge at

normal conditions Qg, Nm

3

/h

52000 60500 63000 70 870

Discharge pressure pк, kgf/sm2, a. 37,6 35,0 35,0 37,4

Rotor speed n, rpm: LPC/HPC5250

1070051509967

520010035

520010035

Overall shaft power Nshaft, kW 10260 11290 11290 13200

4 4 1950 t/day Modernization

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4.4 1950 t/day ModernizationDesign features

LPC

1800 t/day 1950 t/day

HPC

1700 t/day

New gearbox couple

New LPC

4 4 1950 t/day Modernization

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4.4 1950 t/day ModernizationModernized LPC (1950 t/day)

4 4 1950 t/day Modernization

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4.4 1950 t/day ModernizationModernized HPC (1950 t/day)

4 4 1950 t/day Modernization

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4.4 1950 t/day ModernizationGasdynamic calculations (Numeca) 1st stage LPC

4 4 1950 t/day Modernization

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4.4 1950 t/day ModernizationGasdynamic calculations (Numeca) 1st stage LPC

4 4 1950 t/day Modernization

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4.4 1950 t/day ModernizationModernized LPC rotor (1950 t/day)

LPC

4 4 1950 t/day Modernization

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4.4 1950 t/day Modernization1st stage LPC (1950 t/day)

4 4 1950 t/day Modernization

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4.4 1950 t/day ModernizationModernized HPC rotor (1950 t/day)

HPC

4 4 1950 t/day Modernization

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4.4 1950 t/day ModernizationExperimental data (1950 t/day)

Compressor item 101J is tested and shown to be effective close to theproject level.

LPC (1980 t/day) HPC (1980 t/day)

4 4 1950 t/day Modernization

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4.4 1950 t/day ModernizationPolytropic efficiency

Section №  1 2 3 4

Modernized (1980 t/day) 0.83 0.82 0.83 0.82

Modernized (1800 t/day) 0.83 0.81 0.83 0.82

Modernized (1700 t/day) 0.83 0.81 0.77 0.74

Original(1360 t/day) 0.79 0.78 0.76 0.725

LPC HPC

4 4 1950 t/day Modernization

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4.4 1950 t/day Modernization101JT turbine exhaust, 1950 t/day

4 4 1950 t/day Modernization

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4.4 1950 t/day ModernizationResults, 1950 t/day

Q

g

Capacity

N

 

Shaftpower    +    3    5    %

 

    +    2    5    %

 

Contents

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5 Conclusion

Contents

5 Conclusion

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5 ConclusionEntechmach RPC LLC has all the necessary means to perform

work on the compressor modernizationsin ammonia and urea production :

o highly qualified specialists;

o experimental data base;o experience in the design and manufacture of flow parts;o modern software;o own production base;o new high-precision machine tools.

Happy Anniversary!

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Happy Anniversary!Reprintsev Anatoly Ivanovich - 70 years

Chief specialist on compressors

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Thank you for attention!

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188682, RussiaTel./fax +7 (812) 331-16-20