Download - Reciprocating Compressors

Reciprocating Compressors

T H O M A S S E NC O M P R E S S I O N

S Y S T E M S

TCS

-2-0

8/08

-307

03070 TCS Recip Compres herdruk:v1 13-08-2008 13:53 Pagina 1

2

Design &Engineering

Passion f

Research & Development


3

m o r e t h a n o n e h u n d r e d y e a r s o f

Manufacturing& Testing

Re-rating &Rebuilding

Installation& Servicing

n for Compression

Our founder, Mr Thomassen, first started producing

internal combustion engines more than a hundred

years ago. He soon extended his activities to

include the design and manufacture of reciprocating

compressors. What began as a small, local company

has grown into a major international compressor

supplier, capable of providing world-wide sales and

service support.

Our customers, who are located around the globe,

are engaged in the oil, gas, chemical and refining

industries. Exports currently account for more

than 80% of sales.


Thomassen has an esta-

blished reputation for

providing quality, tailor-

made compression solu-

tions to the oil, gas,

chemical and refining

industries. Our in-depth

knowledge of field pro-

cesses and compressor-related systems enables us to

design, install, maintain and repair all types of recipro-

cating and other compression systems. Moreover, our

broad experience enables us to meet the most

stringent requirements.

R e c i p r o c a t i n g c o m p r e s s o r s .

Thomassen’s heavy-duty reciprocating compressors

have the following design features:

● Rigid construction.

● Easy access, facilitating maintenance.

● Horizontally opposed and balanced cylinder design,

resulting in smooth, vibration-free operation.

● Hydraulic crosshead-to-piston rod and piston

rod-to-piston connections.

● Adjustable crosshead shoes, which are

flat-faced for shimming.

● Open type piston- and rider rings for easy

mounting.

● Pressure relief on rider rings to ensure longer life.

● Rolled threads on all high tensile material bolting.

● Ample valve cross-section and special gas

passages within the cylinders, resulting in a

minimum pressure drop, low power consumption

and low operating costs.

With frame sizes up to 25,800 kW, the Thomassen

C-series reciprocating compressor can accommodate

up to 6 compression cylinders. All components, inclu-

ding the crankcase, crankshaft, bearings, crosshead

body etc., have been designed for maximum strength

and durability.

Our Free Floating Piston™, which, as its name suggests,

floats on process gas, enables us to provide custo-

mers requiring non-lubricated compression with a first

class solution. We also manufacture compression sys-

tems capable of:

● processing corrosive gasses, including HCL,

wet C02, SO2 and H2S;

● enduring high operating pressures, up to 600 bars;

● running with suction temperatures below –100oC.

One of the advantages of a reciprocating compressor

is that loss-free capacity control can be realised in

order to:

● keep energy costs low with varying demand;

● keep process conditions stable with

varying demand;

● start the compressor completely or partly

unloaded.

Compressors can have stepped or stepless capacity

control and may be operated manually and/or automa-

tically.

When you specify and buy Thomassen compressors,

you are assured of the very latest engineering techno-

logy and the finest construction available in reciproca-

ting machinery.

Q u a l i t y c o m p r e s s i o n

A Model C-25.2

compressor for use

in a gas depletion

plant of N.A.M. in the

northern part of

The Netherlands

4


The outstanding dependability and low maintenance of

Thomassen compressors has been demonstrated by

the many systems currently in service around the

world.

1.

A Diesel Hydro

De-Sulphuriser (DHDS)

plant using two model

C-25.4 hydrogen compres-

sors. Shell Fredericia.

2.

A Model C-85.6 compres-

sor jointly developed by

Thomassen and Mitsui

Engineering and Shipbuil-

ding. The unit shown here

is one of three supplied

to a hydrocracking plant

in Indonesia. Each unit

compresses hydrogen

from 14.5 to 197.4 bara

(in three stages) at a rate

of 56,265 Nm3/hr.

3.

Two Model C-45.6

compressors used in

a reformer unit.

The 5.5 mW compressors

were supplied - via

Kvearner - to BP

Kwinana, Australia.

2.

1.

3.


D e s i g n & E n g i n e e r i n g .

The fact that we have our own manufacturing capability

allows us to put Thomassen quality at the heart of your

installation. Our technical specifications - which meet or

exceed API and ISO - reflect the strict requirements of

the major oil and chemical companies. We have a strong

design philosophy and engage in fundamental research

and testing, including improved simulation techniques

that are confirmed by strain-gauge measurements of

dynamically loaded components. All components we

develop and design are subjected to rigorous static and

dynamic tests on Thomassen’s in-house heavy-duty

compressor. Moreover, the experience we gain in the

field continually helps us to improve our systems.

T o r s i o n a l v i b r a t i o n a n a l y s i s .

With the increasing application of large, variable speed

compressors, the rotating system must be studied in

detail to determine its torsional behaviour during start-

up and over a wide range of operating speeds and

conditions. As part of this process, it is essential that

the components and oscillating torque in the system

can be described as accurately as possible. Thomas-

sen’s computer model precisely simulates the real sys-

tem by including moments of inertia that are variable

and crank angle-dependent. The model also enables

the influence of individual sources of damping to be

investigated.

6

Design &Engineering


7

F i n i t e E l e m e n t A n a l y s i s .

Thomassen has its own in-house finite element model-

ling (FEM) facilities. It is particularly important that

heavy-duty compressor components are designed as

efficiently as possible. Optimisation of designs will

reduce weight and result in lower free forces and

moments. The use of FEM calculations ensures that

designs have excellent characteristics in terms of

strength, rigidity and reliability.

B e a r i n g S i m u l a t i o n p r o g r a m .

Rod loads in reciprocating compressors are time-

dependent, and differ for all bearings due to the sum-

mation of gas- and oscillating component inertia for-

ces. We have developed a simulation program for a

dynamically loaded bearing, enabling us to analyse its

behaviour under severe and variable operating condi-

tions. This program makes it possible to predict the

influence of various parameters such as load, load

reversal, speed, bearing clearance, oil temperature, oil

viscosity, etc.

C A D D e s i g n .

We make extensive use of solid modelling techniques

when designing compression installations. The above

picture shows a CAD model of a compressor installed

at Petrogal in Portugal.

Our proactive approach to Design & Engineering has

resulted in major improvements in uptime and reliabili-

ty. Our current target is to ensure that our reciproca-

ting compressors can run continuously for a period of

three years. And, as a result of tests run under real

process conditions on our own test compressor, we

anticipate even higher standards in the near future.

Digital image of a 2-cylinder compressor.

Model illustrating the deflection of a

segment of a double-acting compressor

piston with preloaded piston rod.

The loading included different gas

pressures on both sides of the piston as

well as transient thermal conditions.

0.24300

0.21800

0.19400

0.17000

0.14600

0.12100

0.09710

0.07280

0.04850

0.02430

1.0E-16

Disp Res


8

1. Crankcase / oilsump

2. Crankshaft with integral forged drive flange

3. Main bearing

4. Connecting rod

5. Crosshead

6. Adjustable, replaceable crosshead shoes

7. Piston rod with hydraulic connections

8. Partition cover with oil and gas seal

9. Double compartment partition cover with gas seal

10. Crosshead guide / Distance piece

11. Cooling water jacket

12. Stuffingbox

13. Replaceable dry type cylinder liner

14. Valves

15. Forged steel cylinder

16. Piston with PTFE rider- and piston rings

17. Pneumatic valve actuator

18. Multi-valve type cast cylinder

19. Cylinder and stuffingbox lubricator

20. Lube oil header

21. Spacer block and tie rods

22. Frame cover

23. Crosshead guide support

24. Flywheel

25. Single valve type cast cylinder

26. Suction pulsation vessel

27. Discharge pulsation vessel

28. Clearance pocket

Compressor nomenclature

25

26

22

2120

4

2

119

35

6

23

8

10

16

10

18

1

15

1417

11

13

24

7

26

27

9

11

12


9

Frame Size & Ratings

API 618 Reciprocating Compressors

Model Rating Rated Power Rated Speed No. ofkN kW rpm Cranks

C-7 130 800 600 1-2

C-12 185 2,300 600 1-4

C-25 300 5,600 600 1-6

C-35 550 10,300 550 1-6

C-45 825 15,400 500 2-6

C-85 1,250 24,800 375 2-8

CHS 245 4,600 1,200 1-6

18

2814

7

17


I n n o v a t i v e t e c h n i q u e s

Hydraulically Operated

Variable Clearance Pocket

Full assembly of a

Hydraulically Operated

Variable Clearance

Pocket.

The Hydraulically Operated Variable Clearance Pocket

(HOVCP) allows for the loss-free adjustment of com-

pression capacity. The HOVCP system can be actu-

ated automatically, by means of a hydraulic power

pack. As a consequence, it is possible to adjust capa-

city remotely. Replacing an existing (manually opera-

ted) clearance pocket with an HOVCP is easy, allowing

downtime to be kept to a minimum.

The HOVCP has the following advantages:

• High efficiency, loss-free capacity

control system, economic in use.

• Easy and quick installation.

• Remote control.

• Accurate, capacity volume can be

determined precisely.

• Clearance pocket piston position can

be recorded.

• No negative effects on the suction valves.

• Easy to disconnect during maintenance.

• Simple construction, high reliability.

10

HOVCP, including Power Pack Assembly


This design of piston rod connection has been incorpo-

rated in Thomassen reciprocating compressors for

more than 25 years. As the prime reason for piston rod

failure is fatigue, the rod must be designed for maxi-

mum fatigue strength. This particularly applies to the

screw thread of the connections to the crosshead and

the piston. Thomassen has made use of preloaded rod

ends. This feature is highly effective and enables cyclic

stresses resulting from externally applied loads to be

reduced substantially. Moreover, the assembly of the

preloaded joint is both simple and easy to control

accurately.

11

Free Floating PistonTM

Hydrofit The weakest point becomes the strongest

Maintenance on non-lubrica-

ted compressors is often

much higher, not least becau-

se rider ring wear is unpre -

dictable. Given today’s com-

mercial pressures, which dic-

tate running times of three

years or more, higher servi-

cing requirements clearly

present a problem. By rethin-

king the basic principles of

compressor design, Thomassen has come up with a revolutionary

solution, which equips the piston with a gas bearing. This design virtu-

ally eliminates rider ring wear by allowing the piston to float freely on

process gas. The advantage of this idea is that rider ring wear only

occurs for very short periods during start-ups and stops. The Free

Floating Piston™ removes the weakest link in the chain as far as

compressor component failure is concerned.

The Free Floating Piston™

technology is patented.

Side view: Free Floating Piston™.

Side view: Measured pressure distribution

on a Free Floating Piston™.

The inside of the Hydraulic Fit (Hydrofit)


Our engineers regularly advise on adaptations to opti-

mise your existing systems. Combining our broad

expertise with the very latest tools, we not only exami-

ne the operation of the compressor, but also focus on

the process around it. We use these studies to advise

customers about ways in which to improve the effi-

ciency of their installations. Although reciprocating

compressor components last much longer nowadays,

a well-tuned maintenance programme helps you get

the most out of your compression system by avoiding

unnecessary shutdowns. There are several ways in

which this may be achieved.

12

Worldwide ServicingOur service organisation consists of a team of highly experienced

specialists, who install, maintain and repair all types of compressors,

round the clock, all over the world. Our aim is to improve the reliabil-

ity of your compression equipment by closely co-operating with your

in-house engineers.


By monitoring all the key parameters, Thomassen

Compression Systems Monitoring gives you the infor-

mation you need to make cost-effective maintenance

decisions. When equipment is not performing as it

should, it need not necessarily be the compressor that

is at fault. Problems may be caused by factors not nor-

mally accounted for during operation. An on-line per-

formance test is an ideal way of measuring cylinder

performance, valve behaviour, process interaction and

isentropic and volumetric efficiency. We recommend

that clients at least monitor rider ring wear, stuffing

box wear, valve temperature and compressor vibra-

tion. Using additional equipment, coolant temperature,

bearing oil temperature and crosshead oil temperature

may also be measured. The data obtained gives you

an insight into the compressor’s performance and

enables you to service the equipment in good time.

Monitoring and performance tests may be conducted

on virtually any make of compressor.

Trending figure of rod drop, indicating early

rider ring wear

Control Room

100

80

60

40

20

0

3,75

3,00

2,25

1,80

1,35

0

-60 -50 -40 -30 -20 -10 0


In addition to

manufacturing

reciprocating

compressors, we

are your ideal

partner when it comes

to re-rating, rebuilding or overhauling your reciprocating

and/or centrifugal compressors, even if you use non-

Thomassen designs. As part of our overall compression

solution, we offer the kind of servicing, monitoring and

support facilities you might expect from a company with

a passion for compression.

C o m p r e h e n s i v e c o m p r e s s i o n s o l u t i o n s

14


T H O M A S S E NC O M P R E S S I O N

S Y S T E M S

Head Office

Thomassen Compression Systems

Havelandseweg 8-a

PO BOX 99

6990 AB Rheden

The Netherlands

Tel: + 31 26 4975200

Fax: + 31 26 4975201

E-mail: [email protected]

www.thomassen.comFor Service Operating Companies, Sales Offices & Agencies, please visit our website.

TCS

-2-0

8/08

-307

0
