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New technical solutions Russian compassionately for LLC "LUKOIL-Permneftegazpererabotka"

Key equipment in technological processes of gas processing complex – centrifugal compressors. When choosing a supplier of gas compressor units of the enterprise in the first place pay attention to the manufacturer of the experience and resources to design and manufacture unique compressor units according to individual requirements. This article discusses the experience of the manufacturer JSC Kazankompressormash and design Institute CJSC "Naturvetarna them. V. B. Economies" in the implementation of complex projects for the supply of compressor units for one of the largest operators of gas processing complex in Russia – JSC "SIBUR".

Production enterprise JSC Kazankompressormash and research Institute JSC "Naturvetarna them. V. B. Economies" are a major engineering and engineering holding HMS Group and work as a unified scientific-technical complex. Kazankompressormash has 20 years experience in the production of compressors driven by gas turbine units (GTU) with a capacity from 6 to 25 MW, as well as of complete compressor stations. Tight integration with leading Russian developer "Naturvetarna them. V. B. Economies" provides an opportunity to deliver highly efficient and reliable compressor equipment according to the technological characteristics of the customer's facility. An important place in design solutions to issues related to energy saving technologies, reduction of losses of non-renewable energy resources, improvement of environmental situation in the areas of oil and gas production.

In the period from 2008 to 2012 in the framework of the General agreement with OJSC SIBUR about the design, manufacture and supply of equipment Kazankompressormash put OJSC SiburTyumenGaz six compressor units driven by gas turbines: GC-124/14-79 GTU (2 pieces), 66HZ-1162-1,3-38 GTU (3 pieces), GC-375/4-77 STU (1 piece).

Turboplay compressor unit for JSC SiburTyumenGaz
Turbomemory compressor unit for JSC SiburTyumenGaz

Two turboprint compressor unit GC-124/14-79 GTU was supplied to the booster compressor station (BCS) of South balyk GTP. When creating turborider compressor unit were applied progressive technical solutions currently used in the world practice of creating a gas-compressor units.

Compressor units are gas turbine drive with a capacity of 8 MW and performed in hangar design. Centrifugal compressor for compression of associated gas, and further processing performed in a "dry" (oil-free) version, equipped with magnetic bearings company "S2M" (France) and dry gas-dynamic seals, designed and manufactured "Naturvetarna them. V. B. Economies". The case of compression – ten with one intermediate cooling.

the Basic parameters of the compressor GC-124/14-79 GTU:

  • performance, reduced to normal conditions (20 °C 0,101 MPa), nm3/hour (m3/min) – 100000(124,05)
  • initial pressure, nominal, MPa – 1,34
  • the final pressure, nominal, MPa – 7,7

In the compressor unit uses advanced automatic control system, providing functions of control and regulation of all systems of the unit, including a gas turbine engine (based on the controller Yokogawa (Japan) and Allen Bradley (USA). Thus, operation of the unit have been possible without the constant presence of operating personnel.

In the cold season heating cover and block Assembly that allows the unit running in less than 1 hour, even in the harsh conditions of the Siberian climate. Anti-surge compressor system provides automatic regulation and protection of the compressor against surge, and emergency protection (GROOVE) of the compressor protects the equipment against any accidents and human error.

the Development, testing and delivery of aggregates GC-124/14-78 GTU South balyk GTP were carried out in a short time – within 15 months from the date of signing the contract. In 2009, pilot models of units passed the acceptance tests and were accepted for commercial operation. In Assembly GC-124/14-79 GTU was installed gas turbine engine driven aviation type AI-336-2-8 (manufacturer – "Motor Sich", Ukraine). But in response to the need "Siburtumengaz" to increase the flow rate of gas was consistent decision-making on the replacement drive motor for the gas turbine engine NK-ST-10 (manufacturer – JSC "Kuznetsov", Samara) power of 10 MW, which also provided the extension of the control range the performance of the unit compared to the original.

Compressor unit GC-124/14-79 GTU for South balyk GTP, SiburTyumenGaz
Compressor unit GC-124/14-79 GTU for South balyk GTP, SiburTyumenGaz

In 2012, was performed a complex of works on development of design documentation, procurement of equipment, modernization of head Assembly and commissioning tests. Technological features of associated petroleum gas utilization with Mamontov oil Deposit required the creation of a compressor unit high performance 700 million nm3/year.

Compressor unit type 66HZ-1162/1,3-TO on parameters such points was designed and manufactured at JSC Kazankompressormash, installed and successfully operated since 2010 in JSC "Yuzhno-balyk GPK" (Pyt-Yah).

Compressor and is supplied blocks maximum factory readiness. Units low compression and high-pressure lubrication system, sealing system, rack equipment, some gas lines. Engine blocks, mesoamericana engine, fuel and start gas placed in easy-to-assemble building, also included in the scope of delivery of the unit. In the compressor installation used gas turbine engine NK-16ST production of JSC "Kazan production engine-building production Association" (JSC "KMPO").

the Basic parameters of the compressor 66HZ-1162/1,3-TO:

  • performance, reduced to normal conditions (0 °C 0,101 MPa), nm3/hour (m3/min) -83340 (1162)
  • the suction pressure, MPa – 0,13
  • pressure, MPa – 3.7 V
  • the range of variation of the suction pressure, MPa – 0,13–0,17
  • the range of variation of productivity, m3/min – 1162-859
  • In order to comply with environmental requirements and produce products with high value-added Russian oil and gas companies devote considerable attention to the efficiency of associated petroleum gas. In the framework of this task, one of the largest enterprises for processing of hydrocarbon raw materials of LLC "LUKOIL-Permneftegazpererabotka" (LLC "LUKOIL–PNGP") launched the project "Reconstruction of low-temperature condensation and rectification (NEW). The construction of the second line for processing of associated petroleum gas (APG)".

    Supplier of compressor equipment in the framework of the project by the scientific and production complex "CJSC Naturvetarna" OJSC Kazankompressormash (structural engineering holding company OJSC "HMS Group"). During the 2013-2014 enterprises has been successfully implemented complete supply of booster compressor units compressor station. The scope of supply included:

    • turboprint compressor units – 3 PCs.
    • refrigeration centrifugal compressors – 2 PCs.
    • centrifugal compressor – 1 PC.
    • screw – 1 PC.
    • easy-to-assemble building.

    Turboplay compressor unit GC-70/17-62 gas turbine composed of a booster compressor station (photo 1, table. 1) is designed to compression of dry stripped gas from the installation of NEW and feeding it into the main gas pipeline "Gazprom" and the unit of LLC "LUKOIL-Permnefteorgsintez".

    as an actuator applied to a gas turbine unit GTU-PG.

    Photo 1. Booster compressor station "LUKOIL–PNGP" consisting of three turboprint units GC-70/17-62 STU

    table 1. The main parameters of the unit GC-70/17-62 STU

    initial Pressure, MPa (kgf/cm2) 1,7 (of 17.35)
    Pressure, MPa (kgf/cm2) 6,17 (62,2)
    Volumetric capacity suction, m3/min 70

    When you create the Assembly adopted the most advanced technical solutions used in the world practice, including:

    • arrangement of the unit in easy-to-assemble shelter
    • highly efficient flow part of the compressor, placed in a single package;
    • dynamic gas – dry gas seals (dry gas seal) of the compressor rotor;
    • modern automatic control system that provides control and regulation of all systems of the unit (incl. TBG);
    • gas carbon dioxide automatic fire extinguishing system;
    • package contents compressor bypass valve using perfect system anti-surge control and protection.

    Turboplay the unit is delivered ready with the date of the test Assembly the company is the General supplier JSC Kazankompressormash. The equipment unit is in easy-to-assemble building and beyond.

    easy-to-assemble Outside of the building are air-cleaning unit (HEU), exhaust system, the control unit, the air cooling device of the compressor, the air cooling device of the engine, the ventilation unit hangar unit HVAC control unit, the input separator, the end separator, the air cooling device of gas, gas communication, including valves, piping and instrumentation.

    Inside easy-to-assemble building placed unit lubrication of the compressor, the compressor on the frame, the rack dry seal compressor, engine block, block mesoamericana engine, fuel gas system, exhaust and emergency ventilation, system boost of power, lighting systems, fire extinguishing unit.

    the Basic sub-unit of the unit is a compressor with a multiplier on the frame. The centrifugal compressor, two-section, eight-speed, with oil bearings and COMPLETE. The impellers of the first and second sections are arranged back-to-back that provides unloading of the rotor from axial forces and reduce the load on the thrust bearing of the rotor. To control vibration and axial displacement of the rotor in the bearing housings mounted sensors company metrics, (US).

    the engine Block is designed to accommodate gas turbine engine GTU-PG and multiplier and provides somatopleural and explosion protection equipment. Explosion protection is achieved by pressurizing the air inside the engine block.

    In the framework of the project for the first time in Russia created a unique refrigeration unit multiplier type GCM-250/0,9-15,8 (photo 2, Fig. 2) for compression of propane in the process of installing refrigeration.

    Photo 2. Refrigeration unit multiplier type GCM-250/0,9-15,8

    table 2. The main parameters of the refrigeration unit GCM-250/0,9-15,8

    Volumetric capacity, m3/min:
    section low pressure (UMP)
    – the high pressure section (SVD)
    end-gas Temperature, K (°C), not more than:
    – SNM
    – SVD
    289,3 (16,3)
    345,8 (72,8)

    Propane refrigeration compressor unit is based on multi-shaft compressor with a built-in multiplier and for the replacement of obsolete compressors foreign production. The compressors are installed on the existing foundations.

    In the compressor applied to the following design solutions:

    • built-in multiplier implemented with a vertical connector to provide a sealed Parking at high pressure propane;
    • first gear pair made with high peripheral speed of 169 km/s;
    • for smooth effective capacity control applied input control devices.

    the Adopted technical solutions provided a high efficiency compressor and, as a consequence, a significant reduction in electricity consumption, which is relevant for large processing of oil and gas companies.

    To compress the gas in the line of processing of associated petroleum gas was supplied to the centrifugal compressor unit in block-container design GC-83/K.U1 (PL. 3). Modular design to full operational readiness as a result, the timing when executing construction and commissioning.

    For compression of associated gas, followed by feeding it to the turbine drive of technological equipment of LLC "LUKOIL-Permneftegazpererabotka" was staged screw compressor unit GW 14.16-NF4 35 (PL. 3).

    table 3. The main parameters of compressor units

    GT-83/25-48K.U1 GW 14.16-NF4 35
    Performance suction conditions, m3/min 13,8 83,5
    initial Pressure, MPa (kgf/cm2), abs. 1,6 (16,32) 2,46 (25,1)
    Pressure, MPa (kgf/cm2), abs. 3,4 (34,68) 4,7 (48,0)
    Power consumption, kW, not more than 578 3260

    the Compressor unit includes: compressor, drive motor, clutch plate, frame, sound attenuating casing, a plate cooler water cooling (primary and backup), an oil separator of the first stage, the second stage oil separator, valves, shut-off, control and safety valves (set).

    the Compressor developed based on the patented design of the high pressure compressor, with a smooth economical capacity regulation from 100% to 20% due to the integrated valve regulator.

    Compressor unit was created in cooperation with Russian companies JSC "NPO "Iskra", OJSC "Aviadvigatel" JSC "Dimitrovgradkhimmash" (HMS Group), JSC "Lenniihimmash".

    Thanks to the successful cooperation of science and production of oil and gas processing enterprises of OAO "LUKOIL" has received high-quality and reliable domestic compressor equipment.

    ZAO "Naturvetarna" and JSC Kazankompressormash have a unique patented and proven design solutions and broad competences of successful experience and is ready to participate in large-scale projects for the supply of compressors for oil and gas facilities of the Russian Federation, CIS and far abroad.

    Authors: A. M. Akhmetzyanov, A. P. Kharitonov, V. B. Dubinin, M. T. Sadykov (CJSC "Naturvetarna them. V. B. Economies", HMS Group)

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