Borsig BZM - 2016 - Eng

The BORSIG Group
KNM Group Berhad at a glance
 1990 established
 Kuala Lumpur, Malaysia, is the headquarter of

KNM Group Berhad
 World class process equipment manufacturer for

oil, gas, petrochemicals, mining and minerals
processing industries, power industries
 KNM Group Berhad is listed on Kuala Lumpur

Stock Exchange
 In 16 countries worldwide
Organization of KNM Group Berhad
KNM PROCESS SYSTEMS SDN BHD
KPS – TECHNOLOGY &

FBM GROUP DIV BORSIG GROUP DIV KPS PROCESS EQPT DIV
PLANT DIV
BORSIG Process Heat KNM Process Systems Sdn Bhd

FBM Hudson Italiana SpA Exchanger GmbH KNM Renewable Energy Sdn Bhd
KNM Special Process Equipment

FBM Icoss Srl BORSIG ZM Compression GmbH (Changshu) Co Ltd KNM Projects (Thailand) Co Ltd
BORSIG Compressor Parts KNM Process Equipment Inc Verwater KNM Sdn Bhd
FBM-KNM FZCO GmbH
BORSIG Membrane Technology W.E. Smith Engineering Pty Ltd

KNM Saudi Ltd KPS Technology & Engineering LLC
GmbH
GMT Membrantechnik GmbH HEA Australia Pty Ltd KPN Gas Technology Sdn Bhd
BORSIG Service GmbH PT Heat Exchangers KNM Petrosab Engineering Sdn Bhd
BORSIG Industrial Services PT KPE Industries

Sdn Bhd
KNM Brasil Group of Companies
KNM Grinaker-LTA Pty Ltd

Global Facilities of KNM Group Berhad
Selected Representatives of the BORSIG Group
B Czech Republic/Slovakian Republic

Italiy B
People´s Republic of China B
Iraq
B Japan B
B Iran
Kuwait B
B B Pakistan
B United States of America Saudi Arabia B UAE
B Oman
B India
B Mexico B Thailand
B Venezuela
Columbia B
Ecuador B
Peru B
Australia
B
Bolivia B
B Argentina B South Africa
Sites of the BORSIG Group in Germany
B
Sales Office Compressor Parts
FLENSBURG
Pressure Vessels,
Heat Exchangers
B
Power Plant and
Industrial Services HAMBURG Power Plant Services,
Project Engineering
B
BERLIN
Membrane Technology Membrane Technology
GLADBECK
Industrial Services B MEERANE Headquarters of the BORSIG
B
Group
Compressor Services
Compressor Parts
Membrane Technology for

Emission control
RHEINFELDEN Reciprocating and Centrifugal
B
Compressors, BORSIG Blue Line,
Membranes Compressor Services
History of the BORSIG Group
1837 The company is founded by August Borsig
1841 Construction of the first steam locomotive – the company becomes one of the major global
locomotive manufacturers
1857 Production of the first reciprocating compressor
1931 Shutdown of locomotive production, nationalization of the company
1950 Borsig becomes a global player for steam generators, machinery, pressure vessels, heat exchangers,
refrigeration plants and complete plants for the chemical and petrochemical industries
1960 Production of turbo compressors and ball valves begins
1965 Start of transfer line exchanger production for ethylene plants
1970 Borsig becomes part of the Babcock Group
1999 New in the product portfolio: Membrane technology
2000 Production of waste heat boilers for nitric acid, formaldehyde and caprolactam as well as
heat exchangers for partial oxidation of oil or natural gas
2002 BORSIG leaves the Babcock Group (management-buy-out)
2004 Reciprocating and centrifugal compressors re-enter the BORSIG product program
2008 KNM Group Berhad, Kuala Lumpur/Malaysia takes over the BORSIG Group
2012 BORSIG celebrates its 175th anniversary

Company of the BORSIG Group
History of BORSIG ZM Compression
Workshop Meerane
BORSIG ZM Compression GmbH
Workshop Meerane
Infrastructure
• Situated in the econimic area of Leipzig – Chemnitz – Zwickau

• Direct access to motorway A4
• 1 hour drive from Dresden or Leipzig airport
Infrastructure
• 12,500 m² covered area, thereof:

- 3,000 m² manufacturing - 1,700 m² test field
- 4,000 m² assembly - 615 m² pipeline manufacturing
- 1,400 m² storage - 1,800 m² office space
• 5 test beds up to 4,000 kW
• Crane capacity up to 100 t
• Machining capabilities up to 50 t weight and 5 x 10 meters
Products
Reciprocating Compressors for Process Gases

Discharge pressure p = (...1,000) bar
Flow rate V = (... 115,000) m³/h
Coupling power P = (... 16,000) kW
Integrally Geared Centrifugal Compressors

for Process Gases
Discharge pressure p = (… 150) bara
Flow rate V = (... 300,000) m³/h
Coupling power P = (... 25,000) kW
BORSIG BlueLine
combines control system, emergency shutdown, machinery protection and
condition monitoring for reciprocating and centrifugal compressor units
Compressor Parts
Compressor valves – design and manufacture of plate valves and ring valves
Valve service and modification
Engineering and consultancy
Analysis software
Service
Installation/ Commissioning Engineering
Overhauling Maintenance
Spare Part Management Training
Development/ Design
According to following regulations and standards:
 DIN
 ISO 8011 and 8012
 API 614, 617, 618, 672, API-11P and further API recommendations
 NACE regulations
 ASME regulations
 BS standards and others
Using following software:
 AUTO-CAD (2D)
 Pro-Engineer (3D)
 COMOS
 Comprehensive calculation and design programmes
Processing Machines
Manufacturing
RS 5000 CPA DS - CNC external cylindrical grinding machine

External cylindrical grinding of compressor components with an
external diameter of up to 800 mm and a length of up to 5,000 mm
PCR 160 plus - CNC horizontal boring and milling machine

- Travel distances: X = 14,000 mm, Y = 4,000 mm, Z = 3,000 mm
- 10 CNC axes including 2 orthogonal milling heads
- used for the machining of frames, cylinders and distance pieces
KC 150/1 - CNC horizontal boring mill

- Travel distances: X = 4,000 mm, Y = 3,000 mm, Z = 2,500 mm
- equipped with 2 additional rotary tables
- machining of compressor cylinders and distance pieces on all sides
Processing Machines
Manufacturing
STC 800 – 5-axis milling center

• Machining of precision parts – for reciprocating and centrifugal
compressors – up to a diameter of 1,400 mm x 1,350 mm and up to
2 tons unit weight
• Machining of - open or integrally milled - impellers for centrifugal
compressors up to a diameter of 800 mm
HEC 630 – 4-axis horizontal milling center
Machining of precision parts – for reciprocating and centrifugal
compressors – up to a diameter of 1.200 mm x 1.200 mm and up to
1.5 tons unit weight
GROB G550 – 5-axis milling center

• Machining of precision parts – for reciprocating and centrifugal
compressors – up to a diameter of 900 mm x 800 mm and up to
800 kg unit weight
• Machining of - open or integrally milled - impellers for centrifugal
compressors up to a diameter of 500 mm
Test field
Manufacturing
• 1,700 m² test field with 8 test stands for reciprocating and centrifugal compressors
• Reciprocating compressors: mechanical test run according API
• Centrifugal compressors: mechanical test run according API and
performance test according ASME PTC 10
Test field
Manufacturing
• 2 tranformer stations with 1 and 5 MW feed-in power

• test field electric motors up to 4 MW input power
• motors for heavy starting and speeds 0 – 3200 min-1
• 2 cooling systems up to 5 MW cooling capacity coupled with several heat exchanger
blocks
• 2 supply/ exhaust air systems with an
airflow rate up to 90,000 or 40,000 m³/h
respectively for the test of centrifugal
compressors with ambient air
Test field
Manufacturing
• measurement devices for monitoring and high speed balancing
• monitoring equipment with automatic emergency reaction
• acoustic and heat protection cabin for customers with real time live data display
Test field
Manufacturing
• performance tests may be carried out with test gas (CO2, R134a, nitrogen, helium)
• gas analysis unit to determine the exact gas composition during the thermodynac tests
Test field
Manufacturing
Test stand set-up for performance test of a 6-stage centrifugal compressor
Measuring equipment
Quality Management
Most modern 3D measuring equipment such as FARO scanners, laser trackers and
measuring arms for precise measurement of all compressor components
Certificates
Quality Management
 DIN EN ISO 9001:2008
 DIN ISO 14001:2009
 SCC** certificate (Safety Certificate Contractors)
 AEO Certificate (Authorized Economic Operator) –
Customs Simplifications
Delivery and Transportation
Delivery for transport by land, sea or air

Delivery and Transportation
Delivery of two compressor units by plane

Compressor Frames
Vertical (PV) – Horizontal (BX)
PV Frame/stroke BX
90
110
140
180
220
320
400
450
500
Design
Modern tools for CAD design and analysis
Design
Finite element analysis
View of 6 crank
compressor
Design
3D CAD for systems engineering

The complete package in our workshop

Manufacturing
Machining of a crank case on

CNC horizontal boring and milling machine
Machining of a cylinder on CNC horizontal

boring mill
Manufacturing
Preparations for machining of a 4-crank case

Manufacturing
6-crank case before machining on CNC horizontal boring and

milling machine
Assembly
Assembly of a compressor unit

Test run
Mechanical test run acc. API – 4-crank compressor

Horizontal design
Vertical design
Delivered compressor units
References (Extract)
Evonik Degussa / GER MOL / HUN

BASF / GER Mozyr Refinery / BLR
Bayer Material Science / GER OMV / AUT
BP / GER Petro-Canada / NED
Haldor Topsoe / DEN RAG / AUT
Hellenic Petroleum / GRE Samsung / KOR
Hyundai / KOR Sasol / GER
Lurgi / GER Shell / GER
Linde / GER Siemens / GER
Linde Kryotechnik / SUI Tatneft / RUS
Overview compressor sizes
Centrifugal Compressors for Process Gases
Design
BTC60
BTC48
BTC38
BTC30
BTC25
BTC20
Design
Design
• 3D-Stress analysis (finite element method)
• Flow analysis
• 3D engineering (Pro Engineer)
Design
Design
Volute casing
Impeller
Diffusor
Compressor intake
with flange
Dry-gas-face-
seal
Intake nossle
Design
Main technical parameters of impellers:

• calculated, designed and manufactured by
BORSIG ZM
• up to compressor type
BTC120 or Ø 1200 mm (open impeller)
BTC90 or 900 mm (closed impeller)
• 5-axis milled
• all materials from steel to titanium
• three-dimensional designed blades
• very high efficiency up to isen = 87 %
• overspeed test according to API 617
Design
Booster compressor station

with 1 compressor
Gas lines
Gas treatment
Motor
Air cooler
Oil cooler
Fire extinguishing
system
Nitrogen unit
Acoustic enclosure
with air-conditioning
Design
• Booster compressor station for gas

turbines with 2 compressors
• with acoustic enclosure
Design
• Booster compressor station for gas turbines with 2 compressors
• in machine hall
Manufacturing
New boring and milling center
Balancing of rotor
Manufacturing
• Five axis milling of impellers

• Capable for impeller sizes
up to BTC120 (open impeller)
or BTC90 (closed impeller)
• Capable for manufacturing of
open and closed impellers
Assembly
Assembly of turbo compressors

Assembly
Test run
Inhouse ASME
PTC 10 Test
References ( Extract)
Centrifugal Compressors
Centrifugal Compressors for Process Gases:
ELIN Energietechnik / GER
Holborn Europa Raffinerie / GER
Petrobras / BRA
Praxair / USA
Samsung / KO
UTC Engenharia / BRA
Wasserwerke Zwickau / GER
Booster Compressors for gas turbines:

ABB/ GER Gazprom Energoholding / RUS
KES / RUS Mosenergo / RUS
Siemens / GER
BORSIG BlueLine
Integrated automation system for reciprocating and centrifugal compressors
BORSIG BlueLine
PLC ESD
Programmable Emergency Shut
Logic Control Down System
BORSIG
BlueLine
CMS MPS
Condition Monitoring Machinery
System Protection System
MMS
Machinery Monitoring System
• No strict separation of MMS, SPS and ESD necessary

• Stand-alone system architecture possible
• Easy refitting of MMS/ CMS/ MPS in addition to already installed PLC
BORSIG BlueLine
• Overall system for
- open-loop control
- closed-loop control
and
- protection tasks
up to safety level SIL3
• high availability by up to quadruple redundancy

(DUPLEX,TMR, QMR technology)
BORSIG BlueLine
Until now
• separate systems for control, machinery protection, machinery and condition monitoring
• different providers
Open-loop Closed-loop MMS CMS

control control Machinery monitoring Condition monitoring
source: directindustry.de
source: mic.hit-karlsruhe.de GE Measurement & Control Bently Nevada
Siemens
BORSIG BlueLine
New solution
• BORSIG BlueLine combines in one system:

control, machinery protection, machinery and condition monitoring
• one hardware
• one software
• for reciprocating and
centrifugal compressors
BORSIG BlueLine GA DUPLEX/7-S, dual-redundant

BORSIG BlueLine
Advantages
• one contact partner

• reduced costs for hardware and software
• reduced costs for engineering
• 50% space-saving in control box
• simplified service
• reduced training requirements
• many years of experience, worldwide
Services
 Installation/ Commissioning
 Overhauling
 Spare Part Management
 Engineering
 Maintenance
 Training
Installation/ Commissioning
Service
• Assembling and commisioning executed by our specialists
• Efficient field management and supervision
• Coordination of connected subsections and customer staff
• Procedural control and programming
• Commissioning and monitoring
• Machine-specific instructions for compressors
Services
Assembling on site
Services
Installation of a booster compressor station for gas turbines in Winter season in Perm/ Russia
Overhauling
Service
• Troubleshooting
• Error location and breakdown diagnosis
• Repair or substitution of defective parts or components
• Repair on site or in BORSIG ZM workshop
• 24h - Hotline
Spare Part Management
Service
• Set-up of a balanced spare and wear part inventories

• Appraisel of parts and break down
• Repair and rapid manufacturing of components
• Lifetime spare part supply for new reciprocating compressors Cylinder for „ROW“
year of manufacture 1960
made by Borsig ZM
Crankshaft for a L-compressor „Shell 14/16“

year of manufacture 1957 Cylinder for „Burpin“
year of manufacture 1969
Engineering
Services
• Feasibility studies
• Verification and revamp studies
• Engineering services and FEM-analyses
• Pulsation studies
• Regeneration of components by replacement or

substitution
Engineering
Service
• Re-fitting of additional parts or components
• Optimization of the maintainability
• Consultancy and design of monitoring systems
• Replacement of parts or components which are not

available anymore, especially those of other manufacturers
• Adjustment according up-to-date standards

Maintenance
Services
• Maintenance on request
• Maintenance on call order to a service agreement
• Manpower and resource planning
• From the basic to the all-inclusive supervision
Training courses by BORSIG ZM Training Center
Service
• Customer training courses for reciprocating and centrifugal compressors
• Inhouse- and on-site training
• Practical inhouse-training courses at own training compressor

Training courses by BORSIG ZM Training Center
Service
Training programme:
• safe handling and professional maintenance of
BORSIG ZM compressors
• introduction into machine-specific features
• professional handling of particular components
Contents:
• Field of applications and functionality of a
reciprocating or centrifugal compressor unit
• Scope of modifications and adjustment control
• Design and functionality of the main components
• Preventive maintenance
• Error location and causal research
• Up-to-date development and scope of modernization
Subsidiary company
BORSIG Compressor Parts GmbH
Products and Services
BORSIG Compressor Parts GmbH, Gladbeck
• Compressor valves - design and manufacture of

plate valves and ring valves
• Valve service and modification
• Engineering and consulting
• “COMPART” analysis software
• Individual products and special applications –

actuators, oil scraper packings, check valves
Compressor valves
BORSIG CP plate valves BORSIG CP ring valves

• for reciprocating compressors
• universally suitable for all gases and applications
• valve plates made from PEEK, PA, GFK • with high-performance non- metallic
or steel, depending on operating conditions valve plates
• reliability has been proven over decades • Advantage: very even wear and
even under extreme conditions (e.g. heavily self-cleaning effect thanks to rotation
polluted gases) of valve rings
Valve service and modification
Reconditioning of valves
of all manufacturers
Analysis of valve problems

and optimiziation
Modification of steel plate valves,

replacement by plastic plate
Engineering and consulting
• Calculation and analysis of existing compressor and valve problems

• Design of compressor parameters
• Simulation and optimization of valve dynamics
• Finite element analysis (FEA) of mechanically critical components
• Use of in-house software „COMPART“ for reconditioning of compressors and

valves
Individual products and special applications
Check valves
Actuators
Oil scraper packings

Thank you
for your
kind attention!

Borsig BZM - 2016 - Eng

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The BORSIG Group

KNM Group Berhad at a glance

 Kuala Lumpur, Malaysia, is the headquarter of

 World class process equipment manufacturer for

 KNM Group Berhad is listed on Kuala Lumpur

KNM PROCESS SYSTEMS SDN BHD

KPS – TECHNOLOGY &

BORSIG Process Heat KNM Process Systems Sdn Bhd

KNM Special Process Equipment

BORSIG Membrane Technology W.E. Smith Engineering Pty Ltd

BORSIG Industrial Services PT KPE Industries

KNM Brasil Group of Companies

KNM Grinaker-LTA Pty Ltd

B Czech Republic/Slovakian Republic

Industrial Services B MEERANE Headquarters of the BORSIG

Membrane Technology for

1837 The company is founded by August Borsig

1857 Production of the first reciprocating compressor

1931 Shutdown of locomotive production, nationalization of the company

1960 Production of turbo compressors and ball valves begins

1965 Start of transfer line exchanger production for ethylene plants

1970 Borsig becomes part of the Babcock Group

1999 New in the product portfolio: Membrane technology

2002 BORSIG leaves the Babcock Group (management-buy-out)

2012 BORSIG celebrates its 175th anniversary

• Situated in the econimic area of Leipzig – Chemnitz – Zwickau

• 12,500 m² covered area, thereof:

Reciprocating Compressors for Process Gases

Integrally Geared Centrifugal Compressors

According to following regulations and standards:

Using following software:

RS 5000 CPA DS - CNC external cylindrical grinding machine

PCR 160 plus - CNC horizontal boring and milling machine

KC 150/1 - CNC horizontal boring mill

STC 800 – 5-axis milling center

GROB G550 – 5-axis milling center

• 2 tranformer stations with 1 and 5 MW feed-in power

• measurement devices for monitoring and high speed balancing

• monitoring equipment with automatic emergency reaction

 DIN EN ISO 9001:2008

 DIN ISO 14001:2009

 SCC** certificate (Safety Certificate Contractors)

 AEO Certificate (Authorized Economic Operator) –

Reciprocating Compressors for Process Gases

Delivery for transport by land, sea or air

Reciprocating Compressors for Process Gases

Delivery of two compressor units by plane

Finite element analysis

3D CAD for systems engineering

The complete package in our workshop

Machining of a crank case on

Machining of a cylinder on CNC horizontal

Reciprocating Compressors for Process Gases

Preparations for machining of a 4-crank case

6-crank case before machining on CNC horizontal boring and

Reciprocating Compressors for Process Gases

Assembly of a compressor unit

Mechanical test run acc. API – 4-crank compressor

Evonik Degussa / GER MOL / HUN

Main technical parameters of impellers:

Booster compressor station

• Booster compressor station for gas