Gas Compressors

Aziz Fozi
Gas Compressor Engineering
San Diego, California, USA
Overview
• Product History
And Portfolio
• Design Synthesis
• Testing And Facility
Modernization
• Service & Support
• Product Update

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 History

1960-1990

1st & 2nd

Generation
Models

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 History

1990-2000

3rd
Generation

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 History

2000-2010

4th & Future

Generation

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Annual Compressor Production

• >150 Gas Compressors

• >200 Compressor Overhauls
And Restages

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Power-Speed Match

Solar Gas Compressors And

Turbines Speed And Power
Are Matched

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Legacy Products
1st And 2nd Generation Products: 1960-1990

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Current Products
3rd & 4th Generation Products: 1990-Now

Oil & Gas Production C61

C51

C505U

C41

C40M

C33E
C16V
C85
C65

C45

C40P Natural Gas Pipeline

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Over 5200 Shipped

Applications: Gathering, Transmission, Lift,

EOR Injections, Process Plants
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Compressor Drivers

Variable Speed
Gearbox -
Electric Motor
Gas Turbine

Variable
Frequency Drive
Electric Motor

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Design Synthesis
Design Integration
Gas Compressor Business Unit

• Gas Compressor
Engineering And Test
• Gas Compressor CAM
(Assembly And
Manufacturing)
• Supply Chain

One Team

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 Solar Gas Compressor
Engineering, Assembly And Test

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 Design Synthesis

Design Synthesis

Aerodynamics Rotordynamics Structural Design

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Design Synthesis
• International
Manufacturing Base
• Aerospace Quality
Processes

• San Diego-Based
Assembly And Test

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Design Synthesis
Evaluation Of Field Tools

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Aerodynamic
Design
Predefined Stages To Cover
Gas Turbine Operating Envelope

Lines Of Constant Power

Field
Design
Isentropic Head

Point

Inlet Volume Flow (Q1)

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Predefined Stages To Cover
Gas Turbine Operating Envelope
6 Stages

Lines of Constant Power

Field
Isentropic Head

Design
Point
5
Stages

3
Stages
4 Stages
2
Stages
Inlet Volume Flow (Q1)
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Aero Design
• Rotating • Stationary
– Impellers – Inlet
– Inlet Guide Vanes
– Vaneless Diffuser
– Turning Vanes
– Exit Volute

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Aero Design

• 1-D Geometric
Cross Section
Or Mean-Line

• 2-D Blade To
Blade
Passage
Analysis

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Aero Design
CFD Visualizes The Flow Field
ge
Sur
Isentropic Head

Speed

Inlet Flow

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Design Verification:
Research Facility
• Scaled Single Stage
Compressors
• Operated By Design Staff
• Over 10 Years Of Operation
• Extend Aerodynamic Design
Knowledge
• Improved Prediction
Capability
• Understand Component
Performance

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Rotor Dynamics
The Rotor
• Rotor Construction
• Finite Element Analytical
Modeling
• Vibration And Response
• Test

Modal Testing tts10-compressors-27

The Rotor Stub Shafts

Center Tie Bolt

Impellers

Spacer Tie Bolt Nut

Stub Shafts

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The Rotor: Common Practice
Modular Rotor For A Heavy Duty
Gas Turbine

For Presentation At The

AMERICAN POWER CONFERENCE
CHICAGO, ILLINOIS, APRIL 9-11, 1996

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 Stiffness:
Solid Shaft Rotor Compared To Modular Rotor

Modular Rotor Solid-Shaft Rotor

API 617 Compliant

D…Effective Shaft Diameter
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The Rotor
Test: Verification Of Mode Shapes

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The Rotor: Modal Test
Amplitude

1st Bending Mode - C85[F3-1]

Frequency
Calculated Modal Test
1.20

1.00

0.80
Amplitude

0.60

0.40

0.20

0.00
0 20 40 60 80 100 120
-0.20

-0.40

Distance on rotor from Suction End (in)

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 Structural &
Mechanical Integration

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Structural Analysis:
Mechanical Design

• CAD Integration
• Finite Element
Analysis
• Every Component
Analyzed
• New Manufacturing
Methods

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Structural Analysis
3D Finite Element
Analysis

3D Solid Model
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Casting Design:
Fraction Liquid Movie

Caterpillar: Confidential Green

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Structural Design:
Impeller Structural Analysis

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Impeller Manufacturing
Brazed
Impeller
Machined Impeller

Hard-
Hard-Tooled Investment Castings Hard-
Hard-Tooled
Hard -Tooled
Wax Assembly Investment
Investment Castings
Castings

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Production Test
Facilities

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Compressor Test Facilities
Production Air Test Cells
• Centaur 50 Driver
• Saturn 20 Driver

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Compressor Test Facilities

• String Test Cell

• San Diego, Kearny
Mesa Plant

N2
N2 Leak
Leak
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Compressor Test Facilities

Closed Loop Facilities

• San Diego – Harbor Drive Plant
– Centaur 40 Driver
– Up To 3500 hp (2.6 MW)

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Compressor Test Facilities
Kearny Mesa Plant

• Titan 130 Driver

• Max. Pressure 200 Bars
• N2, CO2, Natural Gas
• Customer Package String
Test (Up To 23MW)
• Spare Test Bay: Future
Expansion

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 Closed-Loop Testing

Closed Loop Piping For Full Load Testing Customer Package String Test Cell

Mars Driver
Manufacturing
Building
Titan 130 Driver

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 Spares
&
Restages

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Gas Compressor Designs

1st & 2nd Generation Compressors

• Broad Application Range
• Finite Number Of Components
• Large Population

3rd & 4th Generation Compressors

• Application Optimization
• More Compressor Models
• Better Efficiency, Wider Range
• Larger Number Of
Combinations

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 Spares Philosophy

Gas Compressor Population

10+%
Application
Specific
• Component Availability

• Overhaul And Restages Needs

• Emergency Support

Population
Status 2010
90%
General
Purpose

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Planned And Unplanned Support

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Compressor Spares Philosophy

• Other OEMs
– Spare Rotor
– Spare Bundle
• Solar’s Approach
– Minimum Spare
Purchase Needed

• Market Drivers
– Maximum Availability
– Minimized Risk
– Optimized CAPEX

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Spares Philosophy

• Investment Costs
• Space And Weight Limitations
• Logistics
• Expertise On Site
• Turbomachinery Criticality
• Past Experience

Shared
Shared Responsibility
Responsibility

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Spares Package I

SPARES
PACKAGE
I
Seals and
Bearings

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Spares Package II

SPARES
SPARES PACKAGE
PACKAGE II
I
Seals and Spare
Bearings Impellers

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Spares Package III

SPARES
SPARES
SPARES PACKAGE
PACKAGE
PACKAGE III
II
I
Seals and Spare Spare
Bearings Impellers Bundles

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 Spares Package III

Removal

Bundle Exchange
On-Site

Installation of
New Bundle
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Spare Package Options

SPARES
SPARES PACKAGE
SPARES PACKAGE III
PACKAGE II
I
Spare
Seals and Spare
Bundles
Bearings Impellers

Increasing Availability

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Retrofit Programs
Compressor
Exchange

Wide Pad
Bearing

Dry Type Dry Gas

Coupling Seal

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What Is A Restage?
• Changes Compressor Flow And
Head Characteristics To Optimize Efficiency
Around New Operating Point
• Alters Number And/Or Type
Of Internal Stages
• New Pressure & Flow Conditions
• Changes To Gas Properties

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 When To Restage
• When Approaching
Equipment Limits Contact
– Power Turbine Speed Topping Solar District Office
– Compressor Choke For Restage Inquiry
(Stonewall)
– Compressor Surge (Recycle) Operating Goals
• Restore Original Surge Margin
• When Process Conditions • Restore Original Efficiency
Change >10% • Increase Head-Making
– Composition Capability
– Pressure • Cover Current And Future
– Temperature Operating Points
– Flow

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Compressor Restaging For Declining
Field Conditions

New Restaged Compressor

Design
Point
Original
Operating
Point
Head

Flow
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Restaging Logistics
Where To Restage?
• At Solar Overhaul/Repair
Center
• At Qualified Repair Facility
• At Installation Site
- With Special Field Tools
- With Complete Exchange
Aero Module Or With Pre-
Balanced Rotor Assembly
- Exchange Bearings And
Seal Assemblies

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Overhaul And Repair Facilities
• Mabank, Texas
• Gosselies, Belgium
• Edmonton, Canada
• Bandung, Indonesia
• Melbourne, Australia
• Kuala Lumpur, Malaysia

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Product Updates
 Gas Compressor Family

Production
C61
10,200 rpm
C51
12,000 rpm

C50
14,000 rpm

C41
14,300 rpm
C40M
14,300 rpm
C33
15,500/
C16 19800 rpm
22,300/ C85
C65 7000 rpm
23,800 rpm 10,500 rpm
C45
C40P
12,000 rpm
Pipeline
14,300/15500 rpm

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C85 Gas Compressor

• Modular-Rotor Design
– 1 or 2 Impellers
– Facilitates Flexibility And Restaging
– Scale-up From Existing Pipeliners
• Flange Diameter: 42 in.
(1067 mm), Class 900, R.F.
• Matched to Titan 250
• Casing Rating: 1,600 psi
(110 Bar)
• Pressure Ratio: 1.1 to 1.9
(Staging Dependent)

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C51 Gas Compressor

• Builds On Solar’s
Successful Technology
• Optimized For Titan, Mars
And Taurus 70
Direct-Drive Applications
• More Than 55 Sold And
More Than 25 In Service

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Two-Section Gas Compressor Casing
2nd Stage
Suction
1st Stage
Discharge

2nd Stage
Discharge

1st Stage
Suction

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Production Gas Compressors C61
Mars
C51 Titan 130
C41 Taurus 70 Titan 250
Taurus 70 Mars
Mars Titan 130
Titan 130
Titan 250

150 Bars (LP)

150 Bars (LP) 200 Bars (HP)
250 Bars 200 Bars (HP) 1000m3/min
500m3/min 750m3/min
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Trends In Production Gas Compressors
• More EMD’s
• High Speed Motors

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Summary
• Application Focused
– Pipeline
– Production
• Design Synthesis
• Expanded Test Capability
• Spare Part Support Packages
• Single-Source Compression
Partner SPARES
SPARES PACKAGE
• Product Enhancements SPARES PACKAGE
Ii
Iii
PACKAGE
I Spare
Spare Bundle
Seals and
Impellers
Bearings

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 Total Life-Cycle Support

Turbomachinery
Technology Seminar
2010
Solar Turbines
Owners’ Conference
San Diego 2009