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T H O M A S S E N C O M P R E S S I O N S Y S T E M S
TCS-2-08/08-3070
Reciprocating Compressors
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Passion f
Research & Development 2
Design & Engineering
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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.
more than one hundred years of
n for Compression
Manufacturing & Testing
Re-rating & Rebuilding
Installation & Servicing 3
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Quality compression
Thomassen has an esta-
With frame sizes up to 25,800 kW, the Thomassen
blished reputation for
C-series reciprocating compressor can accommodate
providing quality, tailor-
up to 6 compression cylinders. All components, inclu-
made compression solu-
ding the crankcase, crankshaft, bearings, crosshead
tions to the oil, gas,
body etc., have been designed for maximum strength
chemical and refining
and durability.
industries. Our in-depth knowledge of field pro-
Our Free Floating Piston™, which, as its name suggests,
A Model C-25.2
cesses and compressor-related systems enables us to
floats on process gas, enables us to provide custo-
compressor for use
design, install, maintain and repair all types of recipro-
mers requiring non-lubricated compression with a first
in a gas depletion
cating and other compression systems. Moreover, our
class solution. We also manufacture compression sys-
plant of N.A.M. in the
broad experience enables us to meet the most
tems capable of:
stringent requirements.
●
northern part of
processing corrosive gasses, including HCL, wet C02, SO2 and H2S;
The Netherlands
Reciprocating compressors.
●
enduring high operating pressures, up to 600 bars;
Thomassen’s heavy-duty reciprocating compressors
●
running with suction temperatures below –100 C.
o
have the following design features: ●
Rigid construction.
One of the advantages of a reciprocating compressor
●
Easy access, facilitating maintenance.
is that loss-free capacity control can be realised in
●
Horizontally opposed and balanced cylinder design,
order to:
resulting in smooth, vibration-free operation.
●
keep energy costs low with varying demand;
Hydraulic crosshead-to-piston rod and piston
●
keep process conditions stable with
●
rod-to-piston connections. ●
Adjustable crosshead shoes, which are flat-faced for shimming.
●
varying demand; ●
start the compressor completely or partly unloaded.
Open type piston- and rider rings for easy mounting.
Compressors can have stepped or stepless capacity
●
Pressure relief on rider rings to ensure longer life.
control and may be operated manually and/or automa-
●
Rolled threads on all high tensile material bolting.
tically.
●
Ample valve cross-section and special gas
When you specify and buy Thomassen compressors,
passages within the cylinders, resulting in a
you are assured of the very latest engineering techno-
minimum pressure drop, low power consumption
logy and the finest construction available in reciproca-
and low operating costs.
ting machinery.
4
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The outstanding dependability and low maintenance of
1.
Thomassen compressors has been demonstrated by
A Diesel Hydro
the many systems currently in service around the
De-Sulphuriser (DHDS)
world.
plant using two model C-25.4 hydrogen compressors. Shell Fredericia.
2. A Model C-85.6 compressor jointly developed by 2.
Thomassen and Mitsui Engineering and Shipbuil-
3.
ding. The unit shown here is one of three supplied to a hydrocracking plant in Indonesia. Each unit
1. compresses hydrogen from 14.5 to 197.4 bara (in three stages) at a rate of 56,265 Nm 3 /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.
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Design & Engineering Design & Engineering.
Torsional vibration analysis.
The fact that we have our own manufacturing capability
With the increasing application of large, variable speed
allows us to put Thomassen quality at the heart of your
compressors, the rotating system must be studied in
installation. Our technical specifications - which meet or
detail to determine its torsional behaviour during start-
exceed API and ISO - reflect the strict requirements of
up and over a wide range of operating speeds and
the major oil and chemical companies. We have a strong
conditions. As part of this process, it is essential that
design philosophy and engage in fundamental research
the components and oscillating torque in the system
and testing, including improved simulation techniques
can be described as accurately as possible. Thomas-
that are confirmed by strain-gauge measurements of
sen’s computer model precisely simulates the real sys-
dynamically loaded components. All components we
tem by including moments of inertia that are variable
develop and design are subjected to rigorous static and
and crank angle-dependent. The model also enables
dynamic tests on Thomassen’s in-house heavy-duty
the influence of individual sources of damping to be
compressor. Moreover, the experience we gain in the
investigated.
field continually helps us to improve our systems.
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Finite Element Analysis. Thomassen has its own in-house finite element modelling (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
Digital image of a 2-cylinder compressor.
designs have excellent characteristics in terms of strength, rigidity and reliability.
CAD Design. We make extensive use of solid modelling techniques
Bearing Simulation program.
when designing compression installations. The above
Rod loads in reciprocating compressors are time-
picture shows a CAD model of a compressor installed
dependent, and differ for all bearings due to the sum-
at Petrogal in Portugal.
mation of gas- and oscillating component inertia forces. We have developed a simulation program for a
Our proactive approach to Design & Engineering has
dynamically loaded bearing, enabling us to analyse its
resulted in major improvements in uptime and reliabili-
behaviour under severe and variable operating condi-
ty. Our current target is to ensure that our reciproca-
tions. This program makes it possible to predict the
ting compressors can run continuously for a period of
influence of various parameters such as load, load
three years. And, as a result of tests run under real
reversal, speed, bearing clearance, oil temperature, oil
process conditions on our own test compressor, we
viscosity, etc.
anticipate even higher standards in the near future.
Disp Res 0.24300 0.21800 0.19400
Model illustrating the deflection of a segment of a double-acting compressor piston with preloaded piston rod.
0.17000 0.14600 0.12100
The loading included different gas pressures on both sides of the piston as
0.09710 0.07280
well as transient thermal conditions.
0.04850 0.02430 1.0E-16
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Compressor nomenclature 26
26
25
22 20
24
21
4 27
10
2 6
18
3 5 10 19
1
8
7
9 11 17 12
23
14
11
1 13 1.
Crankcase / oilsump
2.
Crankshaft with integral forged drive flange
3.
Main bearing
16. Piston with PTFE rider- and piston rings
4.
Connecting rod
17. Pneumatic valve actuator
5.
Crosshead
18. Multi-valve type cast cylinder
6.
Adjustable, replaceable crosshead shoes
19. Cylinder and stuffingbox lubricator
7.
Piston rod with hydraulic connections
20. Lube oil header
8.
Partition cover with oil and gas seal
21. Spacer block and tie rods
9.
Double compartment partition cover with gas seal
22. Frame cover
15
10. Crosshead guide / Distance piece
23. Crosshead guide support
11. Cooling water jacket
24. Flywheel
12. Stuffingbox
25. Single valve type cast cylinder
13. Replaceable dry type cylinder liner
26. Suction pulsation vessel
14. Valves
27. Discharge pulsation vessel
15. Forged steel cylinder
28. Clearance pocket
8
16
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18
7
14
28
17
Frame Size & Ratings API 618 Reciprocating Compressors Model
Rating kN
Rated Power kW
Rated Speed rpm
No. of 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
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Innovative techniques
Hydraulically Operated Variable Clearance Pocket The Hydraulically Operated Variable Clearance Pocket (HOVCP) allows for the loss-free adjustment of compression capacity. The HOVCP system can be actuated automatically, by means of a hydraulic power pack. As a consequence, it is possible to adjust capacity remotely. Replacing an existing (manually operated) clearance pocket with an HOVCP is easy, allowing downtime to be kept to a minimum.
HOVCP, including Power Pack Assembly
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.
Full assembly of a
•
Easy to disconnect during maintenance.
Hydraulically Operated
•
Simple construction, high reliability.
Variable Clearance Pocket.
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Free Floating Piston TM
Hydrofit
The weakest point becomes the strongest
Maintenance on non-lubricated compressors is often much higher, not least because rider ring wear is unpre dictable. Given today’s commercial pressures, which dictate running times of three years or more, higher servicing
requirements
clearly
present a problem. By rethinking the basic principles of The inside of the Hydraulic Fit (Hydrofit)
Side view: Free Floating Piston™.
compressor design, Thomassen has come up with a revolutionary solution, which equips the piston with a gas bearing. This design virtu-
This design of piston rod connection has been incorpo-
ally eliminates rider ring wear by allowing the piston to float freely on
rated in Thomassen reciprocating compressors for
process gas. The advantage of this idea is that rider ring wear only
more than 25 years. As the prime reason for piston rod
occurs for very short periods during start-ups and stops. The Free
failure is fatigue, the rod must be designed for maxi-
Floating Piston™ removes the weakest link in the chain as far as
mum fatigue strength. This particularly applies to the
compressor component failure is concerned.
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
The Free Floating Piston™
reduced substantially. Moreover, the assembly of the
technology is patented.
preloaded joint is both simple and easy to control accurately.
Side view: Measured pressure distribution on a Free Floating Piston™.
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Worldwide Servicing Our 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 reliability of your compression equipment by closely co-operating with your in-house engineers.
Our engineers regularly advise on adaptations to opti-
ciency of their installations. Although reciprocating
mise your existing systems. Combining our broad
compressor components last much longer nowadays,
expertise with the very latest tools, we not only exami-
a well-tuned maintenance programme helps you get
ne the operation of the compressor, but also focus on
the most out of your compression system by avoiding
the process around it. We use these studies to advise
unnecessary shutdowns. There are several ways in
customers about ways in which to improve the effi-
which this may be achieved.
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By monitoring all the key parameters, Thomassen Compression Systems Monitoring gives you the information 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 normally accounted for during operation. An on-line performance 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 vibration. Using additional equipment, coolant temperature, bearing oil temperature and crosshead oil temperature
100
3,75
80
3,00
60
2,25
40
1,80
20
1,35
Control Room
may also be measured. The data obtained gives you an insight into the compressor’s performance and
0
0 -60
-50
-40
-30
-20
-10
Trending figure of rod drop, indicating early rider ring wear
0
enables you to service the equipment in good time. Monitoring and performance tests may be conducted on virtually any make of compressor.
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Comprehensive compression solutions
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 nonThomassen 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.
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T H O M A S S E N C 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
Tel: + 31 26 4975200 Fax: + 31 26 4975201 E-mail: tcs@thomassen.com For Service Operating Companies, Sales Offices & Agencies, please visit our website.
www.thomassen.com
TCS-2-08/08-3070
The Netherlands