Multi-Stage Centrifugal Compressors

Reliably serving the energy industries

32

Evolutionary Designs Revolutionary Results

A History of Innovation and Success Product Lines

• Single/Multi-StageCentrifugalCompressors(API617)

• AxialAirCompressors(API617)

• Single/Multi-StageSteamTurbines(API611)

• Multi-StageSteamTurbines(API612)

Applications

• OilRefineries

• FCCApplications

• Chemical/PetrochemicalPlants

• EthylenePlants

• GasLift/GasGathering

• GasInjection/Transport

• LNGFacilities

• GastoLiquids

• AmmoniaPlants

• PowerGeneration

Since 1910, Elliott Company has earned a reputation for providing innovative solutions, unmatched expertise, and first-class service to the global turbomachinery marketplace. Elliott has designed, tested, and installed some of the industry’s most rugged and dependable equipment. In fact, some Elliott compressors and turbines installed in the 1940s and 1950s are still in operation today, either as originally supplied or upgraded to handle new process conditions or more stringent environmental standards.

We have been on the cutting edge of technological advancement throughout our history, consistently providing advanced technology in aerodynamics, rotor dynamics, process simulation, and metallurgy. Our customers have benefited from our state-of-the-art production innovations, including fabricated casing technology, high-pressure casing technology, and impeller welding techniques. The Elliott EDGETM development program evolved from our commitment to providing new approaches, processes, and technology while maintaining the quality and reliability that our customers have come to expect.

We understand that change is essential in achieving and maintaining a competitive edge in today’s business environment. Together with our customers and suppliers, we continue to innovate, improve, and expand our extensive portfolio of products and services that serve the energy industries.

Advanced Technology

Superior Performance Through Advanced Technology

ThroughourEDGEdevelopmentprogram,wecombineourcomprehensiveknowledgeofturbomachinerywiththelatestdesignsoftware,manufacturingprocesses,andmachinetools.Asaresult,Elliott’smulti-stagecentrifugalcompressorsleadtheindustryinbothperformanceandreliability.

Increased Aerodynamic Efficiency

Elliottusesstate-of-the-artinteractivedesignandpredictiontoolstooptimizeaerodynamicperformanceandincreaseflange-to-flangeefficiencies.CompressorimpellerandmatchedstationaryflowpathcomponentsaredevelopedusingComputationalFluidDynamics(CFD)analysesandothercurrentdesigntools.Three-dimensionalbladeprofiles,diffuserflowangles,crossoverbendcurvature,arearatio,andreturnchannelvaneshapesareoptimizedforeachimpellerstagetoprovidethebestpossibleefficiency.Additionalperformanceenhancementsareachievedbyimprovingtheflowdistributionchannelsattheinletanddischargevolutesandsidestreammixingareas.Theseenhancementsallowustoprovidesomeoftheindustry’shighestoperationalefficiencies.

Improved Rotor Stability Characteristics

Throughextensiveresearchinthefieldsofrotor-dynamicstability,aerodynamiccross-couplingstiffness,androtor-bearingsystems,wehavedevelopedproprietaryanalyticaltools.IncorporatingthesedevelopmentsintoElliottcompressordesignshasproducedanumberofproductenhancements.Forexample,we’veincreasedrotorstiffnessbyincreasingshaftdiameter,reducingimpellerweight,andincreasingjournalbearingsizes.Thisallowshighertorquetransmissioncapabilitiesandhigher-speedoperation,withimprovedrotorstabilitycharacteristics,whichareessentialasgasdensitiesandoperatingpressuresincrease.

54

Casing Features

We Perform Under Pressure and Make Field Assembly Easier

EDGE Casing Advantages

• Integralhorizontalflangesonsmallandmediumframes

• Solidendwallswithmachinedflatsforbearingandsealconnections

•MachinedflatswithSAEflangesformostdrainorinjectionconnections

• Through-boltsforcasinghorizontalflanges

• AllowableforcesandmomentsperAPI617

• Three-dimensionalsolidmodelingforimproveddesignandengineeringreviewcapability

• Pro/ENGINEERsolidmodelingfilestoenhanceprecisionduringcomponentmanufacture

ElliottdesignedourEDGEcompressorcasingstoreducetherequiredmanufacturingstepsandsimplifyfieldassembly.Toachievehigheroperatingpressures,weappliedstate-of-the-artsolidsmodelingandfiniteelementanalysistechniques.

Smallandmid-sizedhorizontallysplitcasingsectionsaremadefromasinglepieceofrolledsteelplatewithhorizontalflangesthataremachined—notwelded—intotheside.Caststeelcasingsareusedforsomeapplications.High-strengthcasingthrough-boltsprovidesuperiorclampingforces.Endwallsaremadefromasinglesolidplate.Theresultingcasinghasfewersealingsurfaces,iseasiertomanufactureandassemble,andhasincreasedpressurecapabilitiescomparedtoconventionaldesigns.Largerhorizontallysplitcasingshaverolledbarrelsectionswithwelded-onendplatesandwelded-onhorizontalflanges.

VerticallysplitMB-linecompressorsfeatureacompleteinnercasingassembly.Thisincludesahorizontallysplitinnercasingwithdiaphragms,stationaryseals,rotatingelements,bolted-onendwalls,andshaftendseals.Thismodulecanbeinsertedorremovedfromtheoutercasingasasinglepiece,whichsimplifiescompressorassemblyandreducesturn-aroundtimes.

WetypicallyusemilledflatsforSAEflangedconnections,includingendwall,spraynozzle,casingdrain,bearingretainer,andequalizinglineconnections.Onsmallercasingswherespaceislimited,SAEflangesprovidehigherratingsandmorecompactdesignsthanANSIflanges.

Aerodynamic Components

Advanced Aerodynamics and Enhanced Performance Give Our Customers the EDGE

EDGEcompressorsuseeitherfabricatedsteeldiaphragmsoracombinationcast-and-fabricatedsteeldesignwherethicknessprecludesusingsteelplatealone.Precisionmachiningensuresdimensionalaccuracyandsignificantlyimprovesthediaphragmsurfacefinish.Diaphragmsarehorizontallysplitandfinishedatallhorizontalandperipheraljointsandongaspathsurfaces.

AkeyachievementoftheEDGEdevelopmentprogramisourabilitytooffersuperior,three-dimensionalimpellerdesignsandstationarydiaphragms.Wedothisbymaximizingperformanceoverabroadrangeofpressureandflowapplicationsusingthelatestaerodynamicdesignandanalysistechnologies.Toverifypredictedperformance,single-stagetestingisperformedinvariousconfigurations,suchaswithvanelessorvaneddiffusers,orusinghighorlowtipMachnumbers.Higherandlowerflowstageratingsarederivedfromtheprototypetestdatatoforma“family”ofstages.Withineachstagefamily,impellergeometryisfixed;bladeheightsarevariedforhigherorlowerflows.Usingthismethodology,severalstagefamiliesareusedtospanthedesiredflowcoefficientrange.Impellersandstationarycomponentsarethenscaledupordownfordifferentframesizes.Formaximumflexibility,EDGEaerodynamiccomponentsarealsoscalablefrom90percentto100percentsizewithineachcompressorframesize.

Impellermanufacturingappliesfive-axismillingtoensurethequalityoftheadvancedimpellerdesigns.Impellersarestressrelieved,machinefinished,balancedstaticallyanddynamically,spintested,andthenmountedwithaninterference-fitontotheshaft.Shaft-to-impellerkeysareusedforextrastabilityinhighpressureorhighpowerapplications.

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Proven Turbomachinery Technology

Castnozzlesreducemanufacturetimeandallowhigherratings

Eliminationofdishedheadsincreasespressureratings

Increasedjournalbearingandshaftsealsizes

Non-radialinletguidevanesimproveflowdistribution

Increasedshaftdiameterenhancesrotordynamics

Preciselydesignedandmachineddiaphragms

CFDensurespropersidestreammixing

High-efficiencyimpellersscaleframe-to-frame

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Other Features

We’ve Paid Careful Attention to Every Detail

AspartofourcomprehensiveEDGEdevelopmentprogram,Elliott’sengineersexaminedeachcompressorcomponenttofindwaystosupportourgoalsofhigherefficiency,lowercost,simplermaintenance,andreducedcycletime.Ourdesignsreflectourcommitmenttomakingourproductsthebestintheindustry,downtothelastdetail.

Interstageandbalancepistonsealingisaccomplishedthroughtwocomponentfeatures.First,weuseabradableordeflection-tolerantmaterialssuchasfluorosintornickel-graphiteonstationarysealingsurfaces.Second,wemachineteethontotherotatingsurfaces.Thesefeaturesincreaseefficiencybyreducinggasrecirculationandminimizingthepotentialforshut-downsresultingfromdamagedseals.

Elliottoffersshaftsealstomeetourcustomers’needsinallapplications.Drygassealsarestandardandareavailableassingle,tandem,double,ortripledesigns.Thetandemortriplegassealdesignsincludeanintermediatelabyrinth,

whichcanbebufferedforadditionalemissionsprotection.Ourcustomersrealizecostsavingsbyeliminatingexpensivesealoilsystemsandtheneedtodisposeofcontaminatedoil.GassealbuffersystemengineeringandmanufacturingareavailableatElliott’sDonora,Pennsylvania,plant.

Alternativesealdesignsincludelabyrinthordrycarbonringsealsforlowpressureservices,mechanicalcontactseals(Elliott’spatentedIso-carbonTMdesign),andbushingseals(Elliott’sIso-sleeveTMdesign).Formechanicalcontactandbushingseals,acartridgedesignisalsoavailable.Thisenableseasierinstallationandremovalofthecompletesealassembly.Bufferconnectionsarestandardforallsealdesigns.

Reliability,quality,andsafetyarehallmarksofallElliott-designedcomponents.Forexample,asadesignstandard,replaceablejournalbearingsaresteel-backedandbabbitt-linedwithafive-shoetiltingpad.Thrustbearingsaredouble-actingandself-equalizing.Centerpivotstypicallyareusedtomakeassemblyeasierandtoprovidemaximumprotectionifreverserotationoccurs.Chrome-copperpadsareappliedforbothjournalandthrustbearingsforhighoiltemperatureapplications.

Manufacturing and Testing Capabilities

A Commitment to World-Class Manufacturing

Elliottemployshigh-qualityproductiontechniquesthatminimizecycletimeandcostswhileprovidingourcustomerswiththemostcompetitiveandreliableproducts.OurengineeringandmanufacturingfacilitiesinJeannette,Pennsylvania,andSodegaura,Japan,rankamongtheworld’smostadvancedforturbomachinerydesign,production,andtesting.

OurcombinedmanufacturingcapabilitiesincludeMasterheadmachiningcentersforcasingmachining,rotormachiningcenters,anddiaphragmmachiningcenters.Ourrotorbalancingfacilitiesincludeastate-of-the-artSchenckTrebel-designedbalancingmachinehousedinabunker-stylevacuumchamber.Thetopofthisreinforcedconcretefacilityslidesawayviahydraulicmotors,permittingrotorstobeloweredontothebalancingequipment.

Ourrecentlymodernizedandexpandedtestfacilitiesenableustovalidatethemechanicalintegrityandperformanceofourcomponentsandoverallsystems.Ournewmaintestfacility,whichincreasedourcapacityby50percent,containsahigh-volume,closedloop,speciallydesignedcoolingsystemwiththecapacityfortestinggasturbine-drivencompressortrainsatfullloadsupto100,000HP.

Masterheadcasingcenter

Diaphragmmachiningcell

High-speedbalancefacility

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Standardization of Components

IndevelopingtheEDGEcompressorproductline,wefocusedonstandardizingcomponentsandhardwaretoreducecostsandimprovereliabilityacrossawidearrayofapplications.TheEDGEproductlineconsistsof15standardframesizes,whicharescaledfromthe38Mmedianframesize.Casingboresandinternalaerodynamichardware,suchasimpellers,diaphragms,andshafts,arescaled.Scalingaerodynamiccomponentsimprovesperformancepredictabilityandincreasesreliabilitybypreservinggeometricsimilarityacrossframesizes.Bearingsandsealsareselectedfromvendorstandardsizesforeachapplication.

Compressor Frame Summaries

FrameTypical Flow Range

(icfm) (m3/h)

Casing Rating Axial Split

(psig) (Barg)

Casing Rating Radial Split

(psig) (Barg)

Nominal Impeller Diameter

(in.) (mm)

Nominal Speed(rpm)

10M1,700-5,400 2,900-9,200

1,000 68.95 — —10.38 263.55 19,800

10MB — — 10,000 689.48

15M2,200-7,100 3,700-12,100

1,000 68.9511.93 303.07 17,300

15MB — — 10,000 689.48

20M2,900-9,400 4,900-16,000

1,000 68.95 — —13.72 348.54 15,000

20MB — — 10,000 689.48

25M3,900-12,500 6,600-21,200

1,000 68.95 — —15.78 400.81 13,100

25MB — — 10,000 689.48

29M5,100-16,500 8,700-28,000

1,000 68.95 — —18.15 460.93 11,400

29MB — — 10,000 689.48

32M6,800-21,800 11,500-37,000

1,000 68.95 — —20.87 530.10 9,900

32MB — — 5,000 344.74

38M9,000-28,800 15,300-48,900

1,000 68.95 — —24.00 609.60 8,600

38MB — — 3,000 206.84

46M11,900-38,100 20,200-64,700

1,000 68.95 — —27.60 701.04 7,500

46MB — — 2,000 137.90

56M15,700-50,400 26,700-85,600

1,000 68.95 — —31.74 806.20 6,500

56MB — — 2,000 137.90

60M20,800-67,000 35,300-113,800

1,000 68.95 — —36.50 927.13 5,600

60MB — — 2,000 137.90

70M27,500-88,000 46,700-149,500

750 51.71 — —41.98 1,066.19 4,900

70MB — — 1,500 103.42

78M36,400-117,000 61,800-198,800

600 41.37 — —48.27 1,226.13 4,300

78MB — — 1,500 103.42

88M48,100-154,000 81,700-261,600

600 41.37 — —55.51 1,410.03 3,700

88MB — — 1,000 68.95

103M 63,600-203,000 108,100-344,900 400 27.58 N.A. 63.84 1,621.54 3,200

110M 84,100-270,000 142,900-458,700 400 27.58 N.A. 73.42 1,864.79 2,800

Weights, Dimensions and Configurations

Frame Size

Minimum Rotor Length

(in. / mm)

Maximum Rotor

Length(in. / mm)

Casing Width (includes supports) (in. / mm)

Casing Height(exc. supports)

(in. / mm)

Minimum Cas-ing Weight

(lb/kg)

Maximum Casing Weight (lb / kg)

Typical Weights and Dimensions for Elliott Horizontal Split Compressors*

10M 35/890 64/1,625 37.3/947.4 36.25/921 4,700/2,130 9,000/4,080

15M 35/890 75/1,905 42.5/1,080 41.38/1,051 5,600/2,540 12,700/5,760

20M 40/1,015 80/2,030 48.5/1,232 47.85/1,215 8,200/3,720 18,000/8,165

25M 45/1,145 90/2,285 55.1/1,400 54.12/1,375 11,100/5,035 24,500/11,100

29M 50/1,270 110/2,795 65.4/1,661 59.25/1,505 14,000/6,350 32,000/14,500

32M 50/1,270 124/3,150 70.5/1,791 65.75/1,670 15,700/7,120 45,000/20,400

38M 55/1,400 135/3,430 76.3/1,938 70.62/1,794 23,000/10,430 62,000/28,100

46M 70/1,780 155/3,940 66.5/1,689 89.5/2,273 32,500/14,740 87,000/39,500

56M 80/2,032 175/4,445 76/1,930 93.38/2,372 51,500/23,360 127,000/57,600

60M 90/2,285 190/4,825 89.7/2,278 97/2,464 59,000/26,760 170,000/77,100

70M 100/2,540 230/5,840 103.5/2,629 113.88/2,893 71,000/34,000 210,000/95,250

78M 100/2,540 250/6,350 109.5/2,781 125.5/3,188 95,000/43,100 295,000/133,800

88M 115/2,920 275/6,985 133/3,378 137.5/3,492 130,000/59,000 380,000/172,400

103M 135/3,429 300/7,620 156/3,962 158.5/4,025 215,000/97,500 525,000/238,100

110M 140/3,556 325/8,255 182/4,623 182/4,630 270,000/122,470 690,000/312,980

Typical Weights and Dimensions for Elliott Vertical Split Compressors*

10MB 35/890 62/1,575 43/1,092 42.5/1,080 7,000/3,175 13,000/5,900

15MB 35/890 72/1,830 46/1,168 48/1,219 8,400/3,810 17,500/7,940

20MB 40/1,015 80/2,030 50/1,270 53.75/1,366 12,000/5,440 25,000/11,340

25MB 45/1,145 88/2,235 58.5/1,486 62/1,575 18,400/8,345 36,000/163,030

29MB 50/1,270 105/2,670 64.3/1,633 64/1,626 23,000/10,435 49,000/22,225

32MB 50/1,270 120/3,050 71.7/1,821 76.5/1,943 28,500/12,900 69,000/31,300

38MB 55/1,400 130/3,300 78.5/1,994 83.25/2,115 36,500/16,560 89,000/40,400

46MB 70/1,780 150/3,810 96.5/2,451 86.5/2,197 47,500/21,500 115,000/52,200

56MB 80/2,030 170/4,320 104.2/2,647 102.12/2,594 70,000/31,750 160,000/72,600

60MB 90/1,525 185/4,700 113/2,870 112.5/2,858 90,000/41,000 200,000/91,000

70MB 100/2,540 225/5,715 115.2/2,926 120.96/3,064 100,000/45,350 251,000/113,900

78MB 100/2,540 245/6,225 120/3,048 140/3,556 125,000/56,700 315,000/143,000

88MB 115/2,920 265/6,730 137/3,480 148/3,759 205,000/93,000 465,000/211,000

*All data are estimates.

In-Line

In-Line with Iso-Cooling

Double-Flow

Back-to-Back Iso-Cooler Optional

In-Line with Side-Streams

Elliott Group901 North Fourth StreetJeannette, PA 15644-1473Phone: 724-527-2811Fax: 724-600-8442Email: info@elliott-turbo.com

Elliott Company reserves the right to modify the design or construction of the equipment described in this bulletin and to furnish it, as altered, without further reference to the illustrations or information contained herein.

©Elliott Group 2011

www.elliott-turbo.com