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1< >MAN Diesel & Turbo DF/MDT-NA Gas Storage and Sealed Technology (OSS) Feb 6-7, 2013
Gas Electric Technology Update 2013: Stealth Compressor Stations
MAN Diesel & Turbo North America Inc.
2< >MAN Diesel & Turbo DF/MDT-NA Gas Storage and Sealed Technology (OSS) Feb 6-7, 2013
© MAN Diesel & Turbo Schweiz AG 2012 - All rights reserved.All Data and Information contained in this document is provided without liability for information purposes only,explicitly non-binding and is subject to change without notice. No representation or warranty is given or to beimplied as to the completeness of information or fitness for any particular purpose.Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
All Data and Information contained in this document is provided without liability for information purposes only,explicitly non-binding and is subject to change without notice. No representation or warranty is given or to beimplied as to the completeness of information or fitness for any particular purpose.Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
3< >MAN Diesel & Turbo DF/MDT-NA Gas Storage and Sealed Technology (OSS) Feb 6-7, 2013
Stealth Compressor Stations
Why Stealth Compressor Stations?More and more compressor station encroachments onto populated or residential areas due to new or expanded
infrastructure resulting from Shale play or system expansions.
Station in Maryland in an affluent residential area
Station adjacent to a very large metropolitan city (confidential client
and installation location)ISD 1H 2014
4< >MAN Diesel & Turbo DF/MDT-NA Gas Storage and Sealed Technology (OSS) Feb 6-7, 2013
Definition of a Stealth Compressor Stations
Definition of a Stealth Compressor Station:
• Building aesthetics blending with the surroundings• Safety – Minimize possibilities for leakage / releases
• Low noise• Zero environmental emissions
• No compressor depressurization (blowdown)• No lube oil storage
• No lube oil disposal and associated truck traffic• No ground oil contamination, etc.
• No or minimal exposed aboveground piping• Minimal exposure of gas coolers to outside the facility
Technology that made this happen: MOPICO!
5< >MAN Diesel & Turbo DF/MDT-NA Gas Storage and Sealed Technology (OSS) Feb 6-7, 2013
Stealth Station Design
Stealth Stations Design:Requires a small compressor footprint to allows space for all station piping to be placed inside the compressor building.
Station in Maryland in an affluent residential area
6< >MAN Diesel & Turbo DF/MDT-NA Gas Storage and Sealed Technology (OSS) Feb 6-7, 2013
Operating Experience
Three (3) MOPICO RM 40Commenced operation 1995In 2009 total operating time at this station > 100,000 Hours
7< >MAN Diesel & Turbo DF/MDT-NA Gas Storage and Sealed Technology (OSS) Feb 6-7, 2013
Other Discrete Station Designs
Québec, Canada
8< >MAN Diesel & Turbo DF/MDT-NA Gas Storage and Sealed Technology (OSS) Feb 6-7, 2013
Other Discrete Station Designs
Europe
9< >MAN Diesel & Turbo DF/MDT-NA Gas Storage and Sealed Technology (OSS) Feb 6-7, 2013
Gas Storage Applications
Stagecoach Gas Storage Facility
Employs three identical hermetically sealed turbo compressors for either parallel or 2- into 1-series operation
A high performance gas storage facility in New York State, USA
10< >MAN Diesel & Turbo DF/MDT-NA Gas Storage and Sealed Technology (OSS) Feb 6-7, 2013
Oil-free, Hermetically Sealed MOPICO™
Axial Magnetic Bearing
Overhung Impeller
Directly Installed on to
Motor Shaft (No Couplings)
High Speed Motor
Motor Main Terminal Box
Process Gas Connections
+ hermetically sealed casing+ No shaft seal+ Series / parallel operation+ Active Magnetic Bearings+ Motor internal gas cooling+ No lubrication
11< >MAN Diesel & Turbo DF/MDT-NA Gas Storage and Sealed Technology (OSS) Feb 6-7, 2013
Wear and Maintenance contact and wear-free operation minimum maintenance requirements
Elimination of Components gearboxes couplings lube oil system shaft seals
Emissions environmentally neutral
no emissions to atmosphere lower noise levels no oil spills
Space and Weight minimum space requirements
reduced weight minimal visual impact
Operation best suited for remote operation
minimum local manning requirements
Significant Advantagescompared to
ConventionalCompression Systems
Advantages of High Speed Technology
12< >MAN Diesel & Turbo DF/MDT-NA Gas Storage and Sealed Technology (OSS) Feb 6-7, 2013
Flare
General train layout comparison
Conventional Tandem Casing Train
HP Compressor LP Compressor
Coupling Coupling
Coupling
Motor Gearbox Shaft Seals
+ No gearbox nor Vorecon nor lube oil system+ No shaft seals nor seal system+ No emissions+ Reduced footprint / smaller motor+ Wide operation envelope+ No alignment / re-alignment at site + No misalignment due to piping forces
Flar
e/ve
ntConventional train configuration
MOPICO® / HOFIM™
HP Compressor Motor LP Compressor
Typical Train Configuration
13< >MAN Diesel & Turbo DF/MDT-NA Gas Storage and Sealed Technology (OSS) Feb 6-7, 2013
Elimination of System Fugitive Emissions
NO DRY GAS SEALS ELIMINATE THE FOLLOWING COMPONENTS ON A TANDEM
COMPRESSOR TRAIN • Elimination of 30 Electronic Transmitters, 6 Control Valves
and other local instruments
• Elimination of 120 hand valves
• Elimination of over 72 adjoining flanges
• Numerous tubing fittings and threaded connections
14< >MAN Diesel & Turbo DF/MDT-NA Gas Storage and Sealed Technology (OSS) Feb 6-7, 2013
Consequential Development Path
Two decades of pioneering innovative compression technology
1989-2013
98 compressor units –with over 1,000,000 operating hours
the design concept proved to be excellent for oil & gas requirements
15< >MAN Diesel & Turbo DF/MDT-NA Gas Storage and Sealed Technology (OSS) Feb 6-7, 2013
Centrifugal CompressorAvailibility & Reliability Comparison
Comparison of Compressor Types
Compressor Type Availability %
Reliability %
IMR&O hr/year
Forced DT hr/year
MTBF year
Axial 99,1 99,8 76,4 16,4 9,1
Centrifugal, clean i
99,7 99,8 24,8 18,8 8,0 Centrifugal, fouling service 99,0 99,5 90,6 40,6 3,7
Recip., lubricated 97,3 97,8 237,2 189,2 0,5 Recip., conv. non lube 91,3 92,3 766,1 670,1 0,3
Recip., labyrinth piston 97,6 98,3 207,2 147,2 2,0
Screw, oil free 99,0 99,7 90,0 30 5,0
Screw, oil injected 97,7 98,8 199,9 99,9 1,5 Notes IMR&O Inspection, Maintenance, Repair & Overhaul MTBF Mean Time Between Failure DT Down Time
The above tabulation shows the average values, based on a statistic presented in
Jan. 1999
16< >MAN Diesel & Turbo DF/MDT-NA Gas Storage and Sealed Technology (OSS) Feb 6-7, 2013
ONSHORE GAS TRANSPORTPlant: Chazelles, FranceClient: GRTgaz (GDF Suez)Duty: Pipeline Compressor
MAN Diesel & Turbo EquipmentCompressor type: 3x MOPICO RM50Driver: MAN M43Frame Size: RM50 (Series)Handled Gas: Natural GasFlow: 850 MMSCFDPressure in / out: 655 / 1’240 psiaPower: 17,400 HPSpeed: 9’000 rpmSeal type: None -
Hermetically Sealed
Chazelles M43 RM50 2010
17< >MAN Diesel & Turbo DF/MDT-NA Gas Storage and Sealed Technology (OSS) Feb 6-7, 2013
High-Speed Packaging Zurich
18< >MAN Diesel & Turbo DF/MDT-NA Gas Storage and Sealed Technology (OSS) Feb 6-7, 2013
Summary
Unique station design requirements due to encroachment on to populated or residential areas
Use of sealed integrated high speed technology to mitigate the following issues:
• Safety – No shaft seals / Minimum interfaces• Low noise• Zero environmental emissions• No compressor depressurization needed (blowdown)• No lube oil storage• No lube oil disposal and associated truck traffic• No ground oil contamination, etc.
Questions?