HITACHI Inspire the Next he Kale meter Compressors @dHitachi Plant Technologies, Ltd.Hitachi world leader in the manufacturing of heavy industrial equipment, electronics, and consumer product, maintains our strictly controlled quality standards to offer every customer a superior product, Hitachi Creare Saat turing centrifugal compressors since 1910, and has delivered more than 1000 eee ee ema) cite Eten Cr en ake Ceram tna Me ee Pacey Tee CumCartag Cert eeeg cas NE Sree ETD Deen Senate on See eae tg ee ee ea Oey aR ae cee eM Cee Sn Ce ee eyCONTENTS Compressor Line-up 3-10 jorizontally Spl Overhang Co Components 11-16 i "l Seal Gas S\ gnatic Bearing Control Sy Design Automation Systerr Process Dynamic Simulation Nozzle to Roto, s ‘cilities 19-20 Retrofit Services and Upgrade Compressor a TrainirCompressor Line-up Pee NE ker eee e1s)} Meee eee etc Gee Rg Sean et Se ea Eee Meee rm ele re tc Wall thic a pen Rae eee Eis ais erence roportis fixed by bolts and knock pins to provide high | See Ue eM rel eR eae Ube emia mer tBu eC OR ein AU Coen ee eas ree Telos, een am eee see] -1eis 1Compressor Line-up Horizontally Split Compressors (MCH) SE gene eoge eto Tene ees er Section provide: im dlephragme, ere ed by removing only the bearing itis not necessary Dee ee i eae ene enh)Compressor Line-up eo Re een ela}We have developed standardization of pipeline compressors. In order to optimize the compr. performance in accordance with customer's request, pipeline comp are standardized into 8 Frames & 7 Rotors. ‘The capacity can be covered from approx. 3,000 to 24,000 mist. 10% Retation 2,000 speed © 6000 10,000 15,000 20,000 25,000 30,000 ‘Suction Volume (m/hr) Arrangement of Gas Turbine and Compressor Module Puan Unt Suction Serutter init Volee Sd Scrubber Bind Vae Ste se eT Inet Compartment | ——, 3 Eo | ELEVATION M Surge Tanks cee eye seiaoe Crane Crane —— — jel alter ch ees , |S) sabes ll ag Sa oosdkee =, “aio os qo P che Regen Soviet sect Her Render HesterCompressor Line-up Overhang Compressors which give higher efficiency and wide err! aes PM eto aka ea tea me sae Cregeen reed) NUR oes Pret) See eae ea oe eg ee eee toiComponents Casings kinds. ions. On sing na ntally split type and the other is vertically split type. Based on the pressure and the gas handled, the construc In terms of material used, Diaphragms Diaphragms are located in the casing to effic ly convert th dynamic energy of the gas at the impalier autlet to static pres re provided which dire 1 the gas flow to the d or casting construction, and the return NACA profile wings. In the case of welded onstruction diaphragm, the return vane wings are precision N/G-machined, Pressure a cross the diaphragm differs slightly, but a particularly la differential pressure may occur across the intermediate diaphragms in back-to-back arrangement, In the computer design sys FEM with the n ula diaphragm deforma s are made ‘emphasis places on preventing contract between the diaphragm and he rotor, and the labyrinth and the rotor, Inlet Guide Vane (IGV) 1g IGV, lower starting torque is achieved particularly for ion compressor without raisin motor frame size, brings benefit of wider turn do n range for constant pressureRotors ‘The rotor consists of shaft, impaliers, balancing drum and thrust collar. The shatt is properly heat-treated and. the impellers and balancing drum are shrunkfit to the shaft. Generally, sleeves are placed between the impellers to prevent direct exposure of the shaft to gas, Two or three dimensional impellers are manufactured by applying a welding or diffusion bonding (welding) (08) process, machining, or precision forging. The shape of the gas passage, hydrodynamic design points and detailed dimensions of the impel determined by computer, based on Hitachi's proven are accurately optimum design methods. In the case of welded construction or DB construction, the blades are usually N/C-machined from hubs, welded parts are limited to the shroud and blade. Welded parts are subject to magnetic particle, ultrasonic, radiographic and dye-penetrant inspections, and heat treatment is applied before and after welding and DB, DB is a Hitachi patented technology (PATENT No. US5964398) by which easy manufacturing particularly, for narrow tip width impeller becomes possible and due to which precise dimensional construction (no. deformation such by welding] becomes also possible, The balancing drum, which reduces the axial thrust of each impeller, is designed to minimize the residual axial thrust in all working conditions with due consideration, paid to the force of the coupling. The residual thrust is, borne by titing pad type thrust bearings. ‘The shaft end seal is covered with a sleeve to protect the shatt from damage, especially at points of small clearance. The vibration sensor mounting section is machined simultaneously with the journal bearing part to minimize mechanical runout Laser Slot Welding | Poneaion J Denoat West = ae DimessonsComponents Bearings Journal bearings Tilting pad type bearings are generally used for journal bearings. For every bearing, rotor dynamics calculations are performed, including those for rotor critical speed, stability, and response due to unbalance distribution, with due consideration paid to bearing stiffness and damping caused by cil film. Tilting pad type bearings are particularly effective against oll whirling and have outstanding stability. Hitachi's pads are constructed to allow for aojust ment of the oil clearance. Magnetic bearings Since the active magnetic bearings provide contact-ree rotor support, parts and components do ot wear, In addition, there is no ne@d for a lubricating system, which improves compressor reliability. With, ci-less operation, the bearings suffer no mechanical s. Without a lubricating system and related power required by the components, the uti ‘compressor is significantly reduced, Thrust bearings The thrust bearings are of the double Kingsbury titing pad type for equal distribution of the thrust lo minimization of mechanical loss. Damper bearings Damper bearing is used to dampen the rotor and thus stable operation i film secured, Due to the oil sque outside of the cage-type spring, the Amplification Factor of critical speed is well suppressed,Seals These serve to eliminate or minimize the age of compressed gas from and the entry of air into the compressor casing. The choice of the seal type is made on the basis of the gas characteristics and operating conditions; Dry gas seal Oil film seal Labyrinth seal (1) Aluminum seal (2 Rub tolerance seal (@ Abradable sealComponents Oil Systems The lube ol system provides forced lubrication to the joumal anc! thrust beatings. The seal ol system supplies ol ata slightly higher pressure than the compressor's internal gas pressure (reference gas pressure) in case oil flm seal and mechanical se Both systems are provided with main and auxliary pumps, cookers, filters, eto. for continuous operation. Generally, these systems are designed in accordance with API standards, and all interconnecting piping and valves ere Compact in size and designed to alow access and operation. These systems are available as separate systems or as combined system in which the lube oil system supplies some Gil to the seal all system,Control System : HCCS (Hitachi Compressor Control System) HCCS has adopted HMI as standard. That consists of redundant PLC, anti-surge/ performance controller and vibration/bearing temperature monitoring system, which achieves optimized operation and high reliability. Also, the system is very flexible to meet customer's special requirements. By applying the latest brand new technologies, human-triendly system is feasible. Seal Gas System The dry gas seal requires external seal gas, which shall be fitered and shall be tree of any contaminants that form residues in order to avoid damage of seal components, The seal gas system supplies the seal sor's gas at a slightly higher pressure than the compre fal gas support system is designed to control the seal gas pressure, to measure leakage gas, and to detect abnormal condition ofthe seal internal gas pressure. Generally thy Magnetic Bearing Control System In magnetic bearing systems, the compressor shaft is, levitated in the air gap by controlling magnetic forces of electromagnets. To regulate the shaft position, the position signals are always fedback to the magnetic, forces through the signal processors and power amplifiers. Hitachi has originally developed the controller design and will provide the panel based on this scheme. 16Design Automation System Error Elimination at Every Sta e, from Design to Fabrication, Minimizes Operating Problems. For mission-critical equipment in a plant, such as centrifugal compressors, not even the slightest error in design or manufacture is permissible. Hitachi utilizes the most advanced design and manufacturing technologies availa prod ice compressors the highest quality and reliabilty Working from order specifications, the Design Automation System automatically designs and organizes the manufacture of centrifugal com producing everything from dl ings to tapes for N/C jobs, This system dra on years of experionce as woll as the l st data analysis processes and know-how. {features of this computer design system: © Capable of producing complete, error-free designs based on the latest know-how and calculation pro © Short design times, ensuring qu @ Be dalivery; des producing all drawings and N/C tapes, the system is connected to the overall manufacturing process ntrol system to ensure rapid, high-quality production. Process Dynamic Simulation ‘ioassessonseecaiaiaes ¢ P ‘Simulation feasible = Compreasor startup, shut-down eration of compressors (load-sharing) ‘Others [Sample of Simulation] 4 Propvlene Refrigeration CompressorSt ‘Cone Capac wvNozzle to Nozzle Flow Analysis Rotor Dynamics Calculations The design system outputs data only when the rotor system is completely stable through the entire operating range. Calculations are made not only for torsional analysis and lateral i critical speed analysis but also for response due to unbalan mass distribution, with bearing stiffness and damping, and occasionally aerodynamic excitations, taken into consideration, Packaging with 3-D CAD By adopting 3-dimensional CAD system, packaging of compressor, drivers (ex. motor and gear), seal gas unit, lube unit and relevant auxiliary piping/tubing/wiring are easily planned ancl designed securing good maintenanceabilty and easy access,Test Facilities Se a es saa UN eee ony ceo See een eeu ct Se CEE We iach eo eae ec ag Te etre ae ee Cale Cee cree ieee ters oa el Se ea et tae nop eee Oa erent ak ray Cae tc a asReal Time Access to Hitachi Shop TestAfter-Sales ServicesRetrofit Services and Upgrade Compressor Hitachi has many experiences of retrofit service and upgrade compres sor to centrifugal compressor, Application of latest technologies, high performance impellers, dry gas seal retrofit, coating system and repairing technologies, can realize reduction of maintenance cost and operating cost. Especially, replacement of compressor intemals can be designed to increase the flow rate and for more large demand of process. Hitachi can offer both new high performance compressors and compressor modernizetions. [Before] 40% Capacity-up with Existing S/T & New Compr Training Personnel raining is offered as a service for our customers Conducted in the shop with the actual equipment and skilled instructors on hand, this training allows your staff to acquie/improve the basis knowedge and the skils necessary for compressor operation and maintenenApplications Oil & GasApplications Oil & Gas~ osApplications berriesModel Numbers Hitachi's centrifugal compressors are identified with a 5-black madel number, thus: 026 6 6 2 BCH 306/A ()This prefix number indicates the compression group type. No number indi Je group arrangement with a single outlet and inlet; the number 2 indicates 2-group compression with ck-to-back rotor arrangement; and the number 3 indicates a side ream arrangement ©The letters indicate the type of 19, while BCH indicates a vert ing: MCH represents a horizontally split ca ally split barrel type casing ()The letter 'H’ indicates High-quality, High-perform: High-reliability by Hitachi (4)The next s the nominal diameter of the (The final number indicates the number of stages. Normally, one to nine stages can be ineorporatad in a single casing, (For BCH type compressors, high-pressure models are identified withe a suffix: /A, /B, 0, etc. (See examples below). in addition to the above, there are PCH type compressors, intended mainly for pipeline applications, MCH, BCH, and PCH compres bed on the following pages. 3 MCH 100 6 BCH 45 2 BCH 406 (6) For BCH Type only ry ns umber ot meters hs Unnumbered Straight-through Arrangement "2" Back-to-Back Arrangement Selection Diagram as lar orm nS town hss aa fcr