Jinzhou NEW JCM Machinery Manufacturing Co. Ltd.
TURBOMACHINERY
REVAMPING
RECONCILIATION OF HIGH EFFICIENCY
AND LOW COST
• Revamping and Upgrading
• Adapt existing compressor and steam turbine to new process condition
E N H A N C I N G • E F F I C I E N C Y • R E L I A B I L I T Y
NEW JCM
INTRODUCTION
NEW JCM, carrying the heritage industry brand of JCM, is one of the
major Turbomachinery Manufacturers in China. With more than half a
century of experience, from Maintenance, Repair, Revamp and
Upgrading to Design, Manufacturing and Testing of Centrifugal
Compressors and Steam Turbines, NEW JCM provides Total Solutions
for the compression applications in the oil, gas, petrochemical and the
refining industries.
Located in an industrial area of Jinzhou City, Liaoning Province of the
P. R. China, NEW JCM has the unique capabilities for design,
engineering, manufacture and testing of API 617 Centrifugal
Compressors, API 612 Mechanical Drive Steam Turbines, API 613
Gearboxes, and API 614 Oil Units.
The Company’s main focus is on Compressors and Turbines for
SYNGAS based technologies including Ammonia and Urea Plants,
Methanol Plants and Refrigeration Applications: Other applications like,
injection, recycle gas and natural gas booster compressors are also
among NEWJCM's common products. Years of studying and working
with different plant licensors as well as continuous constructive
feedbacks from different customers, users and operators, NEW JCM
optimised the design and manufacturing methods and hence, its
Compressors and Turbines have established an outstanding track
record for performance, efficiency, reliability, and low maintenance in
the most demanding and arduous upstream, midstream and
downstream applications.
REVAMP
REQUIREMENT
Nowadays, small size plants might not be economical to operate any
longer or may result in less than expected added value to the owners.
Also, high energy costs have raised operators’ awareness and have
directed their attention to the efficiencies of various equipment in the
plant. This brings about increasing interest in revamping / upgrading of
the existing equipment in the plants.
Turbo-machineries, as the heart of the oil/gas/petrochemical plants,
could be the plant bottleneck requiring revamping. At the same time,
machineries are the major energy consumers in a plant hence
improving their efficiency could result in an appreciable energy saving
which will have a tremendous effect on energy consumption rate per Kg
of final product. However, replacement of compressors, and even the
driving turbines can prove to be very costly, so, compressor/steam
turbine re-rating and upgrading could be the more economical solution.
NEW JCM, with a long history in design, manufacturing and testing of
centrifugal compressors and mechanical drive steam turbines, has a
broad experience in upgrading used machines of different world
renowned OEMs and helping the customers to upgrade their plants
and boost their production with the lowest capital investment at the
shortest possible time.
Why Revamp / Upgrade
• More economical compared to new machines,
• Maintain the existing foundation and piping arrangements,
• Increase compressor capacity and hence boost plant throughput,
• Changing the inlet/outlet condition to meet new process requirements,
• Increase efficiency and hence reduce the power consumption,
• Reduction of power consumption is translated into lower
energy/steam consumption,
• Decrease plant down time rate, hence operational costs, by
increasing machine reliability,
• Short period of time required for Return on Investment.
Combined labyrinth-swirl
breaker:Advanced sealings
for internal sealing of
compressors
High Pressure CO2
compressor bundle for
HP casing
Honeycomb type seal:
Used for high pressure
turbine's shaft end seal
UPGRADE
POSSIBILITIES
IN FERTILIZER The final goal of a revamp could be any of the below modifications or
any combinations therein. During a revamp, the aim is to use the
PLANTS’ existing components of the machine as much as practically possible.
COMPRESSORS For process changes, normally, the rotor and the diaphragms need to
be exchanged with optimized design:
AND STEAM
• Increase the inlet flow or side steams of the compressor,
TURBINES • Change the process requirements (pressure/temperature) in
Inlet/Side Stream/Discharge of compressors,
• Control system upgrade (including Antisurge control, Turbine speed
control, logics, hardware, etc.),
• Upgrade from Oil Seal to Dry Gas Seal,
• Material upgrade of Compressors and Turbines,
• Change steam conditions in Steam Turbine,
Inlet/Extraction/Admission/Exhaust to optimize the operating
conditions,
• Reduce the steam consumption by using high technology blade
profiles and steam path design,
• Increase machine reliability by upgrading individual components like
bearings, sealing, TTV’s etc.
The modifications like capacity increase on the compressor side, might
lead to changes in power requirement, and hence, it may be required to
upgrade the steam turbine too. NEW JCM can reduce the amount of
such increase in power requirement by the compressor by using the
most advanced high efficiency 3D impeller profiles. In some cases, like
in the old fashioned compressor designs, the capacity increase can be
done without a need for considerable changes in shaft power – all
depending on the conditions. However, when the steam turbine driver
needs to be upgraded as well, NEW JCM, again, can offer solutions.
A Mega Petrochemical Plant (Ammonia and Urea) : NEWJCM manufactured all four compressor trains of phase 3
Single point of contact for Upgarding Compressor/Steam
Turbine, Single Point Responsibility
Having the knowhow for both Centrifugal Compressor (API 617
design) and the Mechanical Drive Steam Turbine (API 612 Design),
enables NEW JCM to design, modify and upgrade the existing Design,
to Manufacturing and Test both the driver and driven machines.
Furthermore, NEW JCM is well familiar with the process requirements
of different petrochemical plant’s Licensors specially SYNGAS based
plants like Ammonia/Urea and Methanol units.
NEW JCM’s broad experience lies in the field of fertilizer plants. In two
cases, NEW JCM manufactured all four compressor trains of a MEGA
Ammonia and Urea plants (Air, Ammonia, SYNGAS and CO2
Compressor Trains). These plant capacities reached up to 2,250
MTPD Ammonia and 3,250 MTPD Urea. NEW JCM also manufactured
and tested the SYNGAS and the CO2 compressor trains of one of the
largest fertilizers in the world which consists of a single line of 4,000
MTPD Urea plant.
Beside these new machines, NEW JCM has a
broad experience of upgrading used equipment
of different world renowned OEMs. With a
wealth of hands-on experience in both driver
and the driven equipment, NEW JCM can take
the responsibility of the whole train by checking,
upgrading, studying the effects of any
modification or changes in one equipment on
the other one and/or the whole train behaviour.
This would include rotor dynamics study, train
torsional analysis and study the required
changes in auxiliary equipment (if any).
DRY GAS
SEAL
RETROFIT Before 1990, or even from a later date, most of the compressors used
contact type sealing like oil seals. Nowadays, Dry Gas Seal which is a
proven technology, brings a lot of advantages to the plant owners.
These advantages are:
• Less process gas emissions,
• Avoiding contamination of the process gas by the seal oil,
• More simplified lubrication unit by removing high pressure
components, degassing etc.,
• Less maintenance/operational costs,
• Less shaft power losses,
• Improving Product Quality by avoiding Process gas contamination
by the seal oil.
As compressor designers, NEW JCM can retrofit Dry Gas Seals to
your application. Also, NEW JCM can apply DGS to HP casing of CO2
compressor to reduce the leakages which would result into more Urea
products. Such retrofits require re-checking of the rotor dynamics and
stability for which NEW JCM have the full knowledge and softwares.
CONTROL
SYSTEM
UPGRADE • Upgrading the Mechanical Governor to Electronic Governor,
• Antisurge system re-design based on the new conditions and
upgrading the control (if required),
• Optimize or modify the logics, design and hardware of control
systems
• Dry Gas seal control and logics implementation.
• Upgrade turbine trip block to increase safety and operability
MATERIAL
UPGRADE
Material Upgrade is applicable to major components of the
compressor and the turbine. In case of the compressor, Corrosion
could be a possible motive for the requirement of such an upgrade. As
an example, Air and specially CO2 compressor parts are susceptible
to corrosion in case of process malfunction (wet CO2 or Air). Parts in
contact with process gas need to be upgraded to a better and more
resistant material, while keeping the same or superior mechanical
strength requirements. Example of such parts could be impellers of the
first few stages, compressor inlet volute or compressor diaphragms.
In case of turbines, the blades of the last few stages face wet steam
and condensate droplets. This severe condition will cause corrosion
and erosion in the blades of the last stages and considering the long
blade design of the last stages, they experience high moments and
bending forces. Applying high-strength and low-weight Titanium alloy
blades for this application can tremendously reduce the risk or
erosion/corrosion and possible resulting failures.
Left:Weld overlaying of compressor end cover to increase corrosion
resistance Right: Tiatnium Blade for Steam turbine last stages
OIL OPERATED
TRIP AND
THROTTLE Traditionally, the turbine Trip and Throttle Valves were manually
operated. They required intensive labour work to open the valves on
VALVE (TTV) high differential pressure steam and compressing the springs. Also,
remote operation of these valves were not possible.
NEW JCM can upgrade the traditional manual TTVs to Oil Operated
TTVs which let the plant operators start the turbine remotely from the
control room. Also, using oil allows us use high stiffness springs which
leads to shorter TTV closure time during shutdowns.
Manually Operated TTV
Oil Operated TTV (without Hand-wheel)
RENOVATION
OF OLD
MACHINES There are cases where the Compressor OEM does not exist any
longer to provide services for the produced compressors.
Plant owners might need renovation of such equipment as their plant
is still operationally economical and they are willing to continue
production with minimum costs. Having extensive experience with
different compressors and turbines of most OEMs, NEW JCM is
capable of offering the customers a cost effective solution to renew
the internal components by reverse engineering. This could be a
drop-and-fit barrel, for barrel type compressors. Such designs can
save a lot of project time compared to buying new equipment as well
as increasing reliability of the old machine.
SYNGAS compressor internal reconditioned. New steam turbine made by NEWJCM is used because of the
change of inlet steam condition from MP to HP steam.
CASE STUDY 1
CAPACITY INCREASE OF SYNGAS COMPRESSOR TRAIN:
ERDOS CHEMICALS
Because of excess available steam at ERDOS plant (300,000 t/y Ammonia Plant), the owner decided to use
this steam to increase the production capacity by revamping the key equipment of their 300,000 T/y Ammonia
plant. NEW JCM was requested to upgrade the SYNGAS compressor train to meet the new process
requirement. This syngas compressor, like other SYNGAS trains had two vertically split (barrel type) LP and HP
casing compressors. The below table shows the OEM design parameters of the compressors as well as the
revamped conditions (Upgraded by NEWJCM):
PARAMETER ORIGINAL DESIGN REVAMPED CONDITIONS REMARKS
(BEFORE MODIFICATION) (AFTER MODIFICATION)
Inlet flow (Nm3/h) 100,900 125,000 ~24% Increase in Capacity
Inlet Pressure (BarA) 26.5 26.5
Discharge Pressure (BarA) 150 150
RPM 10,300 10,300
Shaft Power (KW) 9,370 10,500 12% Increase in Power
The Internal Bundles of both LP and
HP casings and the rotors were
redesigned and replaced the old ones.
The existing casings and the
end-covers were reused as there was
no necessity to change them.
The modified compressor train was
put in service and successfully met
the new requirements.
SYNGAS train as received in
NEWJCM shop
CASE STUDY 2
INCREASING STEAM TURBINE EFFICIENCY:
PETROCHINA DAQING CRACKING PLANT
Originally manufactured in 1979, the steam turbine (EC-301) was an extraction condensing type turbine. This
turbine was upgraded in 1994 by replacing the nozzles and diaphragms by others.
Considering the old technology, long time of operation and high shaft end leakage, the efficiency of the
machine had dropped considerably. NEW JCM was requested to increase the turbine efficiency, reduce costs
and boost production by removing the existing bottlenecks.
PARAMETER BEFORE MODIFICATION AFTER MODIFICATION
Inlet steam condition 98 Bar@500˚C Same as “before”
Inlet steam flow 165 T/h 150.3
Extraction steam rate 93 T/h @ 40Bar 95 T/h@40 Bar
Power/RPM 18,000 KW/5170 Same as “before”
CASE STUDY 2 cont’
NEW JCM studied the operating condition and design of OEM and offered modification on external and
internal shaft sealing which would result in significiant reduction of steam consumption. Advanced
Honeycomb type sealing was employed instead of the age-old labyrinth type seals to reduce the leakage rate
and increase rotor stability. Interstage seals were also improved and other modifications on the Blade shroud
and tip seals were applied.
The TTV was changed from manual operation to fully oil operated TTV to add remote controllability specially
during start up.
Governor valves, also, reconditioned to increase stability and improving sealing characteristics.
All modifications changed the machine to as good as a New and appreciably reduced the inlet steam rate by
15 T/h (~10%) while increasing the extraction flow by 2.0 T/h.
Used machine in customer plant
CASE STUDY 3
OGDCL Qadirpur Gas Field’s Compressors Revamping
OGDCL is the National Oil & Gas Company of Pakistan and the flagship of the country’s E&P sector. The
Company is the local market leader in terms of reserves and production.
In 2010, OGDCL went through a major expansion project for their Qadirpur Gas Processing Plant. This field
required compression of large volumes of gas. Not willing to invest on new compressor trains, OGDCL intend-
ed to relocate and install Pirkoh Turbo-Compressor for the Qadirpur site. Three trains of gas turbine driven
Natural Gas Compressors with two casings of LP and HP per train were relocated to Qadirpour plant. Howev-
er, there were differences in gas composition and process conditions of these two fields and hence, the
compressors were required to be rerated. The major differences of Qadirpur plant compared to Pirkoh were
higher gas MW, existence of condensate and considerable H2S gas in Qadirpour plant. Over and above
meeting the changes in the process conditions, OGDCL required NEW JCM to increase the capacity of the
compressors as well.
NEW JCM started the feasibility and engineering study to meet the new site operating conditions and offered
an upgrade solution using new bundles for the existing compressors with NACE compliant materials. The offer,
also included reconditioning of the existing DGS as well as upgrading the DGS panel considering H2S gas
traces and condensation possibilities. The Compressor design flow rate was increased from 88t/h to 100 t/h
and the other parameters were designed based on the new plant conditions.
Existing Compressor’s Bundle Removal
at Customer’s Plant
NEW JCM Made New Bundle
CASE STUDY 3 cont’
Considering the gas production requirement in Pakistan, the revamping of all three trains were completed and
delivered within less than a year. NEW JCM conducted the API 617 Mechanical Running and ASME PTC-10
Performance Test on the compressor trains and all trains were commissioned successfully and to the full
satisfaction of the client.
PTC-10 Performance test of re-rated compressors
JINZHOU NEW JCM MACHINERY MANUFACTURE CO. LTD.
No. 18, the second, Jingang Street, Jinzhou Economy Development Zone,
Liaoning Province, 121007, P.R. China
Tel: +86 416 3593099 • Fax: +86 416 3593069
Mobile: +65 9824 8889 • Email:
[email protected]FLUID SCIENCE DYNAMICS (S) PTE LTD
One Commonwealth Lane, #09-29 One Commonwealth, Singapore 149544
Tel: +65 6659 2282 • Email:
[email protected]website: www.fluidscdynamics.com
