COMK/MARK 762/II - Studio Tre Fasi 11/2002

GE Power Systems
Oil & Gas
Nuovo Pignone S.p.A.
Via Felice Matteucci, 2
50127 Florence - Italy
Tel. +39-055-423211
Fax +39-055-4232800
e-mail: info.geoil&gas@np.ge.com
www.gepower.com/geoilandgas
GE Power Systems
Oil & Gas
SRL Centrifugal Compressors for Air and Process Gas
Nuovo Pignone started production - Number of stages - Superior Operation
of overhung-impeller centrifugal - Shaft rotational speed - High efficiency and reliability
compressors (SRL) in 1966. The first - Diameter of impellers - High compression ratio
unit with an integral gear was - Wide range of flow rate
- Height of impeller blades
completed in 1979. - Optimum rotor balance for low
- Exchange surface of coolers
With their simple, compact structure vibration level
and excellent reliability, SRL
compressors are especially suited to Advantages of SRL Compressors - Absence of Lube Oil in Process
a wide range of heavy duty - Simplicity of Installation Gas
applications with air, steam and - Unit prepackaged and tested at factory - Advanced seal system options
other gases such as those employed - No special foundations required available
in the Petrochemical Industry.
The high efficiency, reliability and
operational flexibility of the SRL line
of compressors is the result of the
advanced centrifugal compressor
design achieved through: extensive
experience with machines in service
all over the world; continuous
improvement of the aerodynamic
and mechanical design; use of
sophisticated computer design
codes; advanced manufacturing
processes; and innovative R&D
programs. Customers benefit from
Nuovo Pignone’s advanced
technology through improvement in
plant productivity.
The custom-built compressors in this
line are individually engineered to
meet each customer’s specific
needs using proven standardized
components. SRL compressors
combine the advantages of custom-
built machines (maximum efficiency,
layout flexibility, materials selection
etc.) and standardization (proven,
reliable components; availability of
spare parts).
The SRL compressor series comes
in a range of sizes. For each size the
baseplate, gearbox, stage volutes,
cooler shells, oil and gas piping and
auxiliaries are standardized.
Machines can be produced to meet
the individual requirements of each
application through appropriate
selection of key design factors
including:

©2002 Nuovo Pignone S.p.A. all rights reserved

(Any use or reproduction even if partial is prohibited without a specific written authorization)

2
SRL Centrifugal Compressors for Air and Process Gas
- Ease of Maintenance
- Designed for maintainability
- Accessibility of components
SRL design options
•Single or multi-shaft models
• Direct or gear (integral or
separate) driven
• Fixed or variable speed drivers
(electric motor, steam or gas
turbine, gas or diesel engine)
• Oil-free gas delivery system
• Automatic capacity control
and safety system to reliably
match any operating condition
• Auxiliary systems to meet
international standards and
customer specifications
Package concept
SRL compressors are usually
mounted on a single base together
with all auxiliaries (e.g. oil pumps, oil
reservoir, control instruments) and
are delivered fully assembled and
tested. Outstanding reliability,
ruggedness, low installation and
operating cost, plus ease of
maintenance are the key features of
these packages which are especially
designed for heavy-duty continuous
service.
The packages are usually installed
outdoors and can be fully automated
for remote control.
Compressor nomenclature
Casing sizes and number of impellers
are indicated in the compressor
designation by the digits following
the compressor model. For example,
SRL 806 is the designation for a six
stage compressor, size 800. The
letter D before the compressor
designation indicates a double flow
configuration. (DSRL)
SRL 1001 Propane compressor for
Qatar
3
Compressor Components
CASINGS
Welded casings
Welded casings consist of the
following parts:
- a scroll with the delivery nozzle in
a tangential position
- an end cover that can be bolted
either to a gearbox casing or to a
shaft support (the end cover
contains the seal area; all the
vent/supply channels to the seal
are drilled in the cover)
- a suction duct to guide the flow
through the impeller’s leading edge
- a diaphragm that shrouds the impeller
- a discharge diffuser (vaneless or
vaned).
The scroll is generally fixed to the end
cover with a simple split locking ring
that allows easy disassembly.
Forged casings
Forged casings are used for small
diameter impellers and for high design
pressures, and consist primarily of two
pieces:
- a scroll (produced from a single forging);
- a diaphragm (with the dual
function of suction duct and
discharge diffuser).
The scroll can be bolted either to a
gearbox casing or to a shaft support.
It contains the seal area; all the vent/supply
channels to the seal are drilled in the
casing.
The diaphragm shrouds the impeller
and the discharge diffuser (vaned or
vaneless type) is machined into it. The
diaphragm is fixed to the scroll by
means of bolts or for very high
pressures with shear rings.
Fabricated casings
Fabricated casings are selected for
large single impeller, directly driven
compressors, and consist of the
following parts:
- one external housing (with the
delivery nozzle welded in a
tangential position)
4
- two cover flanges (suction and 1
driver side). The seal area, is contained
in the driver side cover and all the
vent/supply channels to the seal are
drilled in the cover. The shaft support
is overhung and bolted to the driver
side cover
- a diaphragm that shrouds the impeller
- a suction duct that guides flow to
the impeller’s leading edge
- a discharge diffuser (vaneless or
vaned)
- an aerodynamic internal volute.
2
Cast casings
Cast casings are normally used for
standard air and steam machines, but
may also be adopted for low-pressure
process gas applications. They consist
3
4
of the following main components:
- a cast scroll
- an end cover that can be bolted
either to a gearbox casing or to a
shaft support
- a discharge diffuser (vaned or vaneless);
- a suction duct
1 - Welded casing
- a diaphragm that shrouds the impeller.
2 - Forged casings
The scroll is generally fixed to the end 3 - Fabricated casing with internals
flange with a simple split locking ring during assembly
that allows easy disassembly. 4 - Cast casings
Compressor Components
INLET GUIDE VANES
The Inlet Guide Vane (IGV) system
allows wide capacity control of the
compressor with reduced energy
losses.
IGVs consist of a row of
aerodynamically shaped blades
1 THE DISCHARGE DIFFUSER
3 assembly; the shafts are then
4
placed at the inlet of the stage.
The blades can rotate around their
aerodynamic center in order to give
the suction flow a pre-swirl that
guarantees an optimum incidence
angle with the impeller’s leading edge
even at reduced flows, minimizing
inlet losses.
The discharge diffuser can be either
vaneless or vaned (DGV).
Vaned diffusers are used for high
Mach number machines to reduce
thermodynamic losses in the very high
speed impeller exit flow.
2 discharge pressure machines).
IMPELLERS
All impellers used in Nuovo Pignone
centrifugal compressors come from a
number of standard families. Each
family contains a set of geometrically
similar impellers with different flow
coefficients to match flow
requirements. All geometries have
been tested in the company’s R & D
laboratory.
The following types of impellers are
used on SRL compressors:
- semi-open, 3D impellers for
high Mach number applications
and/or when high tip speeds are
needed (mainly air and steam
applications);
- closed 3D impellers for lower-head,
high flow applications;
- closed 2D impellers for small flow
stages (ie, small process
compressors or last stages of high
Semi-open type impellers are
machined from heat-treated, solid
forgings so that both the hub and
blades are of uniform strength. Closed
impellers are welded to the shroud.
Cast impellers may be used for
special applications.
The blades are generally backswept
to different angles in accordance with
the required performance.
Each impeller is dynamically balanced
and overspeed tested before
dynamically re-balanced at low speed
with the impeller mounted.
Nuovo Pignone has acquired vast
experience in manufacturing open
and closed impellers with a large
variety of materials such as carbon
steel or stainless steels (ASTM A 705
gr. 630, X12 Cr 13), materials to
NACE requirements or special
materials (Titanium, INCONEL 718 or
INCONEL 625).
1 - Vaned diffuser
2 - Fully open inlet guide vanes
3 - Rotor assembly during balancing
5
Compressor Components
SHAFTS
Unless the compressor is integrally
geared, the shaft is machined from a
single forging of 40NiCrMo7
(AISI 4340). The impeller can be
overhung mounted at the end of the
shaft by means of a frontal Hirth
coupling, by a flange (for high speed
applications), or hydraulically fitted
with a tapered coupling. Thrust collars
can be either replaceable or
non-replaceable.
SUPPORT CASING
The support casing of the compressor
(except for the Integrally Geared type)
contains the compressor journal and
thrust bearings. The journal bearings
are of the hydrodynamic fluid film
type, tilting pad type for higher
speeds, or built to Customer
specifications.
The bearings are split for ease of
assembly, equipped with anti-rotation
pins and are firmly secured in the
axial direction.
The bearing design suppresses
hydrodynamic instabilities and
provides sufficient damping to limit
rotor vibrations while the compressor
is operating (either loaded or
unloaded) at the specified operating
speed. The thrust bearings are of the
tilting pad type designed for equal
thrust capacity in both directions and
sized for continuous operation under
all specified conditions including all
forces transmitted by the coupling or
by the impeller.
INTEGRAL GEARBOX
The integral gearbox consists of a bull
gear and high speed pinions, with a
single-helical gear mesh.
- Casing: The gearbox casing is
horizontally split. The lower part is
fixed to the baseplate and the
compressor stages are fixed to it.
The gearbox casings can be either
cast or fabricated.
6
- Gear meshing: The gear unit can be 1 - 3D Semi-open impeller
rated in accordance with AGMA or 2 - Support casing with shaft
with API Codes. The toothed portion 3 - Gearbox for a 6-stage electric motor
driven SRL 806 compressor
of pinions is integrally forged with
4 - Gearbox for a 4-stage steam turbine
the shaft. The bull gear is shrunk on driven (direct input) DSRL 504
the low speed shaft. compressor
- Shafts: The shafts are sized to
transmit the gear rated power within
the stress limits of AGMA Codes.
They are made of one-piece, heat
treated forged or hot-rolled alloy
steel, and the entire length of the 1
shaft is machined. Nuovo Pignone
will take complete responsibility
for the lateral and torsional
analysis of the entire train. 2
- Radial bearings: The radial
bearings are of the hydrodynamic
fluid film, tilting-pad type for the
high speed shaft and fixed profile
type for the low speed shaft.
The bearings are split for
ease of assembly, equipped
with anti-rotation pins and are
firmly secured in the axial direction.
The bearing design suppresses
hydrodynamic instabilities and 3
provides sufficient damping to
limit rotor vibrations while the
compressor is operating,
loaded or unloaded, at the
specified operating speed.
- Thrust bearings: The thrust
bearings are designed for equal
thrust capacity in both directions,
and are sized for continuous
operation under all specified
conditions including all
4
external forces transmitted by the
couplings or by the gear mesh.
The thrust bearings of high speed
shafts can be the thrust collar type
(standard for multi-stage
compressors) or the tilting pad type
for single impeller shafts with high
axial thrust. Thrust bearings of low
speed shafts are generally the
hydrodynamic tapered land type
(a tilting pad arrangement
can be supplied on request).
Compressor Components
SHAFT ARRANGEMENT
With Integrally Geared compressors,
many shaft arrangements are possible
in order to suit the required duty. In
particular, the bull-gear can be driven
directly by an electric motor (standard
solution) or by a turbine (gas or
steam); the number of pinions can
vary (depending on the size of the
stage casings) from one to four.
SEALS
The following types of seals can be
installed on SRL compressors:
- Labyrinth seals: Commonly used
when non-toxic gases are handled or
when operating pressures are low.
The seal material can be either
aluminium alloy or stainless steel.
2 serve two vital functions: 1. Provide
4 and no clean buffer gas is available,
- Dry gas seals: Used when treated
gases cannot be discharged, into
the atmosphere.
Seals can be supplied in several
configurations:
1. A tandem seal ring with
intermediate labyrinth.
2. A tandem seal ring without
intermediate labyrinth.
3. A double (face to face)
arrangement.
4. A single ring arrangement.
5. Single, tandem or double
arrangement with carbon ring
third-stage seal (in order to limit
nitrogen buffer gas consumption).
The face of the seal’s rotating ring
is recessed over more than 50
percent of its surface by grooves
from 7.5 to 10 micrometers in
depth etched into the face
material. They extend to the dam
against which the process gas
forms a seal.
The grooves are the key to non-
contact operation of the seal. They
hydrostatic separation of the sealing
faces (utilizing only the pressure of
the process gas, without rotation of
the seal). 2. Generate a pumping
action due to viscous drag through
the gas, thus creating hydrodynamic
separating forces between the
faces, or lift-off.
- Oil mechanical seals: Supplied for
special types of service in which
polymerization of the gas is possible
or at the customer’s request.
Seals are supplied in easily
replaceable cartridges.
Typical seal arrangement
1 - Labyrinth seal
2 - Tandem dry gas seal
3 - Double dry gas seal
4 - Mechanical oil seal
7
Auxiliaries
Lube oil system 1 - Typical API 614 lube oil system 2 - Typical API 672 lube oil system
A force-fed lube oil system ensures diagram diagram
that the journal and thrust bearings are 1
properly lubricated. The system can LSL
LAL

be designed compliant with either API 7

8
FG
6 6 LG

614 or API 672 and is suitable for PDAH

PDISH

PAL PALL
PCV
continuous compressor operation. TO
RESERVOIR

PI
PSL PSL

It generally consists of: TAH

TSH
TI

PI

•
5 5
oil reservoir TO
COMPRESSOR

• steam turbine or electric motor LEGEND

1 - Oil reservoir
driven pumps (the main pump TI PCV

2 - Suction strainer
3 - Oil pump
can also be driven by the PAH
4 - Relief valve
PSH
5 - Oil cooler
compressor/gearbox low speed PI
4 4 PI 6 - Oil filter
LAL
7 - Oil accumulator
shaft) MECHAN.
DRIVEN
3
3 8 - Run-down tank
LSL EH
- Locally mounted
• full-flow oil coolers 2 2
instrument
- Panel mounted
• twin oil filter allowing cartridges to TSHL
1
FROM
COMPRESSOR
instrument
LG - Level glass
be changed during operation TI LG
LSL - Low level switch
LAL - Low level alarm
• automatic by-pass valve to control PI - Pressure indicator
PCV - Pressure control
oil pressure at the bearing manifold PAL PALL
valve
2 PSL - Low pressure
• monitoring and safety instrumentation. PDAH
PDISH
6 6 PSL PSL
switch
PAL - Low pressure
alarm and stand-by
The lube oil console can be either on PI

TO
COMPRESSOR pump start-up
PSLL - Minimum pressure
a separate skid or integrated on the TAH switch
TSH
PALL - Minimum pressure
main baseplate with the machine. PI

shut-down
5 5
PSH - High pressure
switch
PAH - High pressure
Seal oil system PCV alarm
TI
PDISH - High diff. pressure
The seal oil system supplies filtered oil LAL
PI indicator and switch
PDAH - High diff. pressure
to the mechanical seals at the correct 4 4
PI
alarm
LG LSL EH MECHAN. TI - Temperature
pressure and temperature, and can be DRIVEN
3 3
indicator
TSH - High temperature
either derived from the lube oil system FROM
COMPRESSOR
TAH - High temperature
TSHL
alarm
or completely separate. TI 2 2
1 TSHL - High/low
temperature switch
The system is designed in accordance FG - Flow glass

with API 614 and is suitable for

continuous compressor operation.
It generally consists of: 3
LEGEND

• oil reservoir 1 - Oil reservoir

2 - Oil pump
3 - Relief valve
PDCV

• electric motor driven pumps 4 - Oil cooler

5 - Oil filter TSH
BUFFER
GAS

• full-flow oil coolers 6 -Seal OiI Trap

7 -Degassing tank
PDISL
PDCV

M TO OIL

• twin filter allowing cartridges to be

PDAL RESERVOIR
- Locally mounted
instrument
TO COMPRESSOR

- Panel mounted
changed during operation instrument
SUCTION

PDALL
PDSL
LG - Level glass PDAH

• Overhead tank with level or LSL - Low level switch

LAL - Low level alarm
PI - Pressure indicator
TAH

PDISH PDAL
PDISL
S

pressure control PDCV - Diff. pressure control

TSH
5
valve

• automatic seal oil traps PDISL- Diff. pressure indicator

and switch
PDAL - Low diff. pressure 5 5
TI 5
I
TO OIL
RESERVOIR

• monitoring and safety instrumentation. alarm

PDALL- Low diff. pressure
shut-down
LG FG

The seal oil console can be either on a PDISH - High diff. pressure
6 T

indicator and switch

separate skid or integrated on the PDAH - High diff. pressure LAL PI PI
FROM SEAL

FROM SEAL

alarm 3 3
TI - Temperature LG LSL EH

indicator 2 2
I M
TSH - High temperature
switch
TAH - High temperature TSHL

alarm 1 7
TSHL - High/low
temperature switch
FG - Flow glass

3 - Typical seal oil diagram

8
Auxiliaries
• top level diagram
• unit controls to start / stop and
control the compressor, auxiliary
motors and heaters (with status
display)
• process data monitoring (pressure,
temperature, level)
• alarm display
• shutdown display
• surge controller monitoring
• hour meter
• event recorder.
If field instrumentation includes
analogue signals from pressure and
1

PI

PCV

G SEAL GAS
FOR START UP

PDI PAH
PIT PI
PI PI
PAL I
PDIT

Dry gas seal system

PDAH
PDI
FI
PDI
PI
PI PI
LEGEND
The dry gas seal control system FO PCV A - Impeller
L3 BUFFER/
PURGE GAS B - Balancing line
supplies filtered gas (either process or PI
C - Seal gas
E - Purge
FO PAH
PIT PI
E1 - Buffer
other clean gas) and nitrogen buffer gas PAL I
E2 - Purge
Po C E1 E F - Increasing speed gear
to the dry gas seals at the correct L1 - Primary vent
L2 - Secondary vent
F S - Frame
pressure. The system is designed based A - Locally mounted
instrument
- Panel mounted
on Nuovo Pignone’s extensive experience S
instrument
- Function on PLC and
with this type of sealing system. B L1 L2 L3
FI
display (I.O.P.)
- Flow indicator
FO - Flow orifice
It generally consists of: L3 TO SAFE AREA PCV - Pressure control valve
PIT PI
PAHH I PDIC - Pressure differential

• twin filters allowing cartridges to be

PDI
PDAH I
indicator controller
PDIT - Pressure differential
indicator transmitter
changed during operation
PDIT PDIT
PDI - Pressure differential
indicator
PIT - Pressure indicator
• control valves for adequate L3 TO FLARE

buffering of the seals
• monitoring and safety instrumentation
The seal gas system can be either on
a separate console or integrated on
the main baseplate with the machine.
3 alarm annunciator sequence logic,
PI
transmitter
- Pressure indicator
2
Compressor control panel temperature transmitters, the operator
The control panel implements the interface can perform additional
compressor start/stop sequence logic, functions:
• operating parameter display
capacity control logic etc. • PLC set point adjustment
The PLC is programmed prior to • trend recording of process data
shipment and includes a serial The compressor vibration monitoring
communication interface RS422 with system is also located on the control
Modbus protocol for connection to a panel.
supervision and control system
(i.e. DCS, PC, telemaintenance etc.).
1 - Dry gas seal control panel for a
The control panel front includes a
4 stage SRL 254 compressor
video terminal connected to the PLC, 2 - Typical tandem dry gas seal system
which provides the following functions diagram
organized in pages: 3 - Typical control panel

9
General
OPERATION CONTROL
The following methods are available to
control flow and suction or discharge
pressures under varying process
conditions:
• compressor speed variation: this
method is utilized when a compressor
is driven by a variable speed driver
• discharge throttling: a valve is
fitted in the discharge piping so that
pressure at the compressor outlet
nozzle may increase while
maintaining the normal value
downstream of the valve
• suction throttling: a valve is fitted
in the suction piping so that suction
or discharge pressure can be
regulated according to the process
requirements
• adjustable inlet guide vanes:
these vanes alter the gas flow
direction as it enters the
impeller, thus varying the pressure
ratio and flow of the compressor.
These guide vanes can be placed
before each compression stage
ANTISURGE CONTROL
Should a flow below the compressor
surge limit be required a by-pass must
be used. Part of the compressed gas
is recirculated to raise the compressor
suction flow above the surge limit.
The system is standard for all
centrifugal compressors and comes
into operation as a relief mechanism
or when other control system options
are not capable of handling excess
flow or pressure.
When air or inert gas is being
compressed it may be blown-off to
the atmosphere instead of being
recirculated.
1 - Operation control
2 - Indoor facilities for performance tests
or full-load tests with inert gas
10
TEST FACILITIES Full-load, full-pressure tests (including
Compressor components are subject flammable gases) to check rotor
to a long series of tests in order to stability as well as performance of
guarantee perfect matching to their machines or complete systems can
design specifications. Casings are also be carried out.
submitted to hydraulic or pneumatic A number of outdoor full load test rigs
pressure testing, depending on the are available at the Florence and Massa
type of service. Impellers are checked shops providing Nuovo Pignone
with ultrasonic and dye penetrant Customers with test facilities to meet
liquids. Facilities allow overspeed virtually any need.
testing of single impellers.
All compressors are mechanically
tested before delivery. The test driver
may be an electric motor, a steam
turbine (the test facility is equipped
with a complete plant for production of
steam at 55 bar and 500°C) or a gas
turbine.
When Nuovo Pignone supplies a
complete compressor unit with motor,
steam or gas turbine driver, a string
mechanical test can be carried
out on the complete train.
Performance testing with air or
other gases in a closed loop
can also be carried out.
Nuovo Pignone has uprated
and updated its test facilities
with the construction of a new
test room designed for maximum
flexibility to adapt to various test
conditions and requirements.
1 The
T
2
Flow Control:
by adjustable guide vanes
by suction throttling
by speed variation
by discharge throttling
 General 1 RESEARCH AND DEVELOPMENT
Research and Development plays
an important role in Nuovo Pignone’s
strategies and therefore receives
substantial resources.
One of the main objectives is
continuous updating and improvement
of existing products to extend the state-
of-art in the traditional Oil & Gas
applications such as natural gas,
fertilizers, methanol, refining and related
chemical industries.
New products are developed driven
by customer needs in applications
2 fundamental duties of the group is
that fit within Nuovo Pignone’s
business strategy and expertise.
Research on centrifugal compressors
accounts for a substantial portion of
the company’s total research activity.
Nuovo Pignone’s test laboratory is
equipped with a number of advanced
test facilities both for developing and
Pride & tuning major compressor components
(stages, seals, bearings) and for
The Commitment performing all kinds of stress, vibration
and rotor dynamic investigations.
Besides testing, continuous effort is
dedicated to development and
improvement of analytical tools used
in the fluid dynamic, structural and
rotor dynamic design of components
and complete compressors.
Many years of analytical and
experimental research work on
components has led to establishing a
wide selection of standardized stages,
each individually tested and tuned and
application engineering tools that
provide maximum reliability in
performance prediction in all
applications.
Advanced knowledge of non-
stationary flow phenomena and high
speed rotor dynamics has led to the
unsurpassed reliability and
availability of these machines.
QUALITY ASSURANCE
The Nuovo Pignone Quality
Assurance group is centered in
Florence and has a staff of over 60
people stationed throughout the
Company’s plants. One of the
the development of quality standards
and assistance in the correct
application of all quality assurance
processes in all product
development, manufacturing, and
testing operations. Special
laboratories certified by Sinal, are
equipped for measuring mechanical
properties, chemical and optical
emission spectrometric analyses,
fatigue tests and macro and
micrographic examinations (scanning
electron microscopy). A calibration
room certified by SIT for checking and
calibrating lengths, forces and
temperatures is also available.
Nuovo Pignone’s Quality Assurance
System has been certified to meet
ISO 9001 standards for design,
manufacture, installation and after-
sales service of centrifugal
compressors, centrifugal pumps,
reciprocating compressors, gas and
steam turbines, gas expanders, heat
exchangers and pressure vessels by
Lloyd’s Register Quality Assurance
Ltd., one of the most authoritative
international certification
organizations.
1 - Modal analysis of centrifugal
impeller by holographic
interferometry with a laser system
2 - ISO 9001 certification
11
Service
CUSTOMER SERVICE A global service network ensures rapid 1
Nuovo Pignone provides the users of response to maintenance needs
its machines with prompt, efficient and anywhere in the world.
technologically advanced This organization consists of:
maintenance and repair service to • Service centers in strategic locations
guarantee high machine efficiency, worldwide
continuity of operation and maximum • Traveling Service Teams which
safety. This service includes: maintain contact with users through
• Technical support periodic visits to plants
• Periodic visits to plants • Authorized shops which carry out
• Diagnostic analysis of installations machine maintenance with Nuovo
• Overhauls, repairs and conversions Pignone technology.
of installed machinery
• Customized original spare parts Service contracts
supplies Highly-skilled engineers, an extensive
• Maintenance contracts spare parts inventory and an efficient
• Personalized training courses for global service network allow Nuovo
customers’ personnel. Pignone to offer its customers tailor-
made service packages.
SERVICE ORGANIZATION
Nuovo Pignone Global Services is an
2
organization dedicated to meeting
customer service needs.
It is fully integrated with the new
product engineering and
manufacturing organizations to
provide state-of-the-art solutions to the
installed fleet. Global Services
operates a Service Shop adjacent to
the main production plant in Florence
for the high tech overhaul and
refurbishment of machines and
components. A warehouse containing 3
over 40,000 different parts is
maintained and a modern
computerized parts management
system is in place to insure rapid
delivery of replacement parts on either
a scheduled or an emergency basis.

1- Computerized system for spare

parts warehouse management
2/3 - Customer Training features
shop visit

12
Air Compressors 100
General
Air compressors are used in air
DISCHARGE PRESSURE (BAR)

50
separation, synthetic fibre and fertilizer
6 STAGES plants as main process gas
40

30 compressors, and in all industrial plants

20 5 STAGES as service air compressors.

4 STAGES Technical data

10
9
The inlet flow for such machines can
8 3 STAGES
7
6
vary from 10,000 to 200,000 m3/h (6,000
5
2 STAGES
to 120,000 cfm), with a max. discharge
4

3
pressure of up to 50 bar (730 psi).
0 0 0 0 00
2 45 60 80 90 10 1 STAGE Main characteristics
L L L RL L
SR SR S R S SR Air compressors are generally
1.5

1
multi-shaft, integrally geared type, single
10 20 30 40 50 60 70 80 90 100 200.000
or multi-stage (up to 6 stages).
SUCTION VOLUME FLOW (m3/h) Compressors are modularized in order
1 to meet varying Customer needs.
1 - Performance range
High compression efficiencies are
2 - SRL 453 service air compressor installed in an Alfa Romeo
workshop in Milan - Italy (17000 Nm3/h from 1 to 8 bar-abs) acheived by using 3-D impellers
3 - SRL 806-Air compressor for GE’s test bed in Schenectady, NY - USA (4900Nm /h;
3 specially designed for this service.
Suct. press. 1 bar-abs; Disch. press. 27.8 bar-abs; Inst. power 7550 kW) Inlet Guide Vanes are available for each
compression stage, permitting extremely
2
large compressor turndown with high
efficiencies throughout the range. Seals
are generally labyrinth type (single, dry
gas type for last stages of high pressure
applications). Multi-stage compressors
are equipped with inter-coolers with an
integral condensed water separator.
Drivers
Drivers for this type of compressor are
generally electric motors, but it is also
possible to use steam and gas turbines
(either as a direct driver or through an
intermediate gearbox).

3 Package arrangement
In multi-stage compressors, coolers are
located below the compressor together
with the lube oil system in order to
provide a very compact arrangement of
the unit. Lube oil systems can be either
separate or integrated on the main
compressor baseplate.
Applicable codes and standards
Compressors may be designed either
according to API 617 or API 672, or
customized to Customer’s specific
requirements.

13
Process Gas Compressors (Single Stage - Directly Driven)
General
This type of compressor is mainly
used as a booster in petrochemical
applications, or as a recycle
compressor in polyethylene and
polypropylene plants.
Axial inlet flow guarantees an optimum
aerodynamic design, and therefore
very high efficiency. Due to their
rugged mechanical design, this type
of machine delivers very high
reliability.
Almost all gases can be handled by
this type of compressor with
appropriate construction materials and
seal systems.
Technical data
Flows can vary from 5,000 to 120,000
3
m /h (3,000 to 70,000 cfm), with
discharge pressure up to 50 bar
(730 psi).
speed), or by a steam or a gas turbine 1
(directly coupled or via an external
gearbox to increase or decrease
speed).
Package arrangement
The baseplate generally accommodates
both the compressor and its driver.
The lube oil system can be either
integrated with the main machine
baseplate or provided as a separate
console.
1 - SRL 801 for a polyethylene plant
Applicable codes and standards (during assembly)
Generally designed according to (871,000 Nm3/h from 25 to 26.3 bar-abs
API 617, or customized to Customer’s 2,300 kW installed power)
2 - SRL 1001 propane booster compressor
specific needs.
(594,000 Nm3/h from 12.3 to 15.6 bar-abs
4,800 kW installed power)
3 - SRL 451 propane compressor directly
driven by an NG 32/25 steam turbine
(168,000 Nm3/h from 33 to 47.5 bar-abs
1,800 kW installed power)

Main characteristics
Several configurations are available
to cover all applications of this type
of machine. 2
Impellers are 3-D, backswept,
semi-open or closed type, overhung
mounted on the shaft. The thrust
bearing is located between the two
journal bearings and is of the
tilting-pad type.
A special design, with internal spiral
volutes (to avoid any dead-point in the
flow), is available for process gas that
may polymerize during operation (for
example in PP and PE plants).
Inlet Guide Vanes are available for
fixed-speed units to increase the
operating range of the compressor
while maintaining high efficiency.
Seals can be dry gas, mechanical oil
or labyrinth type, depending on the
service requirements.

Drivers
This type of unit can be driven either
by an electric motor (directly coupled
or via an external gearbox to increase 3

14
Process Gas Compressors (Integrally Geared)
General
This type of compressor is used in
several petrochemical processes,
either for low-flow/high pressure
applications, or for high-flow/low
pressure applications.
The integrally geared compressor
features a bull gear and from one to
1 flow guarantees an optimum
1 - SRL 251 natural gas recycle compressors
(2,200 Nm3/h from 1 to 1.5 bar-abs
70 kW installed power)
2 - SRL 253 dichloromethane
compressor all in AISI316
stainless steel materials,
(500 Nm3/h from 1 to 5 bar-abs
455 kW installed power)
3 - SRL 254 natural gas booster compressor
(70,700 Nm3/h from 33 to 68 bar-abs
2,500 kW installed power)
2
3 Inlet Guide Vanes are available to
four high speed pinions. One or two
impellers can be mounted on each
pinion shaft. The multi-shaft
configuration allows frequent
intercooling, and therefore better
compression efficiency
compared to traditional in-line
centrifugal compressors. Axial inlet
aerodynamic design, and therefore
very high stage efficiency.
Due to its rugged mechanical design,
this types of machine delivers very
high reliability.
Almost all types of gases can be
handled by this compressor design
with appropriate construction materials
and seal systems.
Technical data
Flows can vary from 500 to 50,000
m3/h (300 to 30,000 cfm), with
discharge pressure up to 100 bar
(1,500 psi).
Main characteristics
Several configurations are available
to cover all applications of this type
of machine.
Impellers are 3-D or 2-D, backswept
semi-open or closed type, overhung
mounted on the shaft. The thrust
bearing is located on the pinion shaft
and is of the thrust collar type. The
journal bearings of the pinions are the
tilting-pad type.
increase the operating range of the
compressor with low impact on
efficiency.
Seals can be of the dry gas, mechanical
oil or labyrinth type, depending on the
service requirements.
Drivers
This type of unit can be driven directly
either by an electric motor, or by a
steam or a gas turbine.
Package arrangement
The baseplate generally
accommodates both the compressor
and its driver. The lube oil system can
be either integrated with the main
machine baseplate or provided as a
separate console.
Applicable codes and standards
Generally designed according to API
617 or customized to Customer’s
specific requirements.
15
Steam Compressors
General 1
Rising energy costs have led to a
demand for high efficiency machines
for energy recovery.
Steam compressors are employed in
various sectors, such as the agriculture-
food Industry, chemical industry, paper
industry and desalination plants.
Another application of SRL
compressors is in Geothermal power
stations to extract non-condensable
gases from the steam turbine
condensator.

Technical data
Flows can vary from 5,000 to 250,000
m3/h (3,000 to 150,000 cfm) per
1 - SRL 903 for geothermal
impeller, with discharge pressure up to application (4,200 Nm3/h
10 bar (150 psi). from 0.1 to 1.2 bar-abs
550 kW power)
Main characteristics Directly driven by a steam
Steam compressors are of the integrally turbine
geared type, single or multi-stage (up to
6 stages) machines. 2 - SRL 1001 steam compressor
The compressors are modularized,
for a food industry
(101,000 Nm3/h
for flexibity in meeting Customer
from 0.8 to 1.6 bar-abs
requirements. 3,850 kW installed power)
High pressure ratios together with high
compression efficiencies are reached 3 - Typical process diagram
by using 3-D open impellers specially for a food industry
designed for this service. application
2
Inlet Guide Vanes are available for each
compression stage to provide a large
turndown for the compressor with high
efficiencies throughtout the range.
Labyrinth type seals are always used. 3

Drivers
Drivers for this type of compressor can
be either electric motors or steam
FC PI
turbines (as a direct driver).
TIAH
Package arrangement PI PI

The baseplate generally accommodates PI TI

both the compressor and its driver. The
CONCENTRATE
PRODUCT

lube oil system can be either integrated

with the main machine baseplate or
provided as a separate console.
SRL COMPRESSOR

CONDENSATE

16
Installations 1. SRL 601
Polypropylene recycle compressor
installed in Tarragona, Spain
- Flow 229,000 Nm3/h
- Suct. Press. 14.5 bar-abs
- Disch. Press. 15.6 bar-abs
- Inst. Power 850 kW
1
2. SRL 603
Air+carbon monoxide compressor
installed in Geel, Belgium
- Flow 265,00 Nm3/h
- Suct. Press. 1 bar-abs
- Disch. Press. 5.3 bar-abs
- Inst. Power 2,600 kW
2
3. SRL 454
Air compressor for a Caprolactam
plant in Shijiazhuang, China
The compressor is driven by
a steam turbine through an
external gearbox
- Flow 17,000 Nm3/h
- Suct. Press. 1 bar-abs
- Disch. Press. 13 bar-abs
- Inst. Power 2,350 kW

4. SRL 454
Psa tail gas compressor
installed in Tula, Mexico
- Flow 21,300 Nm3/h
- Suct. Press. 1.1 bar-abs
- Disch. Press. 9 bar-abs
- Inst. Power 2,800 kW

17
Installations
5. SRL 603 and SRL 453 5
Compressor for an air fractionating
plant in Middle East
- Flow 27,000/18,000 Nm3/h
- Suct. Press. 0.8/0.8 bar-abs
- Disch. Press. 7.5/9 bar-abs
- Inst. Power 2,800/2,060 kW

6
6. SRL 601
Recycle gas compressor for an
EO/EG plant in Pralca, Venezuela
Single stage compressor, electric
motor, driven through an external
gearbox speed increaser
- Flow 238,000 Nm3/h
- Suct. Press. 19 bar-abs
- Disch. Press. 23 bar-abs
- Inst. Power 1,750 kW

7
7. SRL 801
Nitric acid compressor
installed in Ambes, France
The compressor is driven by a
steam turbine through an expander
- Flow 168,000 Nm3/h
- Suct. Press. 4.6 bar-abs
- Disch. Press. 11.5 bar-abs
- Inst. Power 7,250 kW

8. SRL 903
For geothermal application
installed in Le Prata, Italy
- Flow 4,200 Nm3/h
- Suct. Press. 0.1 bar-abs
- Disch. Press. 1 bar-abs
- Inst. Power 550 kW

18