stealth compressor stations - gas/electric partnership

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.


© 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.


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


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!


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


Operating Experience

Three (3) MOPICO RM 40Commenced operation 1995In 2009 total operating time at this station > 100,000 Hours


Other Discrete Station Designs

Québec, Canada


Other Discrete Station Designs

Europe


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


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


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


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


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


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


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


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


High-Speed Packaging Zurich


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?


MAN TurboEngineering the future –

since 1758.

Engineering the Future –Since 1758.

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stealth compressor stations - gas/electric partnership

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