1 Abou he Company Sumy NPO PJSC Sumy NPO PJSC, founded in 1896, is now one of he larges machine-building enerprises in Europe manufacuring equipmen and developing complex soluions for oil, gas, chemical, perochemical and power indusries. Company producs and services include he following: - compressor equipmen and gas pumping unis; - full range of process equipmen for gas compressor saions; - general-purpose indusrial pumps and elecric pump unis; - pumps and elecric pump unis for nuclear power plans; - hea-exchange and mass-ransfer equipmen, pressure vessels and anks; - process unis for cleaning, processing, reamen and primary condiioning of naural gas and crude; complee oil and gas indusry faciliies and complee chemical and perochemical producion lines; - faciliies on ЕРС erms; - insallaion, supervision over insallaion, precoissioning, designer's supervision, raining of Cusomer's personnel; - spare pars supply, modernizaion and replacemen of equipmen; - engineering. Unique manufacuring and esing complex ogeher wih advanced scienific and echnological poenial and human resources of he Company enables o solve non-sandard asks in erms well ahead of radiional ones. Producs qualiy is ensured by means of qualiy conrol sysem a all producion sages in accordance wih inernaional sandard ISО 9001. Designing, producion and esing of finished producs are performed in compliance wih domesic (GOST, Ukr SEPRO) as well as recognized inernaional sandards (API, ASME, ISO, EN). Abou he Company Sumy NPO PJSC
2 Cоnen Inroducory Par 3 Main Types of Reciprocaing Compressors 4 Basic Design Soluions 5 Design Feaures of Reciprocaing Compressors and Pars hereof 6 Vibraion Monioring of Reciprocain Compressors Condiion 7 Marking of Reciprocaing Compressors Pars and Componens 8 Maerials Used for Manufacuring of Compressor Pars 9 Основные виды поршневых компрессоров 10 2G2.5 10 4GМ2.5 11 2GМ4 12 2GМ10 13 4GМ10 14 2GМ10А 15 2GМ16 16 4GМ16 17 4GМ25 18 6GМ25А 19 GТ1 20 2GТ1.6 21 6W 22 Cerificaes and Approvals 23 Reciprocaing Compressors
3 Inroducory par PJSC «Sumy NPO» is one of he oldes enerprises in manufacuring of heavy duy reciprocaing compressors. 3 The firs super power compressor wih capaciy of 10 000 m /hour for pressure of 300 amosphere was manufacured by he company in 1933 for Bereznikovsky chemical plan. In 1949 he firs heavy duy horizonal compressor 1G-166/320 was produced. Reciprocaing compressors of high and super-high pressure are used for he producion of mineral ferilizers, for producion of polyehylene under high pressure, compression of naural and associaed peroleum gas, air, nirogen, hydrogen, in he perochemical and meallurgical indusries. The specialiss of he company have masered he producion of a number of general-purpose compressors, unique compressors for hydrogen-conaining gas compressing in he oil refining indusry, fuel gas for power plans, for complee faciliies when compressing associaed peroleum and naural gas, compressors for locking end gasdynamic seals of cenrifugal compressor unis. The company focuses on he producion of high-speed reciprocaing compressors, which makes i possible o creae reciprocaing gas-compressor unis driven by gas-pison engines. All compressors are equipped wih a sysem of auomaic conrol and proecion, which ensures conrol of basic operaing parameers, emergency warning and alarms and shudown of prime movers. Depending on he requiremens of he cusomer, he equipmen is manufacured for various parameers of capaciy and power, final pressure and compression raio. Possessing a powerful producion and scienific and echnical poenial, he enerprise can execue he developmen of drawings as soon as possible, produce, es and deliver he required equipmen o he cusomer, perform is insallaion, coissioning and, if necessary, provide is servicing. Inroducory par
4 Main Types of Reciprocaing Compressors No. Base Number Maximum Maximum Type designaion of rows reciprocaing shaf roaional of bearings force, speed, Caalogue page No. 1 2GМ2.5 2 2.5 1000 roller 10 2 4GМ2.5 4 2.5 1000 roller 11 3 2GМ4 2 4.0 750 sliding 12 4 2GМ10 2 10.0 600 sliding 13 5 4GМ10 4 10.0 600 sliding 14 6 2GМ10А 2 10.0 1000 sliding 15 7 2GМ16 2 16.0 375 sliding 16 8 4GМ16 4 16.0 375 sliding 17 9 4GМ25 4 25.0 375 sliding 18 10 6GМ25А 6 25.0 1000 sliding 19 11 GТ1 1 1.0 1000 roller 20 12 2GТ1.6 2 1.6 1000 roller 21 13 6W 6 1.6 1500 roller 22 Reciprocaing compressor designaion srucure: G - / - S Climaic version ype wihou lubricaion of cylinders and rod seals (upon cusomer requiremen) Discharge pressure, abs., kgf/cm 2 Sucion pressure, abs., kgf/cm 2 Volumeric capaciy reduced o sucion condiions, m 3/min per one raw, Compressed medium gas Number of compressor rows Compressor designaion example: 4GM10-48/2-57S UHL4 4 - number of rows; G - gas (compressed medium); М10 - opposie wih reciprocaing force for one row - 10 ; 48 - volumeric capaciy reduced o sucion condiions, m 3/min; 2 - absolue sucion pressure, kgf/cm 2; 57 - absolue discharge pressure, kgf/cm 2; S - version wihou lubricaion of cylinders and rods seals; UHL4 - climaic version as per GOST 15150 Reciprocaing Compressors
5 Basic Design Soluions Design Compressor base: soluions М 2.5 М 4 М 10 М 10А М 16 М 25 М 25А 2, 4 2 2, 4 2 2, 4 4 6 Number of main bearings Moving mechanism lubricaion Lube oil pump drive Barring gear 2, 3, 4 2 3, 5 2 3,5 5 7 Sprinkling Circulaion under pressure - Crank shaf Auxiliary elecric moor no no yes no yes yes no keyed/ End of crankshaf flange Lubricaion wih wih wih wih wih wih wih of cylinders lubricaion lubricaion/ lubricaion/ lubricaion lubricaion/ lubricaion/ lubricaion and rod seals w/o lubricaion w/o lubricaion w/o lubricaion w/o lubricaion Inermediae inser Type A, B, C, D (as per API 618) Main pars manufacuring mehod: Crankcase Casing Crankshaf Samping Forging Connecing rod Samping Forging Forging/ Samping Forging Connecing-rod bol Forging or machining of bar sock Connecing-rod nu Forging or machining of bar sock Crosshead Casing Forging Casing Crosshead pin Forging or machining of bar sock Crosshead nu Forging or machining of bar sock Inermediae inser Cylinder Cylinder sleeve Cylinder cover Pison Rod Rod nu Valve cover Rod seal casing and flange Valve body Valve plae Valve spring Casing Casing/Forging/Forging+welding Casing Casing/Forging Casing/Forging/Welding Forging or machining of bar sock Forging or machining of bar sock Forging Forging Forging Shee machining Broaching Basic Design Soluions
6 Design Feaures of Reciprocaing Compressors and Pars hereof Compressor 1. Forged seel crankshaf for heavy duies. 2. Horizonally balanced opposie rows. 3. Crossheads made of cased seel wih iron shoes (babbi filled) or aluminum shoes. Forced lube oil supply under pressure o upper and lower sliding surfaces for minimum wear. 4. Forged seel connecing rods. 5. Barring gear. Cylinders and pison groups 1. Cylinders wih boom par and rod seals mouned herein (fig. 1) and wihou boom par wih rod seals mouned ino inermediae inser (fig. 2). 2. Guide (journal) rings of pisons for lubricaed and non-lubricaed operaion. 3. Indicaion of cylinder caviies. 4. Rod seals purging. 5. Rod seals cooling wih cooling fluid (waer, ani-freezing agen) or oil. 6. Cylinders srucure wihou cooling or wih cooling wih cooling fluid. 7. Pison rods made of alloyed or corrosion resisan seel. Cylinder Cover-disance piece Cover-disance piece Cylinder Rod seal Rod seal Figure 1 Figure 2 Valves Disc, ring or band auomaic valves depending on compressed gas and average speed of pison. Capaciy regulaing devices (unloaders) 1. Addiional dead space. 2. Pressing of plaes of sucion valves (Hoerbiger, CPI). Pulsaion suppression device Buffer sucion and discharge vessels for each compressor sage. Reciprocaing Compressors
7 Vibraion Monioring of Reciprocain Compressors Condiion Vibraion monioring ypical diagram Vibraional speed sensor Phase sensor Bearings emperaure Rod posiion sensor Vibraion monioring sysem provides coninuous monioring of emperaure of connecion rod bearings and conrol of wear of pison guide rings per rod verical displacemen (insallaion of addiional sensors for rod horizonal displacemen is possible) depending on he urn angle of compressor crankshaf as well as compressor crankcase vibraional speed conrol including archivaion, processing and visualizaion of informaion, possessing warnings and alarms. Vibraion Monioring of Reciprocain Compressors Condiion
8 Marking of Reciprocaing Compressors Pars and Componens Par/componen Marking mehod Marking daa Compressor on nameplae According o API 618 Crankcase impac Main bearings covers impac Main and connecing-rod bearings bushings impac Crankshaf impac Connecing rod Connecing rod bol impac impac Designaion as per drawing, maerial grade, produc No. Designaion as per drawing, maerial grade, bearing consecuive number Thickness, disance of joins undercu, meling No. of babbi filling Designaion as per drawing, maerial grade, meling No., produc No. Designaion as per drawing, compressor row No., maerial grade, sample No. Designaion as per drawing, maerial grade, sample No. Connecing rod nu impac Designaion as per drawing, maerial grade Crosshead impac Crosshead pin impac Designaion as per drawing, maerial grade, meling No., produc No., row No. Designaion as per drawing, maerial grade, meling No. Crosshead nu impac Designaion as per drawing, maerial grade Cylinder group on nameplae According o API 618 Guide impac Designaion as per drawing, maerial grade Inermediae inser (disance piece) Cylinders Rod impac Designaion as per drawing, maerial grade impac impac Pison impac Pison nu impac Designaion as per drawing, maerial grade, produc No., meling No. Designaion as per drawing, maerial grade, produc No. Designaion as per drawing, maerial grade, produc No. Designaion as per drawing, maerial grade, produc No. Crosshead guide Crosshead Rod Inermediae inser Rod seal flange Cylinder Valve cover Connecing rod bol Valve body Crankcase Connecing rod Cylinder cover Crankshaf Connecing rod nu Rod nu Crosshead pin Crosshead nu Oil removing seal Seal in inermediae inser Rod seal casing Cylinder sleeve Pison Reciprocaing Compressors
9 Maerials Used for Manufacuring of Compressor Pars Par Maerial as per GOST Maerial analogue as per ASME/AISI Crankcase СЧ20 A48-No.30B Crankshaf 40, 40ХН, 45, 38Х2МЮА A105, 3140, A107, J24056 (K24065) Connecing rod 40, 45, 40ХН, 30ХМА-Ш A105, A107, 3140, 4130 Connecing rod bol 40ХН2МА-Ш 4340 (9840) Connecing rod nu 40Х, 40ХН, 38ХА 5140, 3140, 5140H Crosshead 20ГЛ, 38Х2МЮА A352GrLCC, J24056 Crosshead pin 20, 20Х A105, 5120 Crosshead nu 40, 40Х 1040, 5140 Inermediae inser СЧ20, СЧ25, СЧ30, 12Х18Н9ТЛ A48-No.30B, No.35B, No.45B Cylinder Cylinder sleeve Cylinder cover Pison Rod СЧ20, СЧ25, СЧ30, СЧ35, 20, 35, 40, 20ГЛ, 20ГМЛ, 20ЮЧ, 40Х, 12Х18Н9ТЛ, 08Х18Н10Т, 03Х17Н14М3 СЧ25, СЧ30, СЧ35, 20Х13, 30Х13, 40Х13, 38Х2МЮА-Ш СЧ20, СЧ25, СЧ30, СЧ35, 20, 35, 40, 40Х, 20ГЛ, 20ГМЛ, 20ЮЧ, 12Х18Н9ТЛ, 08Х18Н10Т, 03Х17Н14М3 СЧ20, СЧ25, СЧ30, 20, 35, 40, 45, 38ХА, 38Х2МЮА, 38ХН3МФА-Ш, 20Х13, 12Х18Н10Т, 08Х17Н15М3Т 38Х2МЮА-Ш, 40ХН2МА-Ш, 20Х13-Ш, 30Х13, 40Х13 A48-No.30B, No.35B, No.45B, No.50B; A105, 1035, 1040, A352GrLCC, 5140, J92630, 321, 316L A48-No.35B, No.45B, No.50B; A420, J24056 (K24065) A48-No.30B, No.35B, No.45B, No.50B; A105, 1035, 1040, 5140 A352GrLCC, J92630, 321H, 321, 316L A48-No.30B, No.35B, No.45B; A105, 1035, 1040, A107, 5140H, J24056 (K24065), 4330, A420, 321H, 316Ti J24056 (K24065), 4340, A420 Rod nu 35, 40, 40Х, 38ХА, 12Х13, 20Х13, 30Х13 1035, 1040, 5140, 5140H, A403, A420 Valve cover Rod seal casing and flange 35, 40, 40Х, 38ХА, 20ЮЧ, 30Х13, 10Х17Н13М3Т 35, 40, 45, 40Х, 40ХН, 20Х13, 08Х17Н15М3Т 1035, 1040, 5140, 5140H, SA-333 Gr3, A420, 316Ti 1035, 1040, 5140, 3140H, A420, 316Ti Valve body 20Х13 A420 Valve plae 30Х13, purchased Lange Consuling A420 Valve spring 12Х18Н10Т 321H Maerials Used for Manufacuring of Compressor Pars
10 Compressor on 2GM2.5 base 2860 925 95 280 reciprocaing, double row on opposie base 2GM2.5 2.5 2 100 1000 130 roller bearings Reciprocaing Compressors
11 Compressor on 4GM2.5 base 2380 1240 4,75 320 532 280 reciprocaing, four row on opposie base 4GM2.5 2,5 4 100 1000 260 roller bearings Main Types of Reciprocaing Compressors
12 Compressor on 2GM4 base 4150 1220 155 755 510 reciprocaing, double row on opposie base 2GM4 4 2 150 750 200 sliding bearings Reciprocaing Compressors
13 Compressor on 2GM10 base 5750 220 1970 1320 450 reciprocaing, double row on opposie base 2GM10 10 2 220 600 580 sliding bearings Main Types of Reciprocaing Compressors
14 Compressor on 4GM10 base 6260 3200 220 1380 1170 450 reciprocaing, double row on opposie base 4GM10 10 4 220 600 1000 sliding bearings Reciprocaing Compressors
15 Compressor on 2GM10A base 3600 1450 200 1007 450 reciprocaing, double row on opposie base 2GM10A 10 2 150 1000 580 sliding bearings Main Types of Reciprocaing Compressors
16 Compressor on 2GM16 base 6050 300 2450 1590 600 1. reciprocaing, double row on opposie base 2GM16 16 2 320 375 1110 sliding bearings Reciprocaing Compressors
17 Compressor on 4GM16 base 6120 4395 300 1850 1620 600 reciprocaing, double row on opposie base 4GM16 16 4 320 375 2200 sliding bearings Main Types of Reciprocaing Compressors
18 Compressor on 4GM25 base 1650 4400 360 1793 700 8700 reciprocaing, double row on opposie base 4GM25 25 4 400 325 3100 sliding bearings Reciprocaing Compressors
19 Compressor on 6GM25A base 4550 1200 4305 1200 300 1385 550 2860 Main Types of Reciprocaing Compressors reciprocaing, six row on opposie base 6GM25A 25 6 150 1000 4700 sliding bearings
20 Compressor on GT1 base 270 1205 260 560 reciprocaing, verical, crosshead, based on GT1 1.0 1 60 1000 20 roller bearings Reciprocaing Compressors
21 Compressor on 2GT1.6 base 320 1580 940 630 reciprocaing, verical, crosshead, based on 2GT 1.6 1.6 2 60 1000 45 roller bearings Main Types of Reciprocaing Compressors
22 Compressor on 6W base 60 60 255 145 940 1160 1175 reciprocaing, crosshead, W-shaped, wih cylinders' air cooling 1.6 6 60 1500 75 roller bearings Reciprocaing Compressors
23 Cerificaes and Approvals Cerificaes of compliance: - Cerificae of qualiy managemen sysem compliance wih ISO 9001:2008 sandard; - Cerificae of compliance of indusrial healh and safey managemen sysem wih OHSAS 18001-2007 sandard; - Cerificae of compliance of environmenal proecion managemen sysem wih ISО 14001-2004 sandard; - Cerificaes of conformiy wih API 618 for reciprocaing compressors on opposie base wih pison load of 2.5, 4, 10, 16 and 25 ons per one row; - ASME Manufacure Approval Cerificae. Main Types of Reciprocaing Compressors