development of a new generation of screw oil injected ... 1. in 2010 to 2016 “vicom-m” npp ojsc...

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Development of a new generation of screw oil injected compressors for

gathering and transportation of associated oil gas

from end stages of separation.

NPP «VICOM-M» Ltd., Kazan,

e-mail:[email protected]

(Director – Timur Berdievich Mirzoev, mob. +79178506175

CEP – Artemiy Valerievich Vasutkin, mob. +79053667416 Site: http://vilom-m.nethouse.ru/

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1. In 2010 to 2016 “VICOM-M” NPP OJSC has carried a series of works for the purpose of development of

automated high reliable screw compressor plants for operation in remote oil fields and to compress associated oil

gas with content of water, aggressive components including hydrogen sulphide, hydrocarbon and other

components.

2. Compressor equipment used in associated oil gas gathering systems from end separation stages in Russia. Since 1975, screw compressor units 7VKG-50/7, 7VKG-30/7, 6GV-18/6-17, 5VKG-10/6 using a common oil

system where bearings are not protected against the effect of compressed gas and oil injected into the operation

chamber and containing water, petrol fractions and other components, including aggressive ones, are operated in

Russian oil fields. Repair works for replacement of bearings are provided in 6 to 12 months depending on gas

composition and humidity.

Application of complicated and expensive carbon end seals using separate oil systems in the Russian compressor

factories allowed to isolate bearings for the period of no more than one year, and this is a particular solution of the

problem. Russian manufacturers turned out to be not ready to introduce new technical solutions.

Imported compressor units have one common feature – all of them are refrigerating compressors for operation in

pure circulation gas systems of refrigerating machines. However, in flowing gas systems of oil and gas gathering

plants the bearings are affected by aggressive oil and gas mixture. In this connection, it is obvious that all screw

compressors with unprotected bearings are not used for the purpose which results in intensive repair works with

frequent replacement of total oil volume in the injection system in every 2 to 3 months of operation in order to

increase the bearings life.

3. Volume of works fulfilled by “VICOM-M” NPP OJSC including:

Search works;

Design developments;

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Manufacture of a head prototype of new “VGA”-VG109/6BM UHL1series block-module compressor

plant;

Experimental- industrial tests at “Tomskneft VNK” UPSV-36k with a control overhaul period of 34000

hours (4 years of operation);

Development of model series in the capacity range of:

Series A-6.0 to 100.0 m3/min – 5 sizes for end pressures up to 1.7MPa

Series B-150.0 to 250.0 m3/min – 3 sizes for end pressures 0.5 to 6.0MPa. works for the development of

Series B are being carried out now. During search and design works the following problems were considered:

1) Provision of total long term pressurization of compressor operation chambers which isolates the bearings from

the contact with compressed gas;

2) Development of a rational design of the compressor unit with increased rigidness of the supporting structure

(frame) in order to minimize vibration.

4. Main principles for building model series.

4.1 Bearing lube oil system and oil injection system for operating chamber are separate, circulation type.

4.2 Compressor operating chamber seal system is made based on “VICOM-M” sealing units allowing to provide

continuous control of pressurization and its dynamics, with operation life till parts replacement not less than

34000 hours.

4.3 Compressor is provided with a slide capacity regulator.

5. Results of field operation.

Specified problems were solved in VG-10/6BM UHL1 compressor plant which was put in operation at

“Tomskneft VNK” UPSV-36k in 2012.

Today, after 34650 hours operation the compressor plant was inspected and the bearings were replaced for the

first time as planned. The compressor plant operated for 4 years automatically with remote control.

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Indicators of basic parameters for vibration and displacement have not changed within the whole period of

operation. Absence of leakage between the oil systems characterized the stability of the seals operation. Condition

of the compressor parts shows that overhaul period for bearings and seals can be increased to 40000 hours.

6. Conclusions 6.1 High capacity B Series screw compressor plants have some advantages in comparison with centrifugal

compressor plants:

6.2 New screw compressor units retaining basic manufacturing process for screw compressor blocks (cutting of

rotors), the main advantage of which is increase of reliability and overhaul period 4 to 5 times, at least, compared

with domestic and foreign compressor plants with common oil system, unprotected bearings bought in tenders,

are developed in Russia and tested in the fields.

6.3. Increase of reliability became feasible due to new arrangement solutions, which increase rigidness of the unit,

in order to reduce noise and vibration, as well as due to application of new seals and pressurization system of the

compressor operation chamber providing favorable operating conditions for bearings in oil and gas fields and

refineries.

Mentioned principally new technical solutions are patented in RF.

6.4 New technical solutions allow to develop compressor plants for aggressive oil gases and process hydrocarbon

gases of wide fraction compositions with the content of water and to guarantee high overhaul cycles up to

35000hours of operation.

6.5 Operating parameter range for “VGA” series compressor units:

For series A – 8 to 140 000 Nm3/day;

For series B – 140 to 360 000 Nm3/day- advantages of screw compressor compared to centrifugal ones:

Independence of compression process on suction gas pressure and composition;

Lack of surge ;

Gas compression at high compression ratios in a single stage;

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Comparatively low rotor speeds;

Comparatively low discharge gas temperatures;

Possibility of injection of various liquids and mixtures into operating chamber depending on process

requirements during hydrocarbon gas production and refinery;

Low noise level;

Available economical and deep slide valve capacity control.

6.6 Today, VG-10/6BM UHL1 series head prototype is operating at the stage of the second overhaul 4-year cycle,

second maintenance is planned for 2020.

VICOM-M is providing supervision for operation of VG-10/6BM UHL1.

6.7 Price characteristics.

Taking in consideration that manufacturing process of “VGA” series screw compressors remains the same the

prices can be within lower bid levels for traditional compressor plants.

6.8 Economical justification.

For three aspects:

Reduction of operational costs;

Refusal of purchase of imported equipment;

Arrangement of export deliveries.

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Block-module automated VG-10/6BM UHL1 compressor plant. Specification TU 3643-VG770-65516507-2011

BKU(compressor plant block) BSU(control system block) VG-10/6BM plant at Igolsk-Talov field operating in the gas delivering system for “Igolsk” power station

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Compressor station valves control scheme

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COMPRESSOR PLANT BLOCK (BKU)

Injection and lubrication

systems

oil and gas air cooling

apparatuses

operated by frequency

converters

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VG-10/6BM UHL1 block module plant in container, based on screw compressor – new generation of Russian

screw compressors for low separation stage associated oil gas compression.

Container of block-compressor plant comprises all required design provision: heating, ventilation, light,

firefighting, gas signalization, bar-crane and special equipment for current overhaul in the BKU room providing

parts replacement to save time.

SCV

Compressor built in oil separator

Oil separator

Driving motor

Arrangement of the compressor unit is based

on vertical oil separator being a carrying

column type high reliable structure, which

provides reduction of vibration, noise, oil

leakage and eliminated alignment of

compressor and electric motor for repair works. This solution is patented in Russia.

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LUBRICATION UNIT

Two separate circulating oil systems are used to increase reliability and life of the plant: 1) Compressor bearings and seals lubricating system is provided with a separate lubricating unit comprising oil tank, oil pumps and block of

filters (filtration degree is 20 microns). Oil pumps and filters are made considering change-over.

2) Oil injection system for the compressor.

To provide operation of two separate oil systems and elimination of contact of oil for bearing lubrication with gas in screw compressor

special oil seals are used to pressurize operation chambers of the compressor and to eliminate oil leakage between the systems.

Separate lube system results in increase of overhaul period of the plant including replacement of:

- Seals in not less than 17000 hours,

- Bearings in not less than 34000 hours.

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Discharge part of the compressor inserted in the oil separator has paraffin deposits after

2500 hours of operation, with provision of inlet separator.

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Screen shot of VG-10/6BM UHL1 unit ( presented by ARM operator, dated 30.01.2017,

37157 hours of operation)

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Inlet and outlet separators with automatic remove of

condensate

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Process control system arranged in

container control block (BSU VG-

10)

In VG-10 compressor plant

control block

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Automated process control system is based on the controller according to the completion (Schneider Electric or other at the Customer’s

request)

Process visualization and controlling is provided from the operator’s panel (Magelis series XBT GT 12 or other at the Customer’s request),

arranged in control system block.

Control system is provided with operator’s place in the Customer’s operator room for remote control and adjustment.

Automation system provides:

Automated protection against emergency modes including compressor electric motor and auxiliaries shutoff and storage of information

about failure reasons;

Local and remote visual control of parameters characterizing operation of plant blocks ;

Remote start of compressor, oil pumps, oil coolers and shutoff valves;

Remote and local compressor electric motor switch-off;

“Pre-emergency”, “Emergency” signals to the operator’s panel;

Automatic control of the control valves;

Automatic retaining of set operating mode;

Automatic remove of condensate;

Light and sound signals for dangerous operating modes.

Scope of delivery for the plant:

BKU – 1 piece

BSU (on the common frame with BKU or separately) - 1 piece

Set of spares for 2 years – 1 set

Set of operational documentation – 1 set

Guarantee operation period – 24 months from delivery time.

Reliability:

Life till current repair, h – 17000 (replacement of seals)

Life till medium repair, h – 34000 (replacement of bearings)

Life till overhaul, h – 50000

Operation life, 25 years Delivery is provided in full shop availability including Supplier’s participation in installation, commissioning works, personnel training, and putting in

operation.

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Federal Services

For ecological, process and nuclear supervision

PERMIT

#PPC 00-047219

To use equipment (technical device, material):

Automated block-module compressor plants VG-10/6BM UHL1 as

per specification 3643-VG770-65516507-2011.

Date:12.03.2012

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Compressor unit VGA-6/6 Parameters Value

1. Volume capacity, range

Normal conditions

Suction conditions

180 to 360(Nm3/h)

3 to 6(m3/min)

2. Suction pressure, range -0.2 to +0.5(kgf/cm2, excess)

3. Discharge pressure, range 6 to 10 (kgf/cm2, excess)

4. Electric motor power, range 30 to 55 (kW)

5. Oil tank capacity 400 (l)



Normal conditions

Suction conditions

360 to 720(Nm3/h)

6 to 12(m3/min)


3. Discharge pressure, range 6 to 10(kgf/cm2,excess)

4. Electric motor power, range 200 to 400 (kW)

5. Oil tank capacity 600 (l)


1.Volume capacity, range

Normal conditions

Suction conditions

720 to 1500(Nm3/h)

12 to 25(m3/min)


3. Discharge pressure, range 6 to 10 (kgf/cm2, excess)

4. Electric motor power, range 90 o 250 (kW)

5.Oil tank capacity 80 (l)



Normal conditions

Suction conditions

1500 to 3000(Nm3/h)

25 to 50(m3/min)

2.Suction pressure, range -0.2 to +0.5(kgf/cm2, excess)

3.Discharge pressure, range 6 to 10(kgf/cm2,excess)

4.Electric motor power, range 6. to 110 (kW)




Normal conditions

Suction conditions

3000 to 6000(Nm3/h)

50 to 100(m3/min)

2.Suction pressure, range -0.2 to +0.5(kgf/cm2, excess)

3.Discharge pressure, range 6 to 10 (kgf/cm2, excess)

4.Electric motor power, range 400 to 800 (kW)


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MOBILE COMPRESSOR PLANT MVGA-12 (MVGA-25, MVGA-50) UHL1

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MOBILE COMPRESSOR PLANT MVGA-12 (MVGA-25, MVGA-50) UHL1 Possible arrangement for MVGA plant

VGA 12/6 compressor unit

Parameters Value


Normal conditions

Suction conditions

360 to 720 (Nm3/h)

12 (m3/min)

2. Suction gas pressure, range -0.2 to +0.5 (kgf/cm2, excess)

3. Discharge gas pressure, range 6 to 10 (kgf/cm2, excess)

4. El/motor power, complete set 75 to 110( kW)

5. Injection system oil receiver capacity 150( l)

6. Lube system oil tank capacity 120( l)


Parameters Value


Normal conditions

Suction conditions

720 to 1500 (Nm3/h)

25 (m3/min)



4. El/motor power, complete set 90 to 250( kW)




Parameters Value


Normal conditions

Suction conditions

1500 to 3000 (Nm3/h)

25 (m3/min)



4. El/motor power, complete set 200 to400( kW)



Delivery set MVGA-12 ,MVGA-25, MVGA-50 includes: 1 )Power cable (300m); 2) Cable for operator room (300M)

3) Set of flexible metal tubes for connection of the plant to external at the Customer’s object. Diameter and length

will be specified additionally.

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TYPICAL COMPRESSOR UNIT VGA-50, MONO-BLOCK VERSION (SERIES A).

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Comments of “TOMSKNEFT VNK” OJSC

“Tomskneft”, Strezhevoy, Russia

Date : November 18, 2016

Dear Mr. Mirzoev!

In 2011 “TOMSKNEFT VNK” OJSC purchased a VG-10/BM UHL block-module automated compressor

plant (hereinafter “plant”) at : “VICOM-M” NPP Ltd. Gas is delivered to the station with specified overhaul period of 17000 hours

for replacement of seal parts, and 34 000 hours for replacement of bearings.

Since putting in operation and after operating 34650 hours in October 2016 the first planned repair was provided including

replacement of frictionless bearings, and then the plant was put in operation again, for the next period. During four years operation the main

parameters characterizing the compressor condition have not changed, and vibration was at the lowest level of allower values(1mm/s). No

deterioration of sealing has been observed in this period. The compressor plant was controlled and monitored from the remote panel.

The next bearing replacement is planned in 35000 h operation. The main features of the plant providing high overhaul period are:

1. Compressor plant is provided with two separate oil systems:

Injection system

Lubrication system

2. Pressurization of the compressor operation chambers is provided by application of new type seals, i.e. contact-oil collar

designed by VICOM-M, which allowed to eliminate contact of bearings wjth compressed gas,

3. The compressor unit is made according to the original scheme with vertical oil separator being a column type frame which

allowed to improve vibration characteristics.

4. Oil replacement periods are reduced for application of domestic oils:

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In lube system – once a year

In injection system – once two years.

Remarks and recommendations for further prototypes.

1) To provide repair of the compressor and other assembles in the container room.

2) To consider the possibility of increasing the bearing life in order to make repairs and replacement at the same time.

3) To increase air change ratio in the container room for operation at high temperatures in suumer

S.V.Fomichev

Chief of oil and gas production Department

“Tomskneft “ VNK OJSC

development of a new generation of screw oil injected ... 1. in 2010 to 2016 “vicom-m” npp ojsc...

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