Engineering the Future – since 1758.

MAN Turbo

Process-gas screw compressors

Designed for suction volume flows of200 to 100,000 m3/h, suction pres-sures down to 0.1 bar (abs.) anddischarge pressures reaching above50 bar, the robust process-gasscrew compressors produced byMAN TURBO can handle highly con-taminated gases and gas mixturesthat would curtail the availability andlife expectancy of other types ofcompressors.

High operational reliabilityThe operational reliability of MANTURBO process-gas screw com-pressors is based on 50 years ofexperience in screw compressordesign, and this in turn is supportedby 100 years of building a widerange of turbomachinery. Many MAN TURBO process-gasscrew compressor units have provenhigh availability factors over morethan 100,000 hours of trouble-freeoperation in unspared refinery service.

Application potentialMAN TURBO process-gas screwcompressors are successfullyapplied to almost all branches ofindustry and for many different pro-cesses. These include mining, ironand steel mills, chemical works, thepetrochemical industry, refineriesand oilfields.

For virtually every application, thescrew compressor can be adjustedto the particular requirements of theprocess for all kinds of gases andgas mixtures. As a positive displace-ment compressor, the screw com-pressor is ideal for the compressionof light gases, and wide fluctuationsin the gas composition do not in-fluence screw compressor perfor-mance. Relative low tip speedsallow the compression of dust ladengases, as well as the injection ofliquids into the compression cham-ber for cooling or washing.

QualityIntensive R & D efforts, the use ofthe most advanced manufacturingand test facilities, exchange of ex-perience with plant users, close co-operation with leading research in-stitutes, as well as our collaborationwith international standards organi-sations (i.e. API 619 committee, ISO, etc.) guarantee both high tech-nical standards and cost-efficiency.

AdaptabilityThe adaptability of MAN TURBOprocess-gas screw compressors is enhanced by a well-conceivedmodular design system and field-proven features. Extensive calcula-tion programmes are available forthermodynamic and mechanicaldesign, which together with modernCAD programs for design, engi-neering and manufacturing ensurethat all customer requirements areconsidered in a most efficient, yettailor-made way.

Performance characteristics

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MAN TURBO process-gas screwcompressors are designed in accor-dance to API 619 and are based ona modular design system with 10different rotor diameters. Designedas single or multi-stage units, theycan be driven by electric motors orsteam turbines.

Compared to other compressortypes used for process-gas appli-cations the process-gas screw com-pressor has the following advantages:• handles gases containing dust or

liquid droplets• changes in gas composition,

molecular weight, and/or pres-sure ratio have nearly no influence on actual gas flow rate

• suitable for liquid injection, for cooling or washing

• operates below the first lateral critical speed

• no surging• excellent part load behaviour with

speed control (~ 50% flow and 50% power at 50% speed)

• no contact of lubricant with process gas

• no wearing parts, which require regular maintenance

• no oscillating masses and there-fore low cost foundations

• high availability up to 99%• designed for a minimum service

life of 20 years and 3 years unin-terrupted operation.

Selection diagramThe selection diagram shows the CP and SKUEL compressor typesand their size as a function of suc-tion flow. Depending on the type of

gas compressed, pressure ratios between approx. 1.3 and 6 can be handled in a single stage, multi-stage arrangements or liquid injec-tion allow higher pressure ratios.

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Product features

CP type for high pressuresWith 7 different rotor diameters the CP series has 3 different length/diameter ratios, giving suction flow rates from 200 m3/h up to 20,000 m3/h.The vertically-split casing construc-tion allows discharge pressures inexcess of 50 bar.

SKUEL type for high flowsThe SKUEL series has 5 different rotor diameters each with 2 differentlength/diameter ratios, with suctionflow rates from 4,000 m3/h up to100,000 m3/h and discharge pres-sures up to 16 bar.

80

100

128

160

200

252

320

321

408

510

643

816

Suction volume flow (cfm)

100 500 1.000 5.000 10.000 50.000

100 500 1.000 5.000 10.000 50.000 100.000

Suction volume flow (m3/h)

CPtype

SKUELtype

50 bar720 psig

max. 16 bar230 psig

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The MAN TURBO modular system

The modular design system isemployed for all key process-gasscrew compressor components, i.e.covering the rotor profile, shafts,bearings and seals allowing flexibleadaptation of the compressor to theapplication under consideration,while retaining its optimum designfeatures.

Process-gas screw compressor stage,

SKUEL type

4 5 516

3

2 6

SKUEL horizontal

sectional view

1 casing

2 male rotor

3 female rotor

4 synchronising gear

5 bearings

6 shaft sealings

5

CP vertical

sectional view

Process-gas screw compressor

stage, CP type

Single wall construction is used to avoid the use of cooling jackets.

Depending on the type of gas tobe compressed, casings can besupplied in nodular cast iron, castcarbon steel or cast stainless steel.

CasingOnly cast casings are used for MANTURBO process-gas screw com-pressors. The bearing housings arean integral part of the compressorcasing. The standard nozzle arrange-ment with top suction and bottomdischarge allows liquid injection dueto the free draining arrangement.

Assembly of process-gas screw

compressor stage type SKUEL643 Components

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Manufacturing a compressor casing

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RotorsAll MAN TURBO process-gas screwcompressors are equipped with single piece forged rotors with anasymmetric rotor profile, to assurethe highest efficiency when handlinga wide variety of gases and gas mix-tures. No internal rotor cooling isrequired due to advanced designand manufacturing methods.

The synchronising gear, located atthe non-driven end of the rotor pair,assures contact-free operation of therotors whilst maintaining their smallclearances.

A variety of rotor materials from car-bon to stainless steel is available toresist any corrosive and/or erosivecomponents within the gas mixture.

CP type variation of L/D SKUEL643 type during assembly

Rotors of a MAN TURBO process-gas

screw compressor

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Multi-face thrust ring (tapered-land

bearing) as part of MAN TURBO

modular system

BearingsBecause of high rotational speedsand bearing loads, process-gasscrew compressors are equippedwith hydrodynamic journal bearingsand tapered land thrust bearings.Forced feed lubrication of thesebearings provides an unlimited lifetime.Tilting pad thrust bearings canbe provided, if specially required.

Combined journal and thrust bearings of

male and female rotor

Labyrinth

Floating rings

Mechanical contact seal

Carbon rings

Carbon rings

Dry gas seal

Liquid systems Dry systems

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Shaft sealingsThe compression chamber of the process-gas screw compressor isseparated from atmosphere by shaftseals; these are installed at eachshaft end of the compressor rotors.

To adapt the process-gas screwcompressor to different applicationsa wide variety of shaft sealingsystems are available. Divided intodry and liquid sealing systems, theexamples show the most commonlyused shaft sealing arrangements. Forspecific processes a number of otheroptions have been developed.

Possible shaft sealing systems

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Single stage units are best suited forpressure ratios up to 6. For pressureratios exceeding the limits of a singlestage compressor, units can be builtwith 2 or 3 stages, which are usuallydriven through a common gearbox. Any combination of compressortypes SKUEL and CP can be arranged into a multi stage unit.

Single and multi stage process-gas screw compressor units

2-stage process-gas screw compressor

unit with a wing pinion speed increasing

gear allowing the speed of each com-

pressor stage to be optimized

Package designEach process-gas screw compres-sor unit is tailor-made to meet therequirements of a specific appli-cation. State-of-the-art 3D design pro-grammes are used to optimizethe overall compressor arrange-ment.

View at a process-gas screw compressor module for an offshore application

3D computer modell

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Gear boxThe speed increasing gear box, usedfor single or multi stage compressordesigns, is designed by MAN

TURBO in accordance to the relevant international standards, i. e. AGMA, API 613, etc.

Control and safety equipmentThe demands for control and protec-tion systems of modern process-gasscrew compressor units in terms ofquality and flexibility are steadilyincreasing. Individually designed control systemsare provided to comply with therequirements of the process andprovide all functions from start-upto emergency shutdown.

View of gearbox internals

Typical control panel for a MAN TURBO

process-gas screw compressor unit

Oil supply systemsProcess-gas screw compressor unitsare equipped with oil supplysystems designed by MAN TURBO.Normally oil systems are integratedinto the compressor package, how-ever separate consoles in accor-dance with API Standard 614 orother customer specifications can be provided if required.

Separate oil supply console

designed to API 614

Acoustic treatmentSpecial attention has to be paid tothe acoustic treatment of a screwcompressor unit.To fulfil environmental regulations,MAN TURBO process-gas screwcompressor units are equipped withspecially designed noise protectionequipment, i. e. silencer systems inthe connecting pipework, noiseenclosures, etc.

Acoustic enclosure of a process-gas

screw compressor unit

Some examples of references

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Refinery Refinery

• SKUEL321/CP128

• 8,200 m3/h flaregas

• 1 to 16 bar

Butadiene extractionButadiene extraction

• SKUEL321 and CP128

• 7,200 and 1,900 m3/h butadiene

• 1.2 to 6 bar

Oil and gas productionOil and gas production

• CP200

• 4,000 m3/h associated gas

• 5 to 20 bar

Styrene monomer productionStyrene monomer production

• SKUEL643

• 56,000 m3/h offgas

• 0.3 to 1.6 bar

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Steel production (coke oven gas)

Power generation (fuel gas)Power generation

• 3 x CP100

• 1,000 m3/h fuelgas

• 15.3 to 28 bar

Soda ash productionSoda ash production

• 3 x SKUEL408

• 13,000 m3/h lime kiln gas

• 0.9 to 3.8 bar

Steel production

• 2 x SKUEL643/SKUEL408

• 41,000 m3/h coke oven gas

• 1 to 11 bar

Hydrogen purification (PSA)Hydrogen purification

• SKUEL408

• 14,000 m3/h PSA waste gas

• 2.5 to 8 bar

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MAN TURBO offers the most com-prehensive turbomachinery productrange in the world. Incorporating200 years of technological achieve-ments by four Original EquipmentManufacturers (OEM), we supplystate-of-the-art products and ser-vices for every industrial process.Tailor-made solutions by MANTURBO are based on an uniquespectrum of compressors and tur-bines – from single machines tototal train capability.

Core competencies and capabilities of MAN TURBO

Product line• compressors (axial, centrifugal,

pipeline, gear type, isotherm, process-gas screw)

• vacuum blowers• process-gas expanders• gas turbines• steam turbines• turbolog® control and monitoring

system• after sales service.

Using four large state-of-the-artproduction sites and test facilitieswhich include a type 1 – test stand,MAN TURBO provides cost-effectiveand efficient solutions worldwide.

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Core competencies• design and engineering• research and development• manufacturing• testing• installation, commissioning and

service support• quality assurance.

MAN Turbo AGSteinbrinkstrasse 146145 Oberhausen / GermanyPhone +49. 208. 6 92-01Fax +49. 208. 6 92-20 19www.manturbo.com

MAN Turbo AG SchweizHardstrasse 319 8005 Zürich / SwitzerlandPhone +41. 44. 278-22 11Fax +41. 44. 278-29 89

MAN Turbo AGEgellsstrasse 2113507 Berlin / GermanyPhone +49. 30. 44 04 02-0Fax +49. 30. 44 04 02-20 00

MAN Turbo S.r.l. De PrettoVia A. Fogazzaro 536015 Schio (VI) / ItalyPhone +39. 0445. 6 91-5 11Fax +39. 0445. 5 11-1 38

MAN Turbo AGHermann-Blohm-Strasse 520457 Hamburg / GermanyPhone +49. 40. 3 70 82-0Fax +49. 40. 3 70 82-19 90

In the interests of technical progress, subject to change without notice.Printed in Germany.June 2008Turbo 946 e 0608 1,0 ba