@ GEPS Oil & Gas Nuovo Pignone INSTRUCTION, OPERATION AND MAINTENANCE MANUAL (CENTRIFUGAL COMPRESSOR 2MCL 806) Volume I Description & Operation - Centrifugal Compressor NUOVO PIGNONE JOB NP. SERIAL NUMBERS CUSTOMER CONTRACT NO. SERVICE PLANT LOCATION PROJECT ITEM N° REQUISITION/PURCHASE ORDER N°NAME MANUFACTURER 110.1675 C1194? GRUPO ALVICA 447000 COKER GAS COMPRESSOR JOSE’ - VENEZUELA HAMACA CRUDE UPGRADER 12-K-001 477042-4-0301-B1 & GEPS Oil & Gas ‘Nuevo Pignone Via F. Matteucci, 2 50127 Florence - Italy Telephone (055) 423211 Telefax (055) 4232800 1675@ GEPS Oil & Gas Nuovo Pignone MANUAL ~ VOLUME I NP. Job: 110.1675 Description & Operation - Centrifugal Compressor (Centrifugal Compressor 2MCL 806; Grupo Alvica — Venezuela ~ Coker Gas Compressor) 10-.01-E 1675 Pr@ GEPS Oil & Gas Nuovo Pignone INSTRUCTIONS MANUAL ‘Status and description of the revisions Siato direvisione] Data] Eseguito | Controllato | Approvato | Deserizione della revisione Revision Status | Date | Prepared | Checked | Approved Deseription ofthe revisions First Issue |29,0601]ISSELnond| Paoletti_|Maccherini INDEX ISSUE _ ty — Second Issue 01.10.01 ISSELnord| ¥ ‘TECHNICAL MANUAL r - Vv © 2001 Nuovo Pignone S.p.A.,tutt | dit risorvath ‘NUOVO PIGNONE PROPRIETARY INFORMATION ‘Questo documont include infomazion’ confenza ea propre Nuovo Pignane ¢ non pus essere prod, copito, 0 Tomo area parte senza preventive consenso sorta Nuovo Pgnone | lstinatanaccotano prendre can ronevole pecauzion per prateggee fal infomation da uso non auoizato oda lore awigazione (© 2001 Nuovo Pignone S.p.A, all rights reserved [NUOVO PIGNONE PROPRIETARY INFORMATION This document ncladespropristan and confidential iormaton of Nuovo Pighone and may not be reproduced, coped, or mise the partes without th prior writen consent of Nuovo Pknone. Fecplunt agrees 0 take reasonable stops fo protect such formation fom unauthorized uso or dslosure DATE: 10-0-E NP. JOB: 110.1675 Pid@ GEPS Oil & Gas Nuovo Pignone ‘ter Sates Seve Inuroducton to Nuovo Pignone aftersales sersice Nuovo Pignone organization is structured in such a way as to guarantee a comprehensive and effective after-sales service for its machinery. Here is briefly described the organization of the company, based on its experience as a manufacturer and on a continuos effort to meet customers needs. Being aware of the importance of maintenance in all operational activities, Nuovo Pignone deals with its various aspects from the design stage, through: - the use of design criteria that enhance maintainability, « the continuos research of innovative solutions to improve availabil - the selection of components and advanced technologies lo enhance equipment maintenance, - the inspection procedures and topics, to be used in connection with a detailed schedule of ‘maintenance operations, =the choice of the spare parts to be Kept in stock, optimizing investment cost vs plant downtime, In late years Nuovo Pignone after-sales service has also been brought up-to-date to guarantee the best support to its customers. In more details: - worldwide, where Nuovo Pignone has been operating for tens of years, the structure consists of a service nctwork which is the natural expansion of the "Customer Service Division” in Florence. ‘There are localized Service Units and authorized Service Shops at strategic points of the world, to ccover areas where plants with Nuovo Pignone machinery are located. ~in Florence, ( Headquarters) specialized depts. which are active from the receipt of the enquiry, to the issue of the offer and, in cease of an order, to the management of all activities connected with the job, up to its completion. This organization, available for all customers, ensures a qualified interface to refer to for any requirements in connection with operation/maintenance of machinery. ‘The names and address for localized Service Units and authorized Service Shops are available at GE POWER SYSTEM WEB SITE (URL: hup:/iwww-gepower.cam) selecting from its home page the following choices: Business sitevGE Nuovo Pignone’Sales Organization (complete URL: hupzlivww.gepower.com/geoilandgas/oil_gashrands‘nuovo_pignone/sales_org html). In the section “Service” ofthis page are available the names ané addresses of localized Service Units divided into geographical areas. In the above indicated web site, in the section “New Units” are available the names and addresses of the Branch Offices Abroad divided into geographical areas. 06-01-E ‘After-Sales Service P12@ GEPS Oil & Gas Nuovo Pignone Alter Sales Service Nuovo Pignone has been managing for many years special aler sales "Support Packages". These packages typically incude: «= diagnostic analysis of machines in operation ~ consultaney in scheduling maintenance based on operational requirements - field maintenance - refurbishing of wom components - original spare parts supplies «technical expertise in updating machines Product engineering departments are staffed with experts in analysing machinery operating data, who provide users with technical consulting services aimed at optimizing use of equipment. The entite service organization guarantees users get the most suitable maintenance to restore original design conditions and the total information relevant to all technological innovations introduced in Nuovo Pignone's products as applicable to the installed machinery. Full flexibility allows us to adapt each maintenance contract upon User's needs Service Agreements in force today, range from "On call" basis to "Global Service" 06-01-8 ‘After-Sales Service P22@ GEPS Oil & Gas Nuovo Pignone VOLUMES INDEX The complete instructions of the compressor unit are subdivided into five Volumes as follows: = DESCRIPTION & OPERATION = COMPRESSOR DRAWINGS AND PARTS LIST - AUXILIARY EQUIPMENT INSTRUMENTATION + LUBE OIL CONSOLE Volume Volume Volume Volume Volume M-TOME 1 ~ TOME 2 ivided into Sections. Each Section can be subdivided into Paragraphs Each Volume includes a Main Index which refers to relevant content of Volume. 10.0 1675@ GEPS Oil & Gas Volume I Nuovo Pignone Contents COMPRESSOR INSTRUCTIONS MAIN INDEX Section - GENERAL General Operating conditions Performance curves ‘Data sheet Overall dimensions and main weights Casing Diaphragms Rotor Balance drum Joumal bearings Thnsst bearing Main reservoir il pumps and driver Cooler Filters Lube oil lines Seal gas lines Filters Instruments Labyrinth seals (intemal) Shaft end seals ~ seal gas system Lube oil system - general ~ SYSTEM DESCRIPTION Description — Compressor 2MCL type ‘Compressor 2MCL 806 - General Emergency lube oil system Lube oil pressure to beatings Oil pressure control valve Seal gas system - general Gas pressure control valve (8) Naphta washing system 1001, 1675 Pra@ GEPS Oil & Gas Volume 1 Nuovo Pignone Contents Section - SAFETY INSTRUCTIONS 3 Definitions Symbols used in the manual Introduction [dentification of danger zones Safeguarding (safety devices and guards) Residual risks Information on hazards in case of failure Intended use of machine General waming information - OPERATION 4 Foreword Preliminary safety check Stop devices Compressor unit operation - general Seal gas system preparation flushing system stating Lue oil system preparation Lae oil system starting Unit startup Unit shut down Instrument setting Routine checks Operating oil pressure and temperature, seal gas pressure Operating and control philosophy - MAINTENANCE, 5 Foreword Safety device maintenance General Inspection and maintenance list General recommendations Procedure for stud bolts tightening of casing Instructions for use of the hydraulic equipment for tightening case nuts and bolts Procedure for tightening bolts and nuts for all the compressors Procedure for tightening tie rods and nuts Journal bearing on end opposite to thrust bearing, TO0L-E 67S P23@ GEPS Oil & Gas Volume I Nuovo Pignone Contents Section, Journal bearing and thrust bearing Check of tilting pad bearing clearance Check of bearing set Check of thrust bearing axial clearance Check of rotor axial displacement Positioning of axial position probe Mechanical gas seals, Rotor, labyrinth seals and diaphragms To establish rotor center position Relative to diaphragms Oil specifica Oil pipings - erection - flushing Areas to be cleaned and interventions schedule Protective compound and cleaning solvent Preservation procedure Tools - parts list Tools - sketches - INSTALLATION 6 Foreword General delivery, unpacking, storage, handling Main equipment weights Foundations Positioning Alignment and coupling Alignment table - TROUBLE SHOOTING 1 Trouble shooting - DISMISSION AND ENVIRONMENTAL IMPACT 8 Environmental impact, Dismission 10-018 1675 P33@ GEPS Oil & Gas Nuovo Pignone General Section 1 GENERAL, SPECIFICATION AND DESCRIPTION Contents Page - GENERAL Ll = OVERALL DIMENSIONS AND MAIN WEIGHTS 13 - OPERATING CONDITIONS 1-5 - START-UP CURVE SOS 3029314 1-6 - PERFORMANCE CURVES SOS 3051014 - DATA SHEETS SOS 9931709/4 - LUBE OIL CONSOLE DATA SHEET SOS 41746i4 1OO-E 1675 Pe@ GEPS Oil & Gas Nuovo Pignone General 1 GENERAL ‘The instructions contained in this manual are referred to a "Coker Gas Compressor Train" for a Crude Upgrade Project. ‘The process gas is compressed from 1.01 Bar a (14.7 PSI a) to 13.6 Bar a (197 PSI a) by ‘two compression stages utilizing one centrifugal compressor of type 2MCL 806. ‘The compressors is driven by means of a electric motor coupled to the compressor by means of a gear box and coupling. ‘The machines are assembled directly on foundations. ‘The arrangement of the machines comprised in the unit is shown on the simplified drawing at page 1-2. The operating conditions of the centrifugal compressor unit are shown in the following pages of this section. This volume of the instructions manual includes: the description of the manufacturing features, the instruction of installation, operation, maintenance and preservation; the de- scription of the lube oil and seal gas systems and of the assembling/disassembling tools. ‘The instructions of the "Auxiliary Equipment" (Volume III of this Manual) and "Instru- mentation" (Volume IV of this Manual), supplied by Nuovo Pignone for this compressor are included in separated volumes of this manual. For the instruction of the electric motor driving the compressor see the proper manual, For the arrangement of the machines and for installation dimensions refer to "Machinery Outline and Foundation” dwg. SOK 6738110/0, included in the “Drawings” Section or volume of this manual. 10-0-E 1675 P12@ GEPS Oil & Gas Nuovo Pignone General 12 GAR Box LUFKIN NETO4C courLie JOHN CRANE-FLEXIBOX | JOHN CRANE-FLEXIBOX Toe 926 | “ON TeGeri ae s200 | FLECTRIC r centrirucaL MOTOR COMPRESSOR | 2MCL 806, =F Hi tu HT vit Lod | | | l) FOUNDATION i i | | | i | i ' | i Ht i | = - . | 2nd SUCTION f= || 1stsvcrion_ ‘Compression unit arrangement - Simplified drawing 165 R22@ GEPS Oil & Gas Nuovo Pignone General 13 OVERALL DIMENSIONS AND MAIN WEIGHTS. For the overall dimensions see drawing at following page. MAIN WEIGHTS Denomination Waa ——— 24000 Gear box N2704C a0 COICE 2MCL 806 Fes00 100-6 1615 PAZ@ GEPS Oil & Gas Nuovo Pignone General 14 4 viewrrom "a" | 5 1S | ) * 22 soo oo 3] 3 ms } | ELECTRIC ar ‘BOX MOTOR d 6 Py |e Fy oo @ 1 Ne SS e1* “|~ CENTRIFUGAL’ L® 4 ccomresson | _\Py oan MCL] | e © Ae 4 oS. ¢ wt feo O]|./Ife o 6 bh: Se @ © @ Overall dimension drawing 1001 i675 riod@ GEPS Oil & Gas Nuovo Pignone General 15 OPERATING CONDITIONS (GUARANTEED POINT) ‘CONDIZIONI DI FUNZIONAMENTO ‘GUARANTEED POINT OPERATING CONDITIONS CASES FASE DI COMPRESSIONE (COMPRESSOR STAGE ‘GAS COMPRESSO, GAS HANDLED. (Main components) PORTATA, WEIGHT FLOW oinin COKER GAS 25 1881 ‘CONDIZIONI ALL*ASPIRAZIONE SUCTION CONDITIONS Peso molecolare Molecular weight 3h 306 Lis 1168: (Compressibiii Compressibility Pressione Pressure Temperatura Temperature oso 0976 47 56 ‘CONDIZIONT ALLA MANDATA, DISCHARGE_CONDITIONS Pressione Pressure Pst Temperatura Temperature cg 6 WoT POTENZA ALLASSE SHAFT POWER BHP VELOCITA’ ‘SPEED pm ‘SENSO DI ROTAZIONE (visto dal lato azionamento) ‘ORARIO ROTATION DIRECTION (viewed from driver end) CLOCKWISE 7850 1535 7535 10.0-E 1615 PelNuovo Pignone| “" “""" GRUPO ALVICA — WOCALITA = PLANT LOCATION JOSE? - VENEZUELA CoMessA-J08 PANTO PLAT 1101675 Hamaca Crude Upgrader Project rowo-1mE START UP CURVE FOR CENTRIFUGAL COMPRESSOR 2MCL806 Hamaca Crude Upgrader Project 19 Jun-01 | Grupo Alvica No: 04477000 477042-4-0301-B1. 2-2 Equip: 12-K-00 { [3 ey CHE A : Tar [2 Wel : 4 Jo A eev SOSTITUTO DA- REPLACED BY [some ety Pent te ndNuovo Pignone FIRENZE Electric Motor + L.S. Coupling + Gear Box + H.S. Coupling + 2MCL806 300 | 20011 | | vouraceno | A, on 8 eee /\\ = a==:VOLTAGETD Vi @ é | | § 1904 Ly = i i € 1004+ Ps Se leas y | Nominal Rotation Speed (%) 60 80 100 T COMPRESSOR TRAIN DATA? ‘Motor nominal worque ‘Compressor + gear box rated absorbed powe [io ‘ation speed. 9S Ube 3120 SHP 1780___ RPM. 7535 RPM NOTES: (1) Values referred to driver shaft according to APIGI7 requirement. (2) Driver torque shall be at least 10% more than the rated torque at all the points of the above diagram, 269007 4035 Lb. 145227 __Lb.ft°2 Ter TRETSED 0 IN. SOS 30293 _14 EMESSO - ISSUED TONGUAUANG. | PAGIASHEET DESCRTONE - DESCRIPTION seta doer © pss MUOWE PRONE i np OTTO OTERO. Ts drument se prope f MUCH PHONE. As resend ozo ok. A 212 TOSCEL [SOSTTUTOOR-RERACEDBY ————__]Nuovo Pignone| “°° rwowoswe, ; renzs STATON — CCONMESSA JOB RTOS EXPECTED PERFORMANCE CURVES OF CENTRIFUGAL COMPRESSOR 2MCL806 Grupo Alvica - Contract 477000 P.O. No. 477042-4-0301-B1 Item: 12-K-001 : EOF in, sossesio a a eel [SIRE PRG pee | Peed — Be eee Se eeNuovo Pignone iene INDEX Rated point 3 Normal 3 (guaranteed) 10 Normal 1 7 Normal 2 24 Minimum flow 31 ze” ier] sescnaione pescurrion are Teil oom sap NW PERGAE Ann aia Sa tessoamers ea pepe MOV PRI Alt wereenmd eanencoun rs. 14/80/010 marten ee. s8/e80) |COKER GAS COMPRESSOR STAGE OVERALL OPERATING POINT RATED 35.0 T T | 25.0 T T 2 T Tt 2 iso @. a i s % so & ! | (eee 26500 ' 27500 2@s00 29500 | 30800 | 31500 32800-33000 11000. - i ot % 10000 |. it & L & | Lt ‘s000 ees ee t | | i = Vt 8 e000 @ i g 8 7000 |_| ro + 26500 27500 20500 29500 | 30800 | 31800 | 2800 | 39500 INLET FLOW ACE /MIN THESE CURVES ARE VALID IN THE FOLLONING CONDITIONS GAS HANDLED COKER GAS MOLECULAR. REIGHT Sarre INTAKE’ PressuRE 15.7 pstA INTAKE TEMPERATURE 405 0e6-F CovPREss. aT SUCTION 0.99, RATIO GF SPEC. HEATS £1458 vos 1103675 | | Bowe Pignone PZ Ce = 4 ev. | onsenizvoa ~ senior [rw Jarorefmmrs[ amar |NSOS30510 —_/4| Tas TE GAUEO ALVICA THANE | TET PECTED DERFORMANCE CURVES FOR COKER. GAS pa 13 7G | ____Eeniba ‘cOMPALSS08 OF 2uEcs06 = ITEM" 12-004‘65000. ICOKER GAS COMPRESSOR STAGE STAGE 1 OPERATING POINT RATED T 1 ~ M1 fy i 2 ss000. 1 1 * ee] 2 toy 3 I @ «5000. = t_T/T g i’ . | E sooo i a 250004 |. ‘24000 2600020000 4.000. 0.000 = | bd : | 4 ~ eS re 8 ty ti | E 0.600, ,ojot - & EET td 2 x i [ i — 2 t a | s { 2 0.400 I | it | 5 | a Es ven || Oa & T vel ed pitt 2490 26800 28000” 30000" 32000 + 24000” 6000 30000 INLET FLOW ACE /MIN THESE CURVES ARE VALID IN THE FOLLONING CONDITIONS GAS HanoLED COMER GAS MOLECULAR WErONT Sa7 {rake Pressure 15.7 psia INTAKE TEMPERATURE 106 OEG-F Cowress. aT SUCTION 0-89. RATIO OF SPEC. MEATS 1186 FLANGE TO FLANGE 08 1101675 Nuovo Pignone | Rev } noe ___ fev. | ccseution = eso wie lorer|momaponaw ]NSOS30510 4] Tres TIE” GRUPO ALVICA EXPECTED BEPOMUNCE CURVES FOR COKER GAS= [COKER GAS COMPRESSOR STAGE STAGE 1 OPERATING POINT RATED 92 i i iL Tt gee i 4 ¥ lea e ELS Bt & | gs 5 7 | Es 7 i + + 25000" aa0o0' 27000” 20000 31000 3000~”~as000”~””—37000 200 a 20 T & o 4 Bes m | & 8 al = 200 8 |B | 5) 58 z 3 220 | t t 2 23000” esd00” e7do0 ” 2odo0 "31000" 33000” 5000 37000 i INLET FLOW ACE /MIN E THESE CURVES ARE VALIO IN THE FOLLOWING CONDITIONS Gas, HaNoLeD COVER 64s 3 Seketetae kexcot sre 3 INTAKE PreSsone 18:7 psta 3 IMtaKe TesoencTune 108 oc 5 Coveness. a7 SUCTION 0-89 ; Sairoror seec nears 96 g a i 081101875 i a | ‘Nuovo Pignone Leta st | Say ead “aT aan fara NS0S30510 4 2 ee Ll : Bec ee Ghuace cunves con coxen a [eve S|__ ETSI UGET CRISIS of Sacto Tew tS xno 5 [Sears mes te tame comeerammme renee | Obtiniee Tao SPs Sey WR ase osama eee | a TT[COKER GAS COMPRESSOR STAGE STAGE 1 OPERATING POINT ATED 7000 = sooo 5 & & 5000 : 8 1000 | i | 3 4 8 3000 i 23000 25000 | 27000” 29000 + 33000-33000” 35000~——-37000 . INLET FLOW ACE/MEN g E THESE CURVES ARE VALIO IN THE FOLLOWING CONDITIONS : 1s HanoneD oxen as a fovecucan NexouT Seve 2 INTAKE PRESSURE 15.7 para 5 Intake TenpenaTunc $08 08G-F : covness. aT suction 0.89 ‘ Ratio OF spec. FEATS 11386 2 3 g a 3 vos 1101675 i Nuovo Pignone thebear out [pv [ oes ecemorion wor [erers|momafenae|NSOS30510 —_/4| «EDS GRUPO, ASTER ce caves rin coun cue ee Tee 5 Feu tS non A L? 5 Soriisee REDO ® [S031 11U1"0 OA-REPLACEO BYteroorta su PorTen vet FEET POLYTROPIC HEAD * POLYTROPIC EFFIC _t JcoKeR Gas COMPRESSOR STAGE 2 OPERATING POINT RATED '35000_ 45000. 35000. 25000. 18000, 2500 | 3500 4800.«=| «550085007500» 8500800 1.000. = 0.200. i 21 0.600. I 0.400. | 0.200 | Hie zo 3600" #500 ss00 | e500” 7500«|«<6500——«9500, INLET FLOW ACE/MIN TWESE CURVES ARE VALIO IN THE FOLLOMING CONDITIONS GAS HANDLED coven Gas fOLECULAR WeIoHT Seat INTAKE PRESSURE a2." ‘psta IWvaKe TeNPenaTune 104 066-7 GoienESS. AT SUCTION Ova74 RATIO GF Spec FEATS $1487 1 FLANGE TO FLANGE woe 1101675 {fy | Nuovo Pignone [zee i |__ewoee _| re | oescnrtiow ~ eccarion Tare [oroareemefemae [NS0S30510 —_/4 THaS= THE GAUPO_ALVICA ae Seecreo peArGbuance cunvES FoR COKER AS 2 37 Sie feu i3-c-001 Seriect CHEATSCoven GAS COMPRESSOR STAGE «2 +~=«=«COPERATING POINT RATED 200 1 2 200 | 8 | B g x0 | = | 8 | F100 | & | g | ° a 0000 240 ria u 300 pt I é :”™ t t . i J 8 | j | @ | | = x0 | | zm t | 2 { {4 \ 8 ieien t+ 4 180 \ ee lee| eee 3000" 4000 «| «5000 6000 7000 8000 9000 10000 INLET FLOW ACF/MIN THESE CURVES ARE VALID IN THE FOLLOWING ceMDITIONS cas wasoueD coven As Socctutan kere Stet INTAKE Pneesune 22-tpsta Intae reweriune 04 obe-F dpueness ar suction — Suart RATIO OF SPECS HATS. S107 108 1101675 t f ‘Nuovo Pignone beav | _emoue bt CESCAIZIONE = DESCRIPTION rare |eon-ow| N.SOS30510 /4 Tit GRUPO ALVICR a | OT Ceres bua cruance curves #08 _conER. ox [B5ICOKER GAS COMPRESSOR STAGE 2 6000 OPERATING POINT ATED 7 7 t ee {oi . 1 ! 7 rl lea: & sooo |__| i bo 1 I Teele] g | | {| tt 3 : TT 4000 a 4 2 fr | = 3 | z : [_. l & 1 i 8 ato { | g | I 3g + ° [ft | 2000 | | | yoo odo 5000 6000” 7000” a0” 900010000 INLET FLOW ACF/MIN THESE CUWVES ARE VALIO IN THE FOLLOWING cONOTTIONS GAS HANDLED COKER Gas MOLECULAR WercHT Set INTAKE PRESSURE: 32:"‘psta INTAKE TOPERATURE fod oEG+F Gennes. aT Suction G.a74 Ratio Gr seec. seats 9.407 voa_1101675 } { ‘Nuovo Pignone nee Zz a | descriTe = ROTTION We [ateajeems| omew |NSOS30510 —_/4 aeee re BEee re SM GrwaNze CURVES FoR COKER eee EO. TchLeao Vers. 149/0R _pRoNORTO ay MOYER OLE) fcacR GAS COMPRESSGA STAGE OVERALL OPERATING POINT NORMAL 3 IGUAR.) 35.0 eee { 2.0 |__| 8 E sol | a w 5 8 5.0 & 27500 20800 | 29500 30800 »«31800 «32500, 33500 34800. 10800 . : CLL LET) foi oa | rfid TT 1 = seo | pees ese Pelee ete eee ee ee ee rt & 1 tt} tty 2 fp 2 alae ale | a | fit it 4 E | — 7 waleml |_| 5 : : : + G iz T B 500 i | £ | & | a 1 3 | | 500 |__| feed 2700 ' 26500 9000 90500 31900. 32500 INLET FLOW ACE /MIN THESE CURVES ARE VALIO IN THE FOLLOWING CONOTTIONS cas HavoLED coneR eas Moecouan werent see3 INtAace Pressure 14:7 sta Intace Tewpenarne 106-086 Goummess. aT SUCTION 0.981 Barto OF spec. MEATS «is 08 1101675 | ‘Nuovo Pignone trite —__rwowe__| fev: | secant — senior Tae Jone |eorelenen |NSOS3OS10 —_/4 Tis = HK GRUPO ALVICE aoe. PRT EAT SeeeP ed be munce cunves FoR coxeA a (derdtcicae Ness. 1/0R/0NA __PoNOND By LONER mA) Pores iene 1705/080 COKER GAS COMPRESSOR STAGE STAGE 4 OPERATING POINT NORMAL 3 (GUAR. 5000, . ] TT | oi TT a | * i ° | | @ «so00f + 8 2 4 2 E ss000. 2 Geta + t 4 zadoo ' 26000” 29000 20000 | 2000 34000 36000-38000 1.000. 1 Bs 0,00. 1 {Tt a 0.600. & 20 pa 2 0.400 z 0.200. Jeeles| | | | ato 26000 20000" 0000” =3e000 | sadoo 2600.” 38000 INLET FLOW ACE /MIN NESE CURVES ARE VALTO IN THE FOLLOWING CONOTTIONS GAS HMIOLED omen cas MOLECULAR. nEGHT Saves INTAKE PRESSURE. 12 esta INTAKE TEMPERATURE 106, OEG“F coeness. AT SUbTION 0.998, RATIO GF SPEC FEATS. f-187 FLANGE TO FLANGE os_1101675 [ ‘Nuovo Pignone trlegv -—| rence fev. | ocsenitio® ~ casera [aoe orars|ommws| orrme NSOS3O5, Waco THe GRUPO ALICE ee STPacrED Pemrarunce cunves FoR covenchee Ners.14/srons —__@reootta wy AOTEER YOR) sorgn 6519/68/00 COKER GAS COMPRESSOR STAGE STAGE 1 OPERATING POINT NORMAL 3. (GUAR. 89 ee 3 RB se & coe B a 1 “ | Ltd 23000 25000 27000 + 29000 | 31000 33000 | 35000-37000 300 4 il ie | i a uw = 280 | 1 1 4. Lat ry eg 1 foi : [— =} é | | © ono 1 it : Coo 8 I ol 2 2a ic [lene 5 { | | g 1 —t a | - 0 ppt ~~ 23000 25000 ' 27000 ' 2e000 ' 21000 33000” 3500037000 INLET FLOW ACE/MIN THESE CUFVES ARE VALIG JW THE FOLLONTKG CONDITIONS Gas MANGLED COKER AS fotecutan werout Stes INTAKE PRESSURE 1a Festa Intane TEHOERATIRE 106. 0EG-F coumness. AT suction 0.898 farto GF seec. feats 1.187 08 1101675 f ‘Nuovo Pignone (eV T “irene ee = NS0S30510_—_/4 TWiga IRE GHUPO ALVICA a Saeed bectuunce. con a LO Ad | __ ae et? |execs ERs. 1480/05 pono sv METER we) aren (en. 1/e0/o6) fe JcoKEA GAS COMPRESSOR STAGE STAGE 1 OPERATING POINT NORMAL 3 (GUAR. 7000 : 4 | d joi | | e | | oe alee eee! Tt | S 4d I Pop é | rif = s000 | n po} + TI z bee ial B 000 ml ee eases g Lt | & | | 8 a 2000 Lot Hdl | 23000 25000 27000" 29000 34000-38000 5000 37000 INLET FLOW ACE /IN THESE QUAVES ARE VALIO IN THE FOLLOWING CONOTTIONS, as wanoneo coxen Gas forecourt Nexon 8 InTace PReseune 14:3 peta Inne Tenpemarune 106 nest GweNESg ar suction Ova0i parroor stecs'reets 9187 wee 1103675 t ‘Nuovo Pignone [Zeer - a fev] cceartiog = Sarr Tare [arore|ooaera [eae |NSOS30510 7 Tike TRE GRUPO ALVICA Ta] REARS seen e Expected EERE GRAMNCE CURVES FOR COKER. OAS a ASGem ie. 14/avons coor ay AOTIER Aa |coKER GAS COMPRESSOR STAGE 2 OPERATING POINT NORMAL 3 (GUAR) 80000. : | 60000. ° 1 BP econ wow [are NS0S30510___/4| Wem = FiRE GHUPO ACVICR- TCE) PTET iN ExecteD BeAreryanice cunves Fon cower ‘a [36/8pores e.s8/oom JCOKER GAS COMPRESSOR STAGE 2 OPERATING POINT MINTWUM FLOW 400 coe es ical T | | : S i | 2 so ff tb yt i 2 200 | = g | £100 | = oS 1 & | 5 | : | E 30004060 340 uo + 8 TT Zw é . 6 180 r : i soto’ «000 ' S000 6000 7000 6000 sod0 10000 INLET FLOW ACF/MIN THESE CURVES ARE VALID IN THE FOLLOWING CONDITIONS GAS HANOLED COKER GAS Socecucak kensir S38 InvaKe PRESSURE 38, psn, INTaMe TenPenaTune 104 pEG-F dquness. ar SutTion . 0.973 fatto OF SheC. HEATS. $108 woe 1101675, i [ ‘Nuovo Pignone eu rine jnev. | O€scarzrone - DESCALPTION were _|row-owe|wnuere| ninee | N.SOS30510 /4 Tio TIRE GRUPO ALICE TR | OEY BPecTeg FEATOMANCE CURVES FoR COKER. GAS a 5937:IcoKeR GAS COMPRESSOR STAGE 2 OPERATING POINT MINIMUM FLOW 6000 ; co ro it 4 e | Ll | % s00 top 1 bot ! £ J | Lo Lotoi it 3 | rp Td & oo i iL 1 tt ef i 3535. L [ 5 — : — B sooo | | ber | | i COT a ; ew | || [ia] 2000 |__| i - aodo 4000” s00o 6000" “7080 ~—~—60d.——9000.——10000 INLET FLOW ACE/MIN THESE CURVES ARE VALIO IN THE FOLLOAING CONDITIONS GAS HANOLED coxen Gas Sotetucan wexcur Sos INTAKE eressune 30. “psta INTAKE Tewenrune $04 oF eet Cowness. xr suction — .a78 favzo oF sec. HATS 1108 08 1101675 Nuovo Pignone (REV sent |nev. | vescrrzione - DESCRIPTION moe |emnono|oecmo| onan |N.SOS30510 /4| ‘Tigto.~ THE GRUPO. ALVICA’ TARGUA-LANG. | DaGiven-SneeT Erected DUA Ghunce cunves Fon cone SHS a [St AYNuovo Pignone FIRENZE ‘COMES. 1101678 (CUENTE- CUSTOMER. GRUPO ALVICA TOCALTIR™ PLANT LOCATION JOSE" VENEZUELA THPANTO- PAN HAMACA CRUDE UPGRADER PROJECT TOL. 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Pl _sixnacaGoalipocanee —_ SheetNo. 35 = £ ESuACA GEHL ae Ca | samara oma mae [Rcenpiaa eaters are —| ee Lr 058) aes | eioear Sanaa rERaSEaT ee | eres | REMARKS rT pepe rer 2K IN. _SOS41746_/4 RETR | PRONE rer | oescaaoneoescReron A 181415 set tomatod 6 pod DVO FENONE Alen Sepp ob ane cosets oped OVE CHONG Als on aes TTL PORES ETT GA AAPG@ GEPS Oil & Gas Nuovo Pignone System description Section 2 GENERAL, SPECIFICATION AND DESCRIPTION Contents Page - DESCRIPTION ~ COMPRESSOR 2MCL TYPE 21 - COMPRESSOR 2MCL 806 - GENERAL 22 - CASING 2d - DIAPHRAGMS, 2.5 - ROTOR 2-6 - BALANCE DRUM 2-8 - JOURNAL BEARINGS 29 - THRUST BEARING 211 - LABYRINTH SEALS (INTERNAL) 212 - SHAFT END SEALS - SEAL GAS SYSTEM 2-13 - LUBE OIL SYSTEM - GENERAL 215 - MAIN RESERVOIR, 2-18 - OIL PUMPS AND DRIVER 2-19 = EMERGENCY LUBE OIL SYSTEM 2-20 - COOLER 2-21 - FILTERS 2.23 - LUBE OIL LINES 2.24 - LUBE OIL PRESSURE TO BEARINGS 2.25 = OIL PRESSURE CONTROL VALVE, 2.26 100L-E 1675 Pra@ GEPS Oil & Gas Nuovo Pignone System description Section 2 Contents Page - SEAL GAS SYSTEM - GENERAL 227 - SEAL GAS LINES 229 - FILTERS 231 - GAS PRESSURE CONTROL VALVE (S) 2:33 - NAPHTHA WASHING SYSTEM 234 - INSTRUMENTS 235 Tore 1675 p22@ GEPS Oil & Gas Nuovo Pignone System description 2 DESCRIPTION COMPRESSOR 2MCL TYPE ‘The Nuovo Pignone centrifugal compressors are designated by a series of a capital letters and numbers, ‘The capital letters describe the casing features; MCL indicates a compressor with the casing. in two halves horizontally spit. ‘The numbers, after the letters, describe the compressor nominal "size" and the impellers num- ber. If the compressor has two back-to-back compression stages the designation is preceded from the number 2. The compressor type 2MCL, though it consists of a single casing, is featured by two stages. In fact the gas comes out and it passes through a cooler, itis again sucked and it is brought to the discharge conditions by the remaining impellers, Example: the designation 2MCL 527 indicates a compressor of nominal "size" 520, with two compression stages, by horizontally split casing and containing a rotor with seven impellers. The compressor consists essentially of a static unit (casing, ciaphragms, seals, bearings and cov- ers) and a moving unit (rotor formed by shat, impellers and balance drum). from 10-84 01020 PL to 0289-8@ GEPS Oil & Gas Nuovo Pignone System description 2 COMPRESSOR 2MCL 806 - GENERAL. ‘The compressors described in the ttle page is a 2MCL 806. ‘The suction and discharge flange of this compressor are tuned downward. ‘The 2MCL 806 centrifugal compressor with two compression stages and nominal "size" of 800 ‘mm has a shaft with six impellers, ‘Three impellers are utilized forthe Ist stage, three impellers are utilized for the 2nd stage. ‘The actual impeller diameters are shown in the compressor rotor dwgs. included in the "Draw- ings" section or volume of this manual. ‘The compressor casing is provided of drains. ‘The assembly sectional drawings, included in the "Drawings" section or volume of this manual is: = SOS 93846/0 for 2MCL 806 included in the Volume II, Section 2. ‘The simplified drawing on the following pages identify the main components ofthis compressor. 10018 1675 Pre@ GEPS Oil & Gas Nuovo Pignone System description 23 srup CASING DIFFUSER CHANNEL. un SING BALANCE CASING srup BOLT HEAD, DRUM BOLT RADIAL PROBE RADIAL BEARING PROBE SUPPORT UPPER HALF END cover~ AXIAL PROBE COVER COVER THRUST JOURNAL BEARING BEARING JOURNAL. BEARING 2 ad DISCHARGE DISCHARGE. || SUCTION MECHANICAL MECHANICAL, DRY GAS SEALS DIAPHRAGM DRAIN IMPELLERS DRY GAS SEALS, ‘Simplified assembly drawing of 2MCL 806 compressor T00LE 1675 P22@ GEPS Oil & Gas Nuovo Pignone System description 24 CASING MCL - 2MCL -3MCL ‘The casing of the MCL compressors consists of two halves, they are held fimmly together on the horizontal centre plane by casing stud bolts. The two mating surfaces are accurately machined for a perfect seal, Four feet projecting from the center plane and laid on special pillars support the casing, “The feet at the coupling end (or main coupling end) are provided with feather Keys to position the ‘machine in longitudinal direction. ‘The machine is positioned in the transverse direction by two feather keys that anchor the vertical plane containing the rotation axis. The feather keys are fited in special corresponding guides ‘welded to the baseplate. This arrangement prevents any casing displacement for the best lining up and it permits completely the thermal expansions. ‘The end seals, which prevent the gas leaking fiom the casing, are housed on the two ends of the easing, ‘The rotor bearings are housed on two supports assembled ot the casing ends. This arrangement allows a check of the bearings without disassembling the compressor. 2.505, 2.02010 Pr@ GEPS Oil & Gas Nuovo Pignone System description 28 DIAPHRAGMS MCL (Refer to typical sketches after para, "Rotor") ‘The diaphragms assembly, built up around the rotor assembly, make-up the stationary parts of the compression stages. ‘Annular passages through the diaphragms constitute the diffusers, where the kinetic energy of the {gas at impeller outlet is converted into pressure, ‘These passages constitute also the retum channels that convey the gas efficiently into the eye of the impellers. ‘The diaphragms are split on the horizontal centerline; these ere assembled in the inner casing. also itis split on the horizontal centerline. In order to leave a certain clearance between casing and diaphragms, the half diaphragms are held inside one half of the casing by means of screwed feather Keys, the clearance obtained Jows the thermal expansion, ‘This solution another permits lifting of the upper half casing without any danger of diaphragms fab ing out. ‘A dowel is fitted on the vertical plane engaging casing and diaphragms in such a way as to equally distribute thermal expansion in both directions, Labyrinth seals are installed in the diaphragms at all intemal close-clearance points to minimize the ‘gas leakages from discharge to suetion pressure areas of the impellers. 2.908 2.04020 Pd@ GEPS Oil & Gas Nuovo Pignone System description 26 ROTOR (Refer to typical sketches in the following pages) It consists of a shaft on which impellers and spacers are assembled, ‘The spacers are shrunk on the shaft and they axially position the impellers and protect the shaft sections, between the impellers, from contact with the gas. ‘The impeller is the part ofthe centrifixgal compressor that add velocity to the gas, ‘The impellers are of enclosed backward-bladed type and are shrunk and keyed into the shaft Before being mounted on the shaft each impeller is dynamically balanced and tested ata speed 15% higher than the maximum continuous speed. During the compressor operation the rotor is subjected to an axial thrust in the direction of the suetion end generated by the pressure difference acting on the shroud and disk of each impeller. In the centrifugal compressors with two compression stages the back-to-back mounting of the impellers reduces the total axial load. ‘The resulting axial thrust is partially balanced by the balance drum andl partially absorbed by the thrust bearing 10-86E 02.05.02 Plz@ GEPS Oil & Gas Nuovo Pignone System description 27 ae SHROUD (COVER) . BLADE, SUCTION DIAPHRAGM _% - - INTERMEDIATE SUCTION DIAPHRAGM LLNS *~ DIAPHRAGM DIFFUSER — BLADE RETURN CHANNEL LABYRINTH SEALS SLEEVE (SPACER) Typical sketch B- Compressor inner components 06018 1683 2