December 2004

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Power-Gen International Orlando

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Gas Compression

New Centrifugal Compressor for Fuel Boost Applications

Coopers MSG Alpha integrally geared compressor promises reliable service, contamination-free gas
by Joe Kane and Phil Burnside

ome new products are borne of good luck and inspired technological breakthroughs. Others come into being as creative new combinations of well-proven, existing technologies. Cooper Compressions introduction of its new MSG Alpha integrally geared centrifugal process gas compressor earlier this year definitely falls under the latter category, according to its creators. All the technology applied to this new product has already matured in a range of other Cooper Compression products. Whats new is the MSG Alphas specific combination of design features that make it ideally suited to fuel gas boosting for even the largest high pressure ratio gas turbines. According to John Bartos, Coopers vice president, engineering and new product development, the MSG Alpha is the most compact Cooper Compression frame available for gas service and one that offers more range in operating performance (higher flow capacity/high suction pressure capability) than flooded or oil-free rotary screw compressors. Significant to this compressor is its excellent efficiency, high reliability, low maintenance cost and traditional Cooper Compression quality, he said. It is available in one- through six-stage configurations. Its multistage, integrally geared, inter-stage cooled, oil-free centrifugal design, combined with its ability to handle power up to 932 kW and pressures up to 82 bar, its ability to accommodate high suction pressures and dual process capability, makes the MSG Alpha an excellent choice for many process gas applications and es-

Shown here is a three-stage configuration of the MSG Alpha integrally geared centrifugal compressor. It is available in one- through six-stage configurations. Its multistage, integrally geared, inter-stage cooled, oil-free centrifugal design is capable of handling power up to 932 kW and pressures up to 82 bar.

pecially for fuel-boosting compression needs with medium natural gas-fueled turbines, such as the LM6000 from GE. The MSG Alpha is a result of the natural evolution of Cooper Compression itself. In its consolidation with Cooper Energy Services, Cooper Turbocompressor became a complement to the natural gas products and markets of CES. As a consequence, the company evaluated centrifugal product solutions in applications that once used primarily reciprocating or oil-flooded screw compressors. The MSG Alpha offers a number of features that make it ideal in demanding fuel-boosting applications, according to Omar Kabir, Coopers senior principal engineer in new product development engineering. As a centrifugal compressor the MSG Alpha delivers high efficiency, high availability, dependability and minimal maintenance demands. The MSG Alphas compression process is dynamic (as opposed to positive displacement) and results in no pulsation within the gas stream. The resulting forces and moments imposed on the support structure are exceptionally

low, resulting in lowered overall costs for foundation and support systems. Furthermore, it has a very small footprint compared to alternative packages. And because of the reliability and extremely high availability typical of integrally geared centrifugal compressors, theres no realistic need for backup compression. One MSG Alpha can often replace up to three reciprocating or oilflooded screw compressors, Kabir said. One key benefit of the MSG Alpha to turbine operators, according to Kabir, is that because the MSG Alpha compression process is oil free the compression process itself cannot contaminate the process or fuel gas with lube oil. Coopers oil-free technology was developed over years of experience with proven centrifugal compressor technology where oil separators and oil treatment are not required or permissible. By design, the compression process and entire gas stream in the MSG Alpha is isolated from the bearings and gearbox, eliminating the possibility of process gas and oil interaction. Downstream scrubbers are not necessary since the

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Gas Compression
design. This permits easy access to internal components for inspection and future upgrades. The central low-speed bullgear permits each pinion to operate at optimum speed to match the flow and peak efficiency characteristics of the impellers. The bullgear is connected directly to the compressor driver by a low-speed coupling. Sleeve bearings are used to support the bullgear journals. The high-performance pinions are supported by hydrostatic bearings. The patented design of the squeezed film bearings and viscous damper results in long-life and virtually vibration-free operation, according to the company. Thrust loads are transferred, using tapered rider ring thrust collars, to the low-speed bull gear thrust bearings. The rider rings are a part of the pinion shaft and ride against the bullgear creating an oil wedge to carry the net thrust load where it is absorbed by a simple low-speed thrust bearing. Each rotor assembly consists of a pinion shaft to which one or two impellers are attached. The pinion gears are hardened and precision ground to AGMA 13 quality standards. Smooth, vibration-free operation is assured through precision component balancing of individual parts and then the final assembly balancing. This design minimizes power loss and maximizes mechanical integrity of the rotating components. The design details mean that an MSG Alpha has no wearing parts requiring periodic changes or replacement of the compression elements, no contamination of the gas stream with particulate matter or lubrication oil and no need of downstream treatment. Aerodynamic performance is the key to compression efficiency. To assure the optimum performance for every application, the aerodynamic components are designed to meet each specific process needs. Three-dimensional computational fluid dynamic (CFD) analysis using real gas properties is used to optimize the compressible viscous flow through each stage resulting in a matched highefficiency impeller, inlet and diffuser combination. After assembly, each unit undergoes

A three-stage MSG Alpha compressor on one of Cooper Compressions five test stands.

Cutaway drawing of the impeller, shaft and seals of the MSG Alpha compressor.

lube oil is not in contact with the process gas and does not become contaminated. That can mean significantly less erosion of turbine blades and other internal parts, Kabir said. The MSG Alpha is a sister to the proven TA 3000 centrifugal compressor that has been on the market for over a decade in critical process air service applications such as chemical and petrochemical industries, said Kabir. He said that the complex combination of dry faced seal and redundant labyrinth seals that assures containment of process gas was introduced in 1994 and has been used on much larger, high-pressure machines with excellent success. Also, the physical atmospheric space between the gearbox and the compressor housing, which has been a classic design of Cooper Turbocompressor, guarantees oil free process gas compression. He emphasized that all rotating elements of the new compressor were transferred from totally proven technology. The MSG Alpha was designed and analyzed using the latest computational engineering techniques including rotor dynamic analysis, computational fluid dynamic (CFD) analysis, and finite element analysis (FEA) to maximize the performance and reliability of each design. Another unique computer design application is the use of parametric solid modeling for pre-engineered building blocks or modules. The parametric assembly forms the core of a new product development process that links and integrates marketing, design engineering and manufacturing on a common platform for a unified and rapid design cycle. The gearbox is a horizontally split

a complete aerodynamic and mechanical test in Cooper Compressions test facility. Testing is performed by experienced engineers and technicians following the guidelines set forth in the ASME PTC 10 test code. Five individual test stands are available to test the units as complete packages under customer-specific design conditions including design speed, gas properties, as well as inlet and intercooler water temperatures. Each stand is equipped with an electronic variable frequency drive capable of supplying either 50 and 60 Hz and voltages ranging from 380 to 4160 V. The stands are also capable of achieving over-speed to ensure the mechanical integrity of the compressor. Closed loop package testing is also available. According to Bob Rajeski, president, Cooper Compression follows a welldefined product development process driven by the voice of the customer. We believe in investing in new product development as we want to create the best value for our customers as their markets and needs change.

Exploded view of the MSG Alpha Compressor in its three-stage configuration.

Copyright Diesel & Gas Turbine Publications Printed in U.S.A.

REPRINTED FROM DECEMBER 2004 DIESEL & GAS TURBINE WORLDWIDE

Oil free. Pulsation free. Vibration free. And they practically take care of themselves.

THE EDGE IS INNOVATION

MSG fuel gas boosters. No matter what the application, our portfolio offers the perfect multi-stage, integrally geared centrifugal compressor solution. Theyre all 100% oil free, pulsation free, and vibration free. They all take advantage of proven Cooper Compression technology, including our unique atmospheric air gap and superior sealing arrangementsay goodbye to oil contamination and our exclusive low-speed rider ring thrust collar, for outstanding, long-lasting performance and extremely low maintenance costs. Theyre US-built, so theyre readily available, faster. And theyre backed by an unbeatable warranty. Our latest, the MSG Alpha, is the only one in the world made to run in the 850-1250 horsepower range, with confidence. And its just one of a complete line of MSG centrifugal engineering wonders. So, really, why not centrifugal when Cooper Compression gives you such an obvious edge? www.msgalpha.com

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