Model: ACB1
The entire set of booster compressor unit equipment adopts integral lever installation and box-type structure. A diesel engine is installed on the lever as the power unit; equipped with domestically produced GYG4H compression main unit. The instrument control system is centrally located for local control, achieving protection and control of parameters such as unit speed, pressure, and temperature. Data transmission interface can be provided according to user needs for convenient on-site centralized monitoring.
Basic configuration features of the booster compressor unit:
- The drive engine adopts Cummins KTA19 diesel engine, with a maximum power of 750HP;
- The compression main unit adopts GYG4H high-speed reciprocating piston compressor, with 2-stage or 3-stage compression, manually switchable;
- Rubber flexible coupling (with safety protection cover);
- Combined wound fin-type air cooler for cooling process gas (3 sets), compressor lubricating oil (1 set), engine jacket water (1 set), and intercooling gas (1 set);
- Equipped with electric control pneumatic valve for automatic loading, unloading, and safe venting;
- The controller adopts Siemens Smart-200 PLC controller, equipped with color data display and operation touchscreen, with data transmission interface for uploading operating parameters to the control room as needed;
- The entire unit is placed in a protective cover, which has functions such as windproof, rainproof, and thermal insulation;
- The equipment is equipped with a remote module, which can view real-time operation data and historical data of the unit through a mobile APP.
Technical Parameters and Main Configurations
Main Technical Parameters of the Booster Compressor:
- Inlet Pressure: 2.0~2.4 MPag
- Inlet Temperature: ≤40~50°C (design point 45°C)
- Discharge Pressure: ≤20.5 MPag (3-stage compression) ≤7.0 MPag (2-stage compression)
- Discharge Temperature (after cooling): ≤50 or ambient temperature +15C
- Discharge Volume: 60-80m³/min
Main Technical Parameters of the Compressor
Compressor Structure Introduction:
The GYG4H split-type compressor has a maximum rated power and speed of 500kw/1500rpm, and can operate at a minimum of 750r/min. The compressor is a horizontal symmetrical balanced type, with 4 rows. The middle body and compression cylinders are all horizontally mounted on both sides of the body, and the compression cylinders are air-cooled.
The crankshaft and connecting rods are made of integral forged alloy steel, in compliance with API-11P and API-618 standards.
The crosshead is made of cast steel, with a surface overlay of babbitt alloy.
The piston rod packing adopts high-quality domestic brands to ensure long-term continuous operation of the unit.
The valves use high-quality domestic brands.
The lubrication system adopts lubrication components from American companies such as Premier or Kenco, divided into low-pressure lubrication and high-pressure lubrication systems.
Compressor Lubrication System
Crankcase lubrication: Pressure lubrication system, equipped with lubricating oil pump (pre-lubrication + main oil pump) and filter.
Crankcase oil level controller: Kenco oil level gauge, standard configuration.
Crankcase oil temperature control: Three-way temperature control valve, opens at 45°C, fully opens at 60°C.
Crankcase lubricating oil cooling system: Lubricating oil pipe bundle box, air-cooled.
Cylinder lubrication system: Force-fed lubrication with oiler.
Oil-free flow protection system: Standard configuration.
Lubricating oil pipelines: Complete piping.
High-level oil tank: Standard configuration.
Lubricating oil consumption: Approximately 10.0 L/d (24-hour continuous operation).
Coupling
Structural Type: High-flexibility rubber coupling.
Equipped with a flywheel.
With protective cover and reserved disc drive hole.
Diesel Engine:
Air Cooler
The air cooler is used for cooling process gas, compressor lubricating oil, engine jacket water, and intercooling gas, with a total of 6 cooling tube bundles.
Process Gas Cooling System: Cools the compressed process gas of various stages. For 2-stage or 3-stage process gas, the discharge temperature after cooling is approximately ≤50°C.
Compressor Lubricating Oil Cooling System: Cools the compressor crankcase lubricating oil.
Equipped with a lubricating oil three-way temperature regulator, which starts opening at 45°C and fully opens at 60°C, ensuring effective cooling of the crankcase lubricating oil and preventing it from being too cold or too hot.
High-temperature oil from the three-way temperature regulator exchanges heat with the air through the lubricating oil pipe bundle box.
A drain outlet is provided at the low point, and an exhaust short circuit is provided at the high point.
Complete piping with equipped ball valves.
Air Cooler Structure:
The air cooler fan is driven by the engine's auxiliary end pulley and is vertically arranged.
The air cooler is of the finned tube bundle type, with the fins arranged horizontally.
The fan blades are made of high-strength composite materials.
The air cooler is equipped with a protective net.
Separator and Buffer Tank
Separator:
Designed and manufactured according to the national standard GB150-1998 "Steel Pressure Vessels."
The separator is welded with high-quality domestic materials, made of carbon steel, and has a vertical structure.
Equipped with an internal wire mesh demister (mist eliminator).
Configured with a high-level alarm switch.
Equipped with an automatic drain valve, DN25.
Buffer Tank or Buffer Pipe
- Designed according to the national standard GB150-1998 "Steel Pressure Vessels."
- The buffer tank is welded with high-quality domestic materials, made of carbon steel.
- The exhaust buffer tank (pipe) has a drain outlet at the low point for manual drainage.
Instrument Air System
The instrument air is used to provide air source for pneumatic valves inside the skid.
Instrument air can be supplied by a front-end screw air compressor, and after pressure regulation, filtration, and purification, it is supplied to the pneumatic actuators inside the booster compressor skid.
Engine Fuel System
The engine fuel system is equipped with a fuel tank, pipelines, valves, etc., inside the skid of the unit.
Fuel tank capacity: temporarily set at 1.0-1.5m³.
Process Gas Pipeline
Process Pipeline
Argon arc welding and manual welding, with 50% radiographic testing.
Pipeline materials are GB/T8163 20# or GB/T5310 20G#.
Weld seam testing: conducted in accordance with the NBT47013-2015 "Non-destructive Testing of Pressure Equipment" standard.
Safety Valve
Spring-loaded safety valves are installed on the inlet pipeline and various stages of exhaust pipelines.
The set pressure is in accordance with API 618 standard, with a maximum temperature of 180°C and stainless steel valve core.
Process gas safety valve vents to the skid side.
Valves
All valves are high-quality domestic valves, including electrically controlled pneumatic valves.
Water pipelines, lubrication pipelines, etc., are equipped with manual ball valves.
All pipelines are piped to the skid side.
Skid Base
The skid base is made of high-quality profiles to maintain sufficient strength and rigidity. The skid surface is covered with patterned steel plates. The entire set of equipment is hoisted using the bottom lifting method.
Separators, engines, compressors, process pipelines, explosion-proof control cabinets, air coolers, box-type protective covers, and other equipment and accessories are all installed on one skid base.
Grounding wire joints that meet electrical protection requirements are provided on the outer side of the skid block.
Box-type Protective Cover
Internally equipped with combustible gas alarm.
Both sides have doors, and the front end has a soundproof louvered door.
Lighting fixtures are installed inside the protective cover for easy equipment maintenance and inspection.
The electrical circuits inside the protective cover are all explosion-proof designed.
Surface treatment: one layer of primer, two layers of industrial magnetic paint, color to be determined.
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