Mitsubishi Heavy Industries Technical Review Vol. 50 No. 1 (March 2013)
31Development ofCompressors and Steam Turbines for LNG Plants

NAOYUKI NAGAI*1

AKIHIRO NAKANIWA*2

MASANORI KOBAYASHI*3 SATOSHI HATA*4

KOJI SHIMIZU*5DAISUKE KIUCHI*6

Mitsubishi Heavy Industries Compressor Corporation (MCO) has until now mostly worked
in the field of petroleum chemistry such as ethylene plant. We are now aggressively expanding ourbusiness into resources and energy market, such as the LNG plant and Floating Production,Storage and Offloading (FPSO), and have completed the technical development of compressors forLNG plants and injection compressors for FPSO. At the world’s first Floating LNG plant, oursteam turbines are being used for the compressor and generator drive. We have studied thetechnological subjects to apply our steam turbines for them, and in this report we would like toexplain their development.

|1. Introduction
Mitsubishi Heavy Industries Compressor Corporation (MCO) has until now mostly worked
in the field of petroleum chemistry such as ethylene plant. We are now aggressively expanding ourbusiness into resources and energy market, such as the LNG plant brought about by the shale gas
revolution and Floating Production, Storage and Offloading (FPSO), based on the technologies wehave cultivated in the field of petroleum chemistry. For resources and energy plant, high reliablemachines are required. To meet this requirement, MCO developed some technologies, and applied
to our machine.
In this report we would like to introduce developed technologies for our compressors andsteam turbines.

|2. Developed Technologies
2.1

Refrigeration compressor for LNG liquefying process at LNG plant inIndonesia

It is very difficult to predict the performance of refrigeration compressors used in the LNG
liquefying process, especially propane refrigeration compressors, as they have a structure thatcombines the compression gas flow and the process gas in the compressor, as well as a highimpeller inlet Mach number.
We have currently received a procurement order for a refrigeration compressor for the LNG
liquefying process at an Indonesian LNG plant, and are now proceeding with the production. A
performance test was conducted at the factory as shown in Figure 1. The measured performancevalues show good conformance with the calculated performance as shown in Figure 2. The
planned performance was verified as having been achieved.
*1

Chief Staff Manager, Technology & Innovation Headquarters/Hiroshima Research & Development Center*2

Deputy Manager, Technology & Innovation Headquarters/Takasago Research & Development Center*3

Director, General Manager, Engineering & Design Division, Mitsubishi Heavy Industries Compressor Corporation*4Manager, Engineering & Design Division, Mitsubishi Heavy Industries Compressor Corporation*5Manager, Turbo Machinery Engineering Department, Engineering & Design Division, Mitsubishi Heavy Industries Compressor Corporation*6

Deputy Manager, Global Marketing ＆ Sales Division, Mitsubishi Heavy Industries Compressor Corporation

Mitsubishi Heavy Industries Technical Review Vol. 50 No. 1 (March 2013)32

Figure 1 Performance test in
propane refrigeration
compressor

Figure 2

2.2

Performance test results of propane refrigeration compressor

One piece impeller

In a conventional refrigeration compressor for the LNG liquefying process, the impellers are
made by welding the blades to a disc and cover. Currently the one-piece impeller (Figure 3) is themainstream in this industry, and it eliminates the welding structure for better quality, a reduction ofperformance deviation and better mechanical reliability.

Figure 3

Transition of impeller structureMitsubishi Heavy Industries Technical Review Vol. 50 No. 1 (March 2013)33

In addition, the large flow type impeller processed with a 5 axis machine (Figure 4), and thevery narrow outlet impeller of a small flow type processed with an electric-discharge machining(EDM) (Figure 5) have already started to prevail in the actual market.

Figure 4 Machined one-piece impeller

2.3

Figure 5 Electro-discharge machined
one-piece impeller

Small diffuser diameter flow path

The smaller the diffuser diameter in the flow path, the more compact the compressor design
can be. This allows reducing the product weight. However, the reduction of diffuser diameter(Figure 6) results in an increase of the Mach number at the diffuser outlet, and a decrease ofefficiency through an increase of the loss head. The lowering of efficiency was recovered by
optimizing the return bend shape connected to the gas return path as shown in Figure 7, and acompact design was achieved while maintaining the current level of efficiency.
Diffuser diameter ratio 1.50D2

Diffuser diameter ratio 1.75D2

Diffuser diameter ratio 1.50D2

Pressure distribution

Mach number mapDiffuser diameter ratio 1.75D2

Figure 6

CFD analysis results of diffuser diameter effectFigure 7

Improved return bend shape for small diameter diffuser

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2.4

Large-size bundle roller

In a vertical split type (barrel type) compressor, the inner parts (bundle) are assembled in theaxial direction, and the bundle must be pulled out in the axial direction on the occasion ofmaintenance. This becomes difficult when the compressor is larger, as the bundle is very heavy.
Especially in the case of FPSO, the maintenance work is more difficult on the ocean with pitching
and rolling.
Rollers were installed at the lower part of the bundle to ease maintenance of the inner partsand reduce the required crane capacity in the field. However, the roller was subject to a heavy load,
and roller breakage and damage to the inside of the casing was a concern. FEM analysis (Figure 8)
was conducted, and a roller shape design method that included aspects such as a proper crowningvalue was established. In addition, a factory test using an actual piece of equipment was conducted
as shown in Figure 9, and the validity of the bundle pull-out procedure and roller design wereverified.

Figure 8 FEM analysis model of roller in bundle

2.5

Figure 9

Bundle pull-out test in plant

Short span / high boss ratio impeller

In the design of compressors to be used at off-shore such as in FLNG plants, a method ofminimizing the weight and installation area is important. An impeller with a short axial-direction
span and increased impeller boss ratio (inside/outside diameter ratio) allows for a shorter shaft
bearing distance, larger shaft diameter, increased shaft system rigidity and high-speed operation(Figure 10). With high-speed operation, a reduction of compression stages and a smaller diametercan be attained, making a compact and high-performance compressor design possible.
However, short span/high boss ratio impellers tend to cause secondary flow and flow
separation, resulting in efficiency degradation and a restricted compressor operation range in flow.

Figure 10

Planning of short span / high boss ratio impeller

As countermeasures, the number of impeller blades was reduced as indicated in Figure 11,
the frictional loss was reduced and the blade load distribution was optimized to reduce the rapid
speed-lowering area and efficiency degradation.

Mitsubishi Heavy Industries Technical Review Vol. 50 No. 1 (March 2013)35

The development of a short span/high boss ratio impeller with a favorable performancecompared with conventional units was achieved through these efforts.

Figure 11 Improved efficiency by reducing impeller
blade number

2.6

On-line cleaning of steam turbines

Steam turbines used to drive compressors are usually operated for long periods. In an LNG
plant, the maintenance interval is extended as long as possible, and the availability of long-term
continuous operation is important for plant management. This tendency is especially noteworthy
for FLNG.
The steam that drives the turbine contains impurities from the boiler water, supplied waterand purified water. When the steam property is insufficient, the flow path is restricted by theadhesion of scale on the nozzle and blade as shown in Figure 12. The steam flow rate is lowered,and the power output is reduced when the casing pressure rises over the allowable pressure due tothe fouling. As a result, plant production levels are adversely affected.

Figure 12

Inside of turbine after 7 years of continuous operation

The methods of removing scale from a steam turbine after a long period of operation are
categorized into two big groups; mechanical removal and cleaning. The liquid cleaning method
does not require that the turbine casing will be disassembled, while mechanical removal does.
However the turbine must be stopped or the steam inlet temperature at the high-pressure stage must
be lowered, and the total power output of the turbine must be lowered drastically for the cleaning.
In addition, the power outputs of other steam turbines sharing steam with the cleaning turbine arealso lowered. This results in a significant effect on plant operations and production levels.

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Accordingly, water injection nozzles were installed on the governing/extraction control valve
boxes as shown in Figure 13, and the steam temperature is only lowered in the turbine being
cleaned. Thus an on-line cleaning system for steam turbines that cleans adhered impurities andprevents performance from being degraded was developed.

Figure 13 On-line cleaning system for steam turbine

One water injection nozzle and valve/valve diffuser was used for the verification
measurement by adjusting the flow speed to the actual piece of equipment. For the internal flow ofan actual extraction control valve box, a detailed flow analysis was conducted as shown in
Figure 14. The flow in each valve was almost independent, and the test results of a single diffuser
were verified to be similarly applicable to multiple valves.
The system was applied to an actual piece of equipment as shown in Figure 15, and thevalidity of this system was verified in the field verification test.

Figure 14

Flow analysis results of steam flow line map in valve box

Figure 15 Results of field verification test of on-line cleaning system

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2.7

Coating for steam turbines

As described above, long periods of continuous operation are required of steam turbines, andvarious coatings were developed as countermeasures for blade erosion.
Figure 16 shows first stage stationary blades being treated by boronizing. This treatment
disperses boron on the metal surface and hardens it by forming a strong metallic boron layer. Thelayer prevents erosion caused by foreign substances coming from the boiler and piping, which are
upstream of the turbine.
Figure 17 shows a ceramic coated blade treated by the ion-plating method. This forms aceramic (TiN) layer to increase durability against drain attack, as well as a chrome (Cr) layer toensure the adhesiveness between the TiN layer and the base material. The treatment is applied tothe low-pressure block blade except for the final stage, where the steam humidity is rather low.

Figure 17 Ceramic coated blade

Figure16 Boronized first stage blades

Figure 18 shows the stellite coating applied to the blade tip in the final stage. This protects
the blade tip, for which the circumferential speed is the fastest, from erosion caused by
impingement with water droplets in saturated steam flying in a radial direction through centrifugalforce. A stellite plate was brazed to the base metal as shown in the Figure on the right in theconventional way. However the cavity between the base metal and stellite plate lowers the fatigue
limit of the base metal. The stellite powder-weld overlay is attached by Plasma Transfer Arc (PTA)
welding, and the finishing of the area is applied.

Figure 18

2.8

Stellite coating on final stage blades

Steam turbine blade fracture analysis

Steam turbines are used to drive compressors and generators in FLNG plants. One of thetechnological subjects is the verification of the design to avoid the dangerous operation of a plant
when its operating speed exceeds the over-speed trip setting. In terms of the behavior (transientimpingement mode) of final stage blade scattering, the blade scattering condition as shown in
Figure 19 was studied as a risk factor. A multi-body dynamics analysis was conducted tounderstand the impingement condition between the flow-guide and casing, and lower pressure
casing penetration was verified as not occurring.

Mitsubishi Heavy Industries Technical Review Vol. 50 No. 1 (March 2013)
38

Figure 19

Behavior of final stage blade scattering|6. Conclusion
MCO has developed technologies related to compressors for LNG plants and driving steam
turbines initially aimed at FLNG plants, conducting the application of these technologies to actualequipment. We also expect these technologies to be applicable to other resource and energy fields
such as compressor trains for FPSO, and effective for the expansion of our business.