MAGMA_Cryostar Magazine6

8/8/2019 MAGMA_Cryostar Magazine6

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2/12Autumn 20052

EDITO

Customer service is the very li e-blood o CRYOSTAR. It encompasses everything rombe ore to a ter-sales service. Above all it re ects CRYOSTARs determination to work withcustomers, delivering what they want when they want it, to the highest internationalstandards.

One aspect o CRYOSTAR customer service is the technological innovations behind ourproducts. In every market, in al l geographies, CRYOSTAR technology provides our customerswith a competitive edge.

CRYOSTAR is at the ore ront o cryogenic technology more than 40 years studying theart o cryogenics has led to a multitude o innovative solutions, new applications andtechnological improvements.

Be it pumps, automation, turbines, expanders or LNG shipboard equipment, CRYOSTARcontinues to invest in research and development. Never a day goes by without our engineerspushing the boundaries in one feld or another.

In recent times we have brought to the market the MTC; the GBSD transport pump range;the Modular Reciprocating Pump; the power recovery turbine; turnkey LNG / biogasinstallations; uelling and flling stations; hydrogen related cryogenic equipment... and thelist goes on.

In this edition o CRYOSTAR magazine we continue to highlight the latest advances intechnology and in Tailored to you, the customer, page 3, we provide some insight into howour business operates.

At CRYOSTAR we believe in innovation, service, research and development, working inpartnership with customers. In the many markets in which our customers operate,competition is keen and demands are constantly changing.

CRYOSTAR recognises th is, which is why we put so much e ort into improving technology,improving our service o erings. Its what makes CRYOSTAR a market leader.

We are committed to the pursuit o innovative technology, committed to meeting ourcustomers needs, any time, any place. CRYOSTAR technology is the jewel in many a cus-tomer crown and were proud o that.

Daniel MEYERPresident

Tailored to you, the customer ............. p 3

Cryostar gets its MAGMA turbo expanders in ethylene market ............. p 5

Everyones a winner with us ............. p 7

Controlling the process ............. p 8

News ............. p 9

Who you gonna call? ............. p 10

Events ............. p 11

Tools and datas ............. p 11


3/12Autumn 2005

Four hundred di erent centri ugal and reciprocating cryogenic pumpmodels, more than i ty di erent turbo machine rame sizes andthousands o precisely engineered designs all to meet the needs o the cryogenic and atmospheric and hydrocarbon gases industries. For40 years Cryostar has been developing custom-made, designed andengineered products and machinery.

But what is that makes Cryostar tick? Well, there is the developmentsside, which can be split into three major plat orms: machinery, ap-plications and process. Machinery is driven by individual customerand general market demand, and is based on existing machines andCryostar expertise. Applications are derived rom working closelywith customers to help them ur ther exploit Cryostar products.

Process, on the other hand, is very much internal, with Cryostarresearch and development engineers working with rontline sta to

ensure the delivery o products to exacting international standards.This way the best process and most e icient machine can be developedor the market and customer ast.

However, developments can also be categorised as on the job ando the job. On the job is usually reserved or those large machines,which are extensions o the Cryostar product port olio. O the job ispredominantly or products later sold in quantity, like small cryogenicpumps or turbines, usually developed without a speci ic order but withan eye on uture customer needs.

Development cyclesProducts that come under on the job are developed and built dur-ing the normal contract and commercial cycle, and delivery times aredictated by the competitive situation.

During such developments, which are usually done by Cryostar engi-neers, there are extensive design reviews and additional calculationcycles with the possible inclusion external consultants. An extensivein-house testing period ollows completion. Importantly, the customer

can also be involved in the assessment cycle. This is because designvalidation testing must ul il predetermined test criteria to gain cus-tomer sign-o . Cryostars inherent attention to detail also means itsdevelopment engineers are involved in the commissioning and star t upo a new machine.

Thousands of engineering solutions for hundreds ofcompanies Cryostar know-how, a jewel in many acustomers crown...

Tailored to you, the customer


4/12Autumn 2005

In case o the o the job developments, the de-sign and production will undergo same cycles, butwithout the customer involvement and typicallywithout any major time constraints. More impor-tant is the extensive and long-term in-house testingo a new product, to demonstrate suitability andper ormance levels to the market. The new productis launched only i the extensive testing shows it

ul ils or supersedes expectations. In many cases

this also includes extended testing at selected cus-tomer sites prior making it generally available.

The test toolsAs well as development validation Cryostar alsohas per ormance testing capabilities. In Hsingue,the company has two large test acilities, one orcryogenic pumps and the other or turbo machines.In Capdenac, Cryostar Automation test acilityallows or complete illing stations and control

systems to be ully tested. All are equipped withautomated data acquisition systems.

The test acility or pumps includes two liquid ni-trogen vacuum insulated cryogenic tanks with ivedi erent metering test lines. Reciprocating pumpsup to 600 bars and 100 l/min, and centri ugalpumps or up to 100 bars at lows up to 14000l/min, can be tested using liquid nitrogen. Thiscryogenic test acility is the largest o its kind orindustrial gases pumps in the world.

The turbo machines test acility has a test space orsimultaneous preparation and sequential testing o

our low-duty compressors and or our high-dutycompressors or LNG carriers (two ship sets) at 60Hz and any voltage up to 6600 Volts. The thirdset o compressors can be under preparation, whilethe orth can be at the completion stage a ter thetesting.

In addition, up to six turbo expanders can be lo-cated in the test hall or testing with pressurizedair. The todays volumes are in the order o 160LNG carriers shipboard compressors and around100 turbo expanders per year. This can be extended

easily by sta working in tailored shi t patterns.

People and Expert iseAnd that is why the backbone o Cryostar is its sta o almost 300. There are engineers with bachelor,master or even higher (PhD) degrees. Through in-ternal training courses and know-how trans er rommore experienced colleagues Cryostar continues tostrengthen its capabilities. Sta development is apriority and Cryostar invests close to three per cento its annual turn over in training with a larger partdedicated to engineering and development sta .This type o investment in people allows Cryostarto tackle and deliver solutions to varied and o tencomplex customer problems. Not only does it haveextensive cryogenic know-how and aerodynamicand hydraulic design expertise to call on, but 35years in this specialist market has armed the com-pany with expertise in many other areas.

They include: materials at cryogenic temperatures,stress analysis, heat trans er, cryogenic vaporisa-tion and condensation together with other unitoperations, oxygen compatibility o materials,and pressure containment design or ex treme pres-sures.

Coupled with these are a multitude o special-ist tools, including: CAD or the design o turbomachines and pumps; CFD so tware or low andpressure distribution analysis in turbo machinesand pumps; and FEA so tware or wheel bladesresonance and or stress and d isplacement calcula-tions, to name but a ew.

For very speci ic tasks like rotor dynamics and ro-tor vibration behavior, aerodynamics and hydraulicdesign and analysis, external consultants can bebrought in or independent evaluations.All these disciplines combine to orm the basis o Cryostars technological and commercial success.

In other words, its what makes the company tick.

The technological testing during the production cycle (hydrotesting, gas leak testing, balancing, over speed testing, holo-

graphic blade resonance testing, etc.) will be the subject of afuture article.

CUSTOMERS


5/12Autumn 2005 5

TECHNOLOGY

For ethylene plant owners, Cryostar has designed andbuilt a dual turbo expander compressor (2-MTC)solution that provides sa ety, ease o control and ex-ibility.

Both low pressure (LP) and high pressure (HP) unitsare mounted on the same skid, with explosion-proo instruments. The units are equipped with activemagnetic bearings and controlled through a Cryostar-programmed Programmable Logic Controller.

Two expanders in series expand the o -gas uid,with braking power being provided by compressorwheels mounted on the same sha t. Both units rotateat the same high speed to maximise the expanderse fciency.

Magnetic bearings provide a 100 per cent leak-sa e de-sign, avoiding any risk o oil ingestion into the processgas. Both LP and HP expanders can be independentlyby-passed by the process gas. There ore, either the LPor the HP machine can be operated as a single unit.This eature enhances process exibility.

At the root o this achievement is a state-o -the-artdesign process or wheels and sha ts. The gas to be ex-panded combines a low molecular weight (less than 5kg/kmol) and a high mass ow (more than 1000 kmol/ hr). The low molecular weight requires extremely hightip speed o the wheels or optimum e fciency.

Cryostar gets its MAGMAturbo expanders in ethylene market

For a price-competitive solution, Cryostar opted ortwo machines belonging to the MTC200 rame size.MTC200 are magnetic bearings turbines braked by acompressor wheel, with an expander wheel diameter o nominally 200mm. For both HP and LP machines, theexpander wheel is made o a high strength aluminiumalloy and the diameter is 210mm. Compressor wheelsare made o the same material with a 220mm diam-eter. All are milled rom solid. This straight orwarddesign solution as described bellow eliminates any risko wheel cracking by blade resonances.

High speed rotor development

Prior to rotordynamics investigations, the naturalresonance o the wheels must be calculated. Themodal analysis o expanders and compressor wheelsshowed no risk o resonance in the range o operatingspeeds. This assessment was per ormed using FiniteElement Analysis (FEA). Once optimised, geometrieso the wheels were ed into models representing ullrotors, to be used or the rotordynamics analysis.

Due to the high maximum continuous rotatingspeed close to 40,000 rpm, and the relatively largewheels or MTC200 machine rame size, the newrotor design was a challenge that Cryostar expertswere eager to ace. Actually, with respect to the lat-eral critical speed analysis (LCSA), several iterationswere needed to meet the API acceptance criteria.


6/12Autumn 2005

TECHNOLOGY

The LCSA aims to de ining rotornatural requencies associated

with structural de lections o therotor. Natural requencies areconverted into rotating speedvalues called critical speeds.

All structures possess naturalrequencies at which they vibrate

most violently when struck. For arotor, a state o resonance can bereached i the rotation requencyequals one o the rotor natural

requencies. This phenomenonleads to de ormations, which canseverely damage the structure.

With regard to LCSA, API 617standards require that either thede lection o the structure is lowenough or that the di erencebetween the maximum continuousspeed and the irst critical speed

is high enough (see Technicaldata panel or accurate criteria).

The LCSA enabled Cryostar toind the appropriate rotor or a

resonance- ree design. Iterativere inements o detailed design

eatures were carried out in closeco-operation with S2M, themagnetic bearing supplier. APIacceptance criteria were metwith a remaining sa ety margin.

High-tech design methods,combined with pragmatictargets, resulted in a smartand robust solution.

*The irst two-stage CryostarMAGMA turbo expander 2-MTCo this high speed con iguration

was designed and built or coldproduction in a new ethylene plantin Qatar.

Technical data

The amount o expected de lection o the rotor is quanti ied by API stan-dards with the ampli ication actor AF (The higher the Ampli ication Fac-tor, the sharper the de lection peak):

N c1: Critical speed corresponding to the maximum de ectionN1 and N 2 : Lesser and greater speeds at 0.707 x peak de ection (The peak de ection is at criticalspeed Nc1)

The di erence between the maximum continuous speed and the frst criticalspeed is quantifed by API standards with the separation margin SM, defnedas ollows when the critical speed is greater than the maximum continuousspeed:

Nmc: Maximum continuous speed

Depending on the AF value, the API 617 standards acceptance criteria is:

1. I

2. I ,

in case o a critical speed higher than the ma ximum continuous speed.

3. I ,

in case o a critical speed lower than the minimum speed (not applicable to the developed case).

Revolutions per minute

V i b r a

t i o n

l e v e

l

N 1 N 2

N c1

A c1

0.707 peak

CRE

SM

Operating speeds CRE

SM

N mc N cn


7/12Autumn 2005

Mahmood Javed, R&D Manager at Abdullah HashimGas in Saudi Arabia, visited the Cryostar headquartersin Hsingue, France on 29 April with his wi e, as parto his prize or winning the Cryostar Middle EastCompetition in February this year.

His visit began with the presentation o a souvenirCryostar photo album along with a ew words o con-gratulations rom Daniel Meyer, Cryostars President.This was ollowed by a slide show on the company anda tour o the site with Philippe Fauvel, Sales Manager,South Europe and the Middle East.

The tour started in the main administration buildingwhich contains sales, purchasing and central manage-ment or the company. Although based in France, theheadquarters is on the borders o both Germany andSwitzerland, an important actor or a company whichexports around 90 per cent o its products. Even ouremployee base is multinational, said Philippe. Wehave over 230 people rom 12 countries working at

our French headquarters alone.

The tour also took in Cryostars research and develop-ment o fces. We have a team dedicated to R&D,explained Frdric Marcuccilli,R&D engineer. And it is thanksto this team that we are able todevelop and customise solutionsto exact needs o individual cus-tomers.

At the assembly workshop,our winner was able to see frsthand the construction o severalproduct lines rom the large LNGcompressors to the vast range o world-leading Cryostar cryogenicpumps. Mahmood was very impressedwith the high quality o Cryostar

production tools and the commit-ment shown o all employees. Cus-tomer satis action is something weall ocus on, said Philippe.

WINNER

At a cost o over 4 million Euros, Cryostars testing a-cilities represents a huge customer service investment.We have the worlds most sophisticated test stand orpumps, said Laurent Rapp, test stand manager, Notonly has it helped to expand our R&D programmebut we also provide individual customised test reports.One hundred per cent o the material our customersbuy is tested be ore delivery.

Final stop on the tour was the on-site maintenanceshop and customer service department.Our winner expressed his hopes that the visit wouldbe the start o a strong relationship between the twocompanies.

The winners weekend continued with sight seeingtrips around the region including Colmar, in Alsace,France, and the Black Forest in Germany.

The Middle East Competition was a great success withtriple the industry average in responses. It is hoped

that the programme can now be expanded to otherregions.

Everyones a winner with us


8/12Autumn 2005

Controlling the process

PROCESS CONTROL

The escalating plant sizes are putting tremendouspressure on reliability and availability requirementsto avoid any downtime or production loss. In ad-dition, to reduce installation costs, less manpoweris available on site, so reducing the manual activityto a minimum requires increased use o processautomation.

Since the beginning o the process industry, controlsystems have been required to meet ever-changingdemands. So over the last ew years, Cryostar hasimplemented many di erent PLC con igurationsto suit speci ic customer needs. The latest maindevelopments are:

RedundancyIn order to deal with increased demand on avail-ability, PLC redundancy is implemented. It avoidsdisruption o the process in case o machine PLC

ailure. Di erent redundant con igurations arepossible. As a minimum, the power supply and theCPU are duplicated, where the second unit takesover the duty instantaneously in case the irst ai ls,ensuring continuous machine operation.A urther extension o redundancy can be the dupli-cation o the inputs and outputs (e.g. an analogue4-20mA output signal is ed a hal -signal by each o two output modules, and ull-signal by one modulein case the other ails). Detected instrument ail-

ures, resulting in the shutdown o machinery, alsoleads to a reduction in overall plant reliability andavailability. So spurious trips have to be avoided.This is done by triplication o selected sensors andby the implementation o a two-out-o -three vot-ing (2oo3) so at least two sensors must detect the

aulty situation in order to initiate a shutdown andthe process continues in case o ailure o a singlesensor.

Sa etySa ety systems have traditionally required hard wir-ing and the use o electro-mechanical components.Today, except or speci ic sa et y unc tions like theemergency shutdown, dedicated Sa ety PLCs have

started to replace the other sa ety related hard-wired circuits.

As state-o -the-art technology sets the trendtowards application o best in class PLCs and assa ety o people and environmental protectionbecome more important, customers will rejectlower integrity systems. This, together with the

likelihood that sa et y integrated level requirementsmight be needed in the uture, drives the use o thesa ety PLC.

To meet rising customer expectation in the fast changing Programmable LogicC o n t r o l l e r ( P L C ) w o r l d , C r y o s t a r m a k e s u s e o f c u t t i n g e d g e s o l u t i o n s . . .


9/12Autumn 2005

Remote I/OTo reduce site installation costs, PLC remote input/output (remote

I/ O) technology has been developed. This is where multiple hard-wiredcables are replaced by a single or a redundant communication link.This technology has been around or some time, and since it is now

ield proven, its popularity has increased. It is now also certi ied orhazardous areas, even or Zone I (on shipboard applications the remoteinput/output is becoming standard equipment).

Inter acesData exchange with the di erent plant central controls, emergencyshutdown or machine maintenance systems are done by serial commu-nication links, with Modbus the pre erred protocol.Flat panel displays with touch-screens are orcing the traditional lampand push-button machine inter aces into the history books. The colourdisplays, showing machine mimics, on-line machine per ormance andoperating conditions, are much more user riendly and able to providemore in ormation. In conclusion, whether installed in hydrocarbon or industrial gas plants,Cryosta rs equipment is critica l or plant operation. The availabil ityrequirement or this equipment remains high and customer expecta-tions continue to rise. This applies, o course, to both the mechanical

components and the control system, which is why Cryostar is at thecutting edge o technological changes and trends o ering state-o -the-art solutions to ul il customers growing requirements.

Biggest turbo expanders ever built by Cryostar

The biggest turbo expanders ever built by Cryostar - 2 MTC600/240 or the Orman Lange (Norway) project - were suc-cess ully tested and shipped in September. The main charac-teristics o these huge machines are:

- MTC 600/240 rame size going up to 12 MW

- Largest magnetic bearings or high speed applications withdiameter 240 mm

- Compressor housing diameter 1600 mm and 100 bar designpressure.

In testing the machines the ollowing were used: six oil reescrew compressors, diesel motor driven, with total 2,375 kWpower and 16,000 m3/hr throughput in addition to the in-stalled PGW 4 stage centri ugal compressor with 1250 kWelectric motor and 11,000 m3/hr.

NewsExhibition in China

Cryostar attended the IG China exhibition in Hang-zhou in September. A team rom our Hangzhou o -

fce and a delegation o the Cryostar SAS (France)management team attended to present Cryostar andits solutions to the Chinese market. The response wasexcellent and many Chinese customers took the op-portunity to discuss current and uture projects.

PROCESS CONTROL

Cryostar USA East is moving

We are pleased to announce that in order to meetgrowing demand in the US, Cryostar USA PA willmove to a larger acility in Allenton, PA. The new a-cility enjoys a total o 750 square metres o shop oorand o fce space. The new address is:

5897 Colony DriveBethlehem, PA 18017USA


10/12Autumn 20050

FOCUS ON ... THE CUSTOMER SERVICE DEPARTMENT

Cryostars Customer Service Department (CSD)is dedicated to achieving and even surpassing thehighest standards o service expected by all custom-ers. We are continually looking to improve andextend the services we provide, said Didier Walch,Customer Service Director. At Cryostar we wantto grow our customer partnerships and develop inunison with the customer, to realise an enduringand mutually productive uture together. The CSD, based at the company headquarters inFrance, is currently sta ed by more than 40 marketand product service specialists, all dedicated toensuring e icient, and customer ocussed, be ore,during and a ter sales service.

In act, t his central team manages all customer ser-vice activity around the world. The team developsall Cryostar standards, which are then duplicatedacross the companys network o business centresand local agents, ensuring consistently high qualityservice on all ive continents.

But the network is not just a day-to-day supportmechanism or customers, it represents a power-

ul combination o local solution providers able totap into an international pool o experience andexpertise.

Every Cryostar business centre maintains a 24-hour emergency telephone service and our engineersare available or call out at any time, said JulienRivello, Customer Service Operations Manager.

Product reliabilityCryostar understands the importance to customers

o product reliability. As a result, dedicated main-tenance shops and maintenance teams are based inFrance, the UK, China and the US.Expert support is equally available in other regions

Who you gonna call?or start-ups, consulting, commissioning and on-

site maintenance and audits.

OEM guaranteed high quality parts, ully compre-hensive parts kits, management o spare and wearparts and scheduled or emergency delivery timesare another o the cornerstones on which Cryostarsnetwork meets the needs o customers. And so isthe web-based spare parts supply portal which willsoon be on-line, allowing contracted customers toorder spares, check pricing and receive deliverycon irmation.

Adding value is another Cryostar cornerstone.The CSD does this by providing e iciency and/or

li etime improvements and retro it upgrades o existing machines, o ten increasing running hoursand creating important savings or our customers.Another aspect is ully customised training sessions

or all Cryostar products and applications, usingall the latest tools and technologies or learning.

Years o experience and expertise in the industryenables Cryostar to take on the ull service element

or the customer, said Marc Runser, Applicationsand Customer Service Manager, Distribution prod-ucts and services.We can provide individual, innovative serviceagreements, customised to particular requirements,with a ocus on providing peace o mind or thecustomer. Cryostar maintenance agreements can includeanything and everything, rom the basic preventivemaintenance o pumps and turbines, through toconsulting, training, crane h ire and repainting.

Cryostars Customer Service Department is allabout customer care so i you have a problem youknow who to call.


11/12Autumn 2005 11

April, 25-29, 2006Welding Zagreb, Zagreb Fair,Avenija Dubrovnik 15, HR-10020 Zagreb, Croatia

May, 23-26, 2006

SVARKA - WELDING 2006,Lenexpo Fairgrounds, 103 Bol-shoy Prospect; St. Petersburg,199106, Russia

Tools and datas:Combustion constants of Hydrocarbon Gases

EVENTS & TOOLS

Heat of Combustion Pound per Pound of Combustible Gas

BTU per Pound Required for Combustion Products of Combustion

Name of gas Symbol MolWeight Gross Net O 2 + N2 = Air CO 2 H2P N2

Carbon (Solid) C 12.011 14,093 14,093 2.664 8.863 11.527 3.664 - 8.863

Hydrogen H2 2.016 61,100 51,623 7.937 26.407 34.344 - 8.937 26.407

Carbon Mon-oxide CO 28.010 4347 4347 0.571 1.900 2.471 1.571 - 1.900

Methane CH4 16.043 23,879 21,520 3.990 12.257 17.265 2.744 2.246 13.275

Ethane C2H6 30.070 22,320 20,432 3.725 12.394 16.119 2.927 1.798 12.394

Propane C3H8 44.097 21,661 19,994 3.629 12.074 15.703 2.994 1.634 12.074

Ethylene C2H4 28.054 21,644 20,295 3.422 11.385 14.807 3.138 1.285 11.385

Propylene C3H6 42.081 21,041 19,691 3.422 11.385 14.807 3.138 1.285 11.385

Acetylene C2H2 26.038 21,500 20,776 3.073 10.224 13.297 3.381 0.692 10.224

EventsNovember, 2005

Oil & Gas Exhibition 2005, FieraMilano, Padiglioni 14, 15, 16,20145, Milano, Italy

November, 2005

IPPEX 2005, Nippon ConventionCenter, Nakase 2-1, Mihama-ku,Chiba City,261-0023, Japan

February, 2006

SOPEC 2006, Dhahran Inter-national Exhibition Centre,P.O.BOX 7519, Dammam 31472,Saudi Arabia

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