Refinery Train Package

Modular technology on customer demand

2 Refinery Train Package
Current fuel programs specify drastically reduced limits on sulfur levels for
gasoline, kerosene and diesel fuels used in engines ranging from vehicles, jets
and ocean-going vessels. These programs will yield enormous long-term benefits
for public health and the environment.

Major oil companies emphasize the importance of hydrotreating – a refinery

process for reducing sulfur, nitrogen and aromatics while enhancing cetane
number, density and smoke point.

Fast changes in spot market prices for both crude oil and products have forced
refiners to plan investments for higher operational flexibility. Hydrocrackers are a
key factor in achieving greater refinery agility to comply with market fluctuations
while maximizing refinery margins.

With a focus on hydrotreating, hydrodesulfurization and hydrocracking processes,

MAN Diesel & Turbo used its proven barrel compressor and steam turbine tech-
nology to create the high-efficiency modular packaged compressor unit named
Refinery Train Package (ReTPac).

Refinery Train Package 3

 Sulfur-Free Diesel and Gasoline
Environmentally friendly solutions thanks to
MAN Diesel & Turbo compressors

Recycle gas compressor

Hydrogen makeup

Hydrocracking
reactor
Furnace

Pretreating
reactor Process gas
Product fractionator

H 2-rich gas Naphtha

Fresh feed

High-pressure separator Middle distillate

Low-pressure separator

Lube stock
Typical hydrocracking process scheme

Driving demands ReTPac targets

 increase of 350% in diesel and gasoline  centrifugal compressors in hydrotreating and
production over the last 5 decades hydrocracking applications
 stricter environmental laws. Limitations regarding  modular configuration, pre-engineered, packaged
ultra low sulfur content in fuels design which provides:
 higher operational flexibility demands on refiners - maximum flexibility in compressor train compo-
due to fast changes in spot market prices nent selection
 short delivery times for long lead items and - fast delivery for materials and documentation
documentation - easy maintenance, good access
 upgrade and service-friendly rotating equipment - fast erection and short commissioning time
- easy to upgrade, modular design
- attractive price

4 Refinery Train Package

Compact Efficient Upgrade-friendly
Main components of the package

Compressor – API617 Dry gas seal system – API614

 vertically-split, forged casing  condition and monitoring of seal gas
 cartridge design for ease of removal for  tubing or piping
maintenance  600, 1,500 or 2,500 lbs
 impellers are milled or eroded, with welded or  coalescer filter and heater for primary seal gas to
brazed covers prevent condensation
 single-piece shaft without sleeves or keyways for  double filter for secondary seal gas (nitrogen)
enhanced rotational stability
 tandem dry gas seals, bi-directional Lube- and control oil system – API614
 tilting pad journal and thrust bearings  main oil pump driven by API611 steam turbine,
 materials according to specific requirements, or electric motor
including sour / wet gas applications  auxiliary oil pump driven by electric motor
 reservoir and piping in stainless steel
Steam turbine – API612  double shell and tube cooler
 impulse control wheel and multi-stage reaction  overhead tank
type blading  bladder type accumulator
 axially-split casing in cast steel with downward
exhaust nozzle Monitoring and control system
 tilting pad journal and thrust bearings  SIMATIC S7-400FH for anti-surge, performance
 condensing unit, including pump skid, drainage and auxiliary controls with redundant CPU and
header and evacuation unit for condensing type power supply
steam turbine  BRAUN or Woodward governor for overspeed
 gland steam condenser protection
 Bentley Nevada 3500 system for vibration and
Alternatively electric motor driven temperature monitoring
 squirrel cage induction motor
 air or water cooled
 non-sparking (EExn) or purged (EExp)
 conformance
Weights and dimensions main skid
with IEC or NEMA

Coupling – API671 Length m 9–11

 flexible-element-disc
Width m approx. 4.5
or diaphragm type
 non-sparking
Height m approx. 4
guard
Weight tons 40–65

Refinery Train Package 5

 Modular Packaged – Flexible Solution
Hydrotreating and hydrocracking compressor packages

Modular configuration Features and benefits

The modular configuration ranges from pre-engi-  very attractive CAPEX
neered train components such as centrifugal barrel  supply of basic design documentation within 4 weeks
type compressors, coupling, mechanical drive steam  short delivery time of 11-12 months
turbines and baseframe to system components such  efficiency optimized to customer requirements
as lube- and control oil system, dry gas seal condi-  pre-tested single lift skid for fast erection and short
tioning system and unit control panel. This concept commissioning time
ensures maximum flexibility in the selection of com-  good access for easy maintenance
pressor train components without compromising on  upgrade-friendly due to modular,
efficiency and reliability. pre-engineered design
 low operational costs
 superior quality, secured by an optimized supply
chain (frame agreements with suppliers)
 maximum flexibility in compressor train components
selection

6 Refinery Train Package

 Compressor

Dry gas seal conditioning and

monitoring system
Steam turbine

Condensing unit

Lube- and control

oil system

Refinery Train Package 7

 Technical Data

Compressor

RB28 RB35 RB45

MAWP – LP / MP barg 98 / 255 98 / 255 98 / 221

Max. capacity
low flow casing m 3/h 3,500 7,100 17,700
high flow casing m 3/h 8,000 16,000 28,000
Speed range (100%) rpm 8,000–16,500 8,000–14,500 8,000–12,500
Speed variability % 70–105
Casing connections
low flow casing inch 8 / 6 12 / 10 20 / 16
high flow casing inch 12 / 10 16 / 14 24 / 20
Nozzle rating lbs up to 2,500 up to 2,500 up to 1,500
Nozzle facing RF (up to 600 lbs) or RTJ (up to 2,500 lbs)
Nozzle forces and moments x NEMA SM23 5
Max. discharge temperature °C 180

p-V-diagram

MAWP MP RB 28 MP
255 barg
RB 35 MP
RB 45 MP
100
MAWP LP
98 barg
RB 28 LP
MAWP [barg]

RB 35 LP

10
RB 45 LP

ps min = 4 barg

1
100 1,000 10,000
Suction volume flow [m3/h]

8 Refinery Train Package

Steam turbine

DG040/040 DK040/070 DG040/050 DK040/080

Max. power MW approx. 5 approx. 10

Speed range (100%) rpm 8,000–16,500 8,000–14,500
Speed variability % 70–105
Live steam bara/°C 66 / 460
Max. back pressure bara 10 0.7 24 0.7
Casing connections
inlet / outlet inch 6 / 14 6 / 26 8 / 16 8 / 32
orientation side / down side / down front / down front / down
Nozzle forces and moments
inlet / outlet x NEMA SM23 2 / 2 2 / 1 2 / 2 2/1

Refinery Train Package 9

All data provided in this document is non-binding. This data serves informational
purposes only and is especially not guaranteed in any way. Depending on the sub-
sequent specific individual projects, the relevant data may be subject to changes
and will be assessed and determined individually for each project. This will depend
on the particular characteristics of each individual project, especially specific site
and operational conditions. Copyright © MAN Diesel & Turbo.
D02082049EN Printed in Germany GMC-OBH10152.0

MAN Diesel & Turbo

Egellsstr. 21
13507 Berlin, Germany
Phone +49 30 440402-2639
turbomachinery@mandieselturbo.com
www.turbomachinery.man.eu

MAN Diesel & Turbo – a member of the MAN Group