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Distributor / authorized representative that deals with supply & delivery of booster compressor stations to industrial enterprises of Russia

Engineering company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), Russia, has been successfully working with a number of Russian industrial enterprises at the local market for more than 20 years. Since the company’s founding, it has acquired immense engineering experience, market reputation, and has realized more than a hundred large-scale projects at the industrial plants in Russia. Our company is continuously in search of new business partners, who consider Russian market investment-attractive and want to boost their sales in the region, as well as expand their field of activities and enter a new international level.

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We are interested in cooperation with the manufacturers of booster compressor stations, who are looking for an official and reliable distributor to supply their equipment to the industrial plants in Russia.

The company’s top management and sales team are well acquainted with the Russian market, its mentality and laws; they also understand industrial specifics of the financial and economic activities of the Russian customers. All our sales managers have a large customer database, extensive experience of successful sales and well-established connections with the potential buyers of your booster compressor stations. This allows our managers to promptly set out the most promising directions for promotion and to ensure a rapid entry of the products into the promising Russian market. Our employees, who are fluent in English and German, are focused on working at the international market with the supplies of foreign equipment.

Our team of experienced engineers, who can handle the most serious technical problems, constantly keeps in touch with the Russian customers, holds meetings and delivers presentations regarding the latest achievements of our manufacturing partners. They point out the engineering challenges and actively communicate with all the departments at Russian plants. That is why the specifics of doing a business in the Russian Federation are well-known to us, and we also know the equipment of the local industrial plants and their up-to-date modernization needs.

Once we become your authorized representative for booster compressor stations in Russia, our marketing staff will carry out a market research in order to check the demand for booster compressor stations, will submit a market overview for booster compressor stations that you offer and evaluate the needs for this type of equipment at local plants. Our specialists will also estimate the potential and capacity of this market at local industrial plants. Our IT-team will start developing a website for your products in Russian. Our experts will assess the conformity between your booster compressor stations and customer needs as well as analyze the common reaction to the new goods in general. We will look into the categories of potential customers, and pick out the largest and the most promising plants.

Upon becoming your authorized agent on the territory of Russia, ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will obtain certificates, if required, for a batch of the goods or for various types of booster compressor stations in compliance with Russian standards. We can also arrange the inspection in order to obtain TR TS 010 and TR TS 012 Certificates. These certificates provides permission to operate your equipment at all industrial plants of the EAEU countries (Russia, Kazakhstan, Belarus, Armenia, Kyrgyzstan), including the hazardous industrial facilities. Our company is eager to assist in issuing Technical Passports for booster compressor stations as per Russian and other EAEU countries’ requirements.

Our engineering company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), collaborates with several Russian design institutes in various industrial segments, which allows us to conduct preliminary design as well as subsequent design works according to the standards, construction rules and regulations that are applicable in Russia and other CIS countries. It also enables us to include your booster compressor stations into the future projects.

The Company has its own logistics department that can provide packing service, handling as well as the most efficient and cost effective mode of transportation of the goods (incl. over dimensional and overweight goods). The goods can be delivered on DAP or DDP-customer’s warehouse basis in full compliance with all the relevant regulations and requirements that are applicable on the Russian market.

Our company has its own certified specialists who will carry out installation supervision and commissioning of the delivered equipment, as well as further guarantee and post-guarantee maintenance of booster compressor stations. They will also provide necessary training and guidance for the customer’s personnel.

Overview: booster compressor stations

To the present moment compressor equipment (stations) has become widespread in many industries, and is used in medicine, pharmacy, and in the field of vehicle maintenance, as a source of compressed air for pneumatic tools, etc. The increase in demand for compressed gases has given rise to many types of compressors that differ in design, operation principle and performance. Compressor equipment (stations) is usually referred to as auxiliary, meaning that it is not directly involved in the production process, but this does not prevent it from being an integral and necessary for operation part of production lines and various technical systems.

Since it is often not necessary to integrate the compressor itself in the process line, and you only need to supply compressed gas generated by it, the rational solution would be to combine the compressor and its accessories in a single unit, which can be purchased, installed and connected as one. This allows you to simplify the process of engineering and maintenance of the equipment. The set of devices intended to produce compressed gas that includes a compressor mounted on a common base with the motor, transmission and other auxiliary equipment, is called the compressor unit.

Another reason to construct compressor units was the need to have a mobile source of compressed gas. For example, for power portable pneumatic tools, the supply of which with compressed air is obviously inconvenient, or for temporary units for the extraction of minerals such as oil and gas, that are deployed in remote or hard-to-reach areas. Mobility in this case can mean both a possibility to transport the compressor unit without the need for complicated installation at the destination point, and the provision of the unit itself with devices for transportation, for example, wheels.

Design

A variety of configurations of compressor stations and units is very large due to the high potential for the combination of individual elements. The set of these elements itself can vary greatly from time to time, but we can identify a number of basic ones:

  • base;
  • compressor;
  • motor;
  • mechanical transmission;
  • receiver
booster compressor stations
General view of the compressor station

Without compressor, obviously, the station is not able to perform its primary function, and the compressor operation in its turn is not possible without the supply of mechanical energy from the drive. The receiver serves as an intermediate container for compressed gas and makes it possible to smooth the pulsation of the outlet flow. In some cases, the receiver is not necessary, and it may not be a part of the station. The base serves as a foundation for placing other equipment, whereby the receiver can perform its role, if the weight and dimensions of the compressor and drive allow it.

The quantitative composition of the elements of the compressor station also varies depending on the requirements of the task. If the compressed gas is highly polluted, or the degree of its pollution may increase from time to time, then you need to set additional filters that can run continuously or join the operation as required. There may be cases in which the compressor unit should run smoothly for a long time, i.e. the equipment cannot be stopped for repairs and maintenance. As a solution to this problem, an additional backup unit is installed along with the working compressor or compressors. In this case, it is possible to maintain the station without interrupting its operation. By the time one of the operating devices begins to require repair, it is removed from the common gas flow line, and the backup compressor is connected instead, which allows performing the necessary maintenance work while preserving the unit performance. Further, the devices can be removed from the common flow alternately to ensure the cyclicity of their operation and stops.

booster compressor stations
Operation modes of the compressor station consisting of three compressors

Apart from the basic elements, if required, the station may be equipped with a variety of devices and auxiliary systems. To increase the service life of the main equipment you need to use lubrication and cooling systems (oil or air), as well as various filters for gaseous medium installed both upstream and downstream of the compressor. If the station is required to provide the compressed gas flow with variable pressure and flow rate, its design is completed with the control instrumentation and automation system, as well as control interfaces. If the compressor unit constitutes a separate module operated in severe climatic conditions, it is also completed with heating and ventilation systems to maintain optimum conditions inside.

booster compressor stations
Auxiliary devices of the compressor station

Classification

Due to the complexity of their design, compressor stations have an extremely broad classification that can be based on the classification of its components. Of course, the division based on the compressor applied will be the primary one, which is why units can be divided into:

  • displacement type;
  • dynamic type.

The first group uses reciprocating, diaphragm, vane, screw compressors, etc. The gas compression by decreasing the volume of the working chamber, which leads to an increase in the pressure inside it, allows compressor units of this type to develop a significant pressure at the outlet. The second group uses centrifugal, axial and jet compressors, in which the pressure increase is achieved by increasing the kinetic energy of the gas flow, which is then partially converted into the potential pressure energy.

In addition, the classification can be made in the context of the main characteristics of the compressor. These main characteristics include:

  • generated pressure;
  • provided capacity.

Depending on the pressure, compressors are divided into ultrahigh (more than 100MPa), high (10MPa to 100MPa), medium (1.2MPa to 10MPa), and low (0.15MPa to 1.2MPa) pressure compressors. Based on the capacity (flow rate), the division is carried out as follows: low-capacity (up to 10m3/min), medium-capacity (10m3/min to 100m3/min), and high-capacity (more than 100m3/min).

The second important element of the compressor station is the compressor drive, which includes the motor itself and the mechanical transmission transferring the torque from the motor shaft to the compressor shaft. The following compressor units can be distinguished in this case: with diesel, gasoline, electric, etc. motor, and by the type of their connection to the compressor: with belt, chain, gear, etc. transmission. This classification is especially important for mobile compressor units, since not all energy sources may be available, depending on the place of use. Therefore, in areas remote from power lines, it is easier and more expedient to use the compressor unit operated by liquid or gaseous fuel that can be delivered by individual transport.

Mobile units can have various mobile bases ranging from small rollers to a closed car trailer. The specific choice will depend on the place of use and the application of the unit. For a car service it will be enough to install the compressor and all the necessary elements on the mobile platform, which can be manually moved by a worker within the premises, whereas a powerful and large-sized compressor used to supply compressed air to construction tools would be better placed in a truck trailer or on the frame of the car itself.

booster compressor stations
Types of the compressor station drives

An important feature of compressor units is the ability to make them mobile, and therefore they are divided into:

  • stationary units;
  • mobile units.

In general, depending on the type of platform on which the equipment is disposed, compressors can be installed on:

  • receiver;
  • trailer (uniaxial or biaxial; open or closed);
  • frame (closed or open).

Among the variety of compressor stations and units one can distinguish several key areas. One of them is the provision of compressed air for various pneumatic tools. In this area, the most demanded are mobile stations used by road and construction services. It also can be mobile or stationary spray guns and sandblasting units.

booster compressor stations
Compressor station arrangement types

Application areas: An option to arrange the compressor, motor and transmission directly on the receiver is very common, since the unit becomes compact and provides easy access to the parts for inspection and repair. In addition, it can be made mobile, if you equip the receiver with wheels. The largest and most sophisticated compressor units are disposed on frames mounted on the foundation. The whole structure can constitute a single module with built-in ventilation and heating, which allows you to move this unit using transport and use it in any weather and climatic conditions.

The second wide area is the supply of compressed gas (including air) to a variety of equipment in factories and production lines. It can be pneumatic presses, pneumomotors, crane equipment, adjustment and shutoff valves, etc. Since these consumers of compressed air are mainly large objects mounted on the foundation, the corresponding compressor stations are made stationary, adapted for working with specific equipment.

In chemical engineering compressor units serve for supplying compressed gas to the chemical synthesis devices, so they are subject to additional requirements for chemical and corrosion resistance to the discharge gas, and for the level of sealing and explosion safety. At the same time, almost everywhere in factories there are lines of compressed nitrogen used to purge equipment and pipelines. The advantage of nitrogen in this case is caused by the inertia of the gas, its availability and the possibility of obtaining from atmospheric air by membrane separation or fractional distillation. Atmospheric air or pure oxygen under pressure is also used as an oxidant for chemical synthesis reactions. The latter is widely used in metallurgy, which makes compressor stations popular in this area.

General information on booster compressor stations

The development of gas fields is associated with a number of features that impose additional requirements for the organization of the process. Therefore, there are three main phases: increasing, stable and declining production. The actual development begins at the stage of drilling and field construction, which corresponds to the phase of increasing production. Upon completion of the above activities, the field switches to the operating mode set by technical and economic assessment, which corresponds to the phase of stable production. During this time, about 2/3 of all the gas reserves are withdrawn. Next comes the phase of declining production, characterized by a decrease in production levels due to the partial decommissioning of the wells because of their drowning or the decrease of gas extraction below the level of profitability. In such conditions, additional 10% of the reserves are withdrawn from the field. In the development of medium and small fields, the phases of increasing and stable production may be absent altogether.

At the beginning of the field development, as a rule, the existing reservoir pressure is enough to transport gas from the well to the site of its treatment and then to the pipeline without the use of compression equipment. However, throughout the production process, the reservoir pressure gradually decreases, and at the phase of stable production, and especially at the stage of declining production, you may encounter a problem, in which the current pressure is not enough to supply to the pipeline. Therefore, from a technological point of view, the field development is divided into two phases: natural pressure phase and compressor phase. As the name implies, their difference lies in the use of the compressor unit intended to increase the pressure of the produced gas. Such units are referred to as booster compressor stations (BCS). They are designed to perform the following tasks:

  • recovery of low-pressure gas;
  • compression of oil and associated petroleum gas for further supply;
  • maintaining the predetermined outlet gas pressure;
  • cleaning, purging and pressure testing of pipelines.

The compressor phase of the field development is an important component of the entire production process. 50-60% of the total gas reserves is withdrawn during the natural pressure phase, whereas the field exploitation in the compressor mode allows you to extract additional 20-30% of the total reserves, which is a significant value. Equipment for the gas preparation is intended for its certain pressure, and at a certain pressure gas should be supplied to the gas pipeline. When the reservoir pressure falls, BCS ensures a constant outlet pressure through its additional increase up to the desired value. All this makes booster stations one of the most important elements of the gas production.

In addition to wells, BCS can be installed in underground gas storage facilities, whereby their task will be to withdraw the gas from the storage and supply it to the pipeline under the necessary pressure. The same compressor station carries out the reverse operation, where the gas is withdrawn from the pipeline and pumped into the storage. Such BCS should be able to generate high gas pressure at the outlet; otherwise, the volume available for storage will be used inefficiently. Underground storages located in hard rock formations can store gas at high pressure from 0.8MPa to 1MPa.

booster compressor stations
Installation of a booster compressor station on the gas field and in the underground storage

Design and operation principle

Booster compressor stations can differ greatly in design and configuration, but we can identify a number of basic elements:

  • compressor unit;
  • drive;
  • accessories.

The fundamental element of BCS is the compressor itself or a group of compressors responsible for increasing the pressure of the flowing gas. The compressor is driven by the drive connected thereto. Accessories mean any additional devices required for the correct operation of the station. This may be a lubricating oil circulation system, cooling system, a set of instrumentation and control equipment, etc. If BCS constitutes a single module, accessories can include such auxiliary systems as heating, lighting, ventilation, etc.

Classification

Booster compressor stations are complex units that perform the task of transferring and discharging the gas, the key element of which is the compressor unit. Therefore, the main classification of BCS depends on the compressors used, which are usually of the following types:

  • reciprocating;
  • screw;
  • centrifugal.
booster compressor stations
The main types of compressors used in booster compressor stations

Reciprocating compressors are positive displacement compressors operating by means of the directional reduction of the working chamber volume formed by a cylinder and a movable piston, where the gas is compressed. The advantages of such devices are a relatively simple design greatly facilitating technical service and repair, as well as easy maintenance and reliability. Reciprocating compressors make it possible to develop significant gas pressure, and are less expensive in comparison with other types. However, these benefits are opposed by such disadvantages as the uneven flow of the produced gas and cyclical changes in the working chamber volume caused by the reciprocating motions of the piston. In addition, they are noisier and experience vibration loads during operation. Booster compressor stations equipped with reciprocating compressors largely adopt their characteristics. They are quite inexpensive and easy to handle, but also able to compress the gas to high pressures. Reciprocating compressors of small sizes can be easily disposed even on the receiver, whereas large ones can require a more stable platform.

The screw compressor also belongs to the positive displacement type, but it forms the working chambers through cutting off the space by the compressor housing and one or more engaged screws. Such devices are capable of developing significant pressure, which in the case of reciprocating compressors would have to be provided by a multi-stage gas compression scheme. Screw compressors, as well as booster stations based on them, are more complex and expensive compared to analogs, but also show high reliability and simplicity of operation like reciprocating ones, but require strict compliance with the operation standards. Low noise and compact dimensions make it possible to use screw compressors successfully in a variety of mobile BCS. However, they are also used in large compressor stations in industries and gas production enterprises, especially in high-tech ones, as they can create a flow of compressed gas without pulsations typical for reciprocating CS.

The centrifugal compressor increases the gas pressure by transferring the kinetic energy to its flow, which is then partially converted into the potential energy of pressure. The kinetic energy is transferred from the blades of the rotating impeller, and converted into the potential energy in the diffuser at the outlet of the compressor. Such principle of the gas compression is called dynamic. Centrifugal compressors in similar conditions are not able to develop such high pressures as reciprocating and screw ones, and are often made multi-stage to obtain the necessary amount of compression. At the same time this type, and, therefore, the corresponding type of compressor stations, is capable of providing a high gas flow rate, which makes such CS popular in gas production enterprises, as well as in places where there is the need to generate the compressed air in large amounts. Furthermore, the discharge during the operation of the centrifugal compressor is carried out uniformly without pulsations, which facilitates the pumping.

The next in importance classification of booster compressor units and stations can be made based on the drive type. It defines the type of fuel that can be used for the BCS operation. Given the fact that such equipment is often located at great distances from transport routes and in remote locations, the possibility or the impossibility to supply a certain type of fuel can become crucial. The following types of drives are used the most often:

  • gas-motor;
  • gas-turbine;
  • electric.

The gas-motor drive is based on the internal combustion engine that runs on gaseous fuels, which are a rather cheap and accessible energy source. Such devices are reliable and easy in operation. The start of the drive is carried out by means of the compressed air, and the revolutions are adjusted by the alteration of the gas supplied to the cylinders.

In the gas turbine drive the mechanical energy is produced, as the name implies, by means of the turbine, in which the hot gas expands, generated in the combustion chamber where the fuel and the atmospheric air are supplied to. The air is sucked in by the compressor, so the start of the gas-turbine unit requires a separate power source (starter). The main components of the gas-turbine unit are the compressor, combustion chamber, and turbine. This type of drives has become widespread, as it is not tied to fuel supplies from the outside and operates with the same gas, which is pumped by BCS. The excess of the generated energy can be used for heating and electric power supply of the station itself and nearby objects.

The electrically driven BCS, despite the need to supply the electric power, has a number of advantages over gas motor and gas turbine units. First, the use of electric power saves the pumped fuel itself, and is beneficial to the ecological performance of BCS due to the reduction of harmful emissions into the atmosphere. Second, the electric motor is much easier to adjust and automatize, which considerably simplifies the control over the operation of the entire station and makes it possible to reduce the necessary operation personnel. Third, the working conditions on such BCS are significantly improved due to the reduction of noise, vibration and dust content in the air.

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We are always open for cooperation, let’s move forward together!

Upon becoming the official distributer of booster compressor stations, our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), carries out the following: finds the buyers of your products on the market, conducts technical and commercial negotiations with the customers regarding the supplies of your equipment, concludes contracts. Should a bidding take place, we will collect and prepare all the documents required for the participation, conclude all the necessary contracts for the supply of your equipment, as well as register the goods and conduct customs clearance procedures. We will also register a certificate of transaction (Passport of Deal) required for all foreign trade contracts in the foreign currency control department of the authorized Russian bank so that currency transaction could be effected. If required, our company will implement an equipment spacing project in order to integrate your equipment into the existing or newly built production plant.

We are convinced that our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will become your reliable, qualified and efficient partner & distributor in Russia.

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