설명
LW-13/30 Nitrogen Compressor – Medium-Capacity Oil-Free N2 Booster for 3.00 MPa High-Pressure Process Applications
Engineered to deliver 13 m³/min at 3.00 MPa discharge pressure, the LW-13/30 is a two-stage, three-row oil-free piston nitrogen compressor designed for high-pressure nitrogen injection, gas liquefaction booster duty, and demanding petrochemical process applications. Zero oil contamination, continuous-duty rated, and built for 24/7 industrial reliability at elevated pressure.
제품 개요
그만큼 LW-13/30 nitrogen compressor occupies a critical position within our oil-free piston compressor portfolio, bridging the gap between medium-capacity boosters and high-pressure process compressors. With a rated capacity of 13 m³/min 그리고 탁월한 3.00 MPa discharge pressure, this unit is purpose-built for applications where both substantial flow and elevated pressure are non-negotiable requirements.
What distinguishes the LW-13/30 from conventional alternatives is its fully oil-free compression pathway. The piston rings and rider bands are precision-machined from advanced self-lubricating PTFE composite materials that operate without any hydrocarbon lubricants, ensuring the nitrogen stream remains completely uncontaminated. This intrinsic oil-free characteristic achieves ISO 8573-1 클래스 0 인증 natively, eliminating the capital expenditure and ongoing maintenance burden of downstream oil-removal filtration systems that would be mandatory with lubricated alternatives.
The compressor architecture employs a two-stage, three-row (二列三级) configuration—a unique arrangement that divides the total pressure ratio across three compression cylinders arranged in two rows. This staged approach is essential for managing the extreme thermal loads associated with 3.00 MPa discharge pressure while preserving the integrity of the PTFE sealing elements. Each stage features an independent intercooler, ensuring gas temperatures remain within safe operating envelopes even during sustained maximum-capacity operation. The robust cast-iron frame and dynamically balanced forged steel crankshaft are rated for a minimum service life of 120,000시간 표준 유지보수 절차에 따라.
Technical Specifications – LW-13/30
| 매개변수 | 값 | 단위 |
|---|---|---|
| 모델 | LW-13/30 | – |
| 무늬 | Two-stage, Three-row (二列三级) | – |
| 용량 | 13 | m³/min |
| 토출 압력 | 3.00 | MPa |
| 압축기 크기 (길이 × 너비 × 높이) | 2860 × 1685 × 2610 | mm |
| 무게 | 6.60 | 티 |
| 힘 | 160 | 킬로와트 |
| 전압 | 380 | 다섯 |
| 가스 매체 | 질소(N₂) | – |
| 매끄럽게 하기 | 오일 프리 | – |
* 모든 사양은 표준 참조 조건(ISO 1217, 부록 C)에서 측정되었습니다. 실제 성능은 현장 고도, 주변 온도 및 흡입구 조건에 따라 달라질 수 있습니다.
주요 특징 및 엔지니어링 장점
1. Three-Stage Compression for Extreme Pressure Ratios
The LW-13/30 employs a unique two-stage, three-row (二列三级) architecture that divides the extreme pressure ratio required for 3.00 MPa discharge across three compression cylinders. This multi-stage approach is thermodynamically essential because a single-stage or even two-stage compressor would generate discharge temperatures exceeding the safe operating limit of PTFE sealing materials (approximately 180°C). By splitting the compression work across three stages with two inter-stage coolers, the LW-13/30 maintains per-stage discharge temperatures below 155°C, preserving PTFE ring integrity and extending valve plate life by approximately 50% compared to two-stage designs attempting equivalent pressure ratios. The three-row arrangement also provides improved force balance compared to single-row configurations, reducing foundation requirements.
2. High-Pressure Oil-Free PTFE Composite Sealing
The LW-13/30 utilizes a proprietary 자가 윤활 피스톤 링 및 라이더 밴드 어셈블리 manufactured from high-density PTFE composites specifically formulated for high-pressure, high-temperature service. These rings are reinforced with glass fiber and bronze particulates to achieve a coefficient of friction below 0.05 without any external hydrocarbon lubrication. At 3.00 MPa discharge pressure, the partial pressure of oil vapor would be extremely high in a lubricated compressor, making downstream oil removal virtually impossible. The oil-free design achieves ISO 8573-1 클래스 0 준수, eliminating the need for coalescing filters, activated carbon adsorbers, and oil monitoring instrumentation that would add significant capital and operating costs to a lubricated system.
3. Reinforced Frame for High-Pressure Mechanical Loads
본체는 다음 재료로 주조됩니다. GG25 회주철 with significantly reinforced wall sections, additional ribbing, and integral cooling water passages. The high-pressure cylinders feature thicker walls and enhanced structural support to withstand the peak gas forces associated with 3.00 MPa operation. The three-row arrangement distributes the mechanical loads across multiple crankshaft throws, reducing the peak bearing loads per cylinder and improving overall crankshaft longevity. The frame is dynamically analyzed using finite element modeling to ensure stress concentrations remain within safe limits under all operating conditions, including emergency shutdown transients.
4. Standard 380V Drive with High-Torque Motor
The LW-13/30 is driven by a 160 kW, 380V, 50Hz three-phase induction motor rated to IEC 60034-1 efficiency class IE3. The motor is specifically selected for high starting torque to overcome the substantial initial resistance of the three-row compression train. The standard 380V configuration integrates directly into existing low-voltage industrial distribution panels without requiring medium-voltage infrastructure, making this high-pressure compressor accessible to a wide range of industrial facilities. For sites with 6kV or 10kV bus systems, an optional motor with integrated step-down transformer can be supplied.
응용 시나리오
High-Pressure Nitrogen Injection for Enhanced Oil Recovery
In oil and gas production, the LW-13/30 serves as a high-pressure nitrogen injection compressor for enhanced oil recovery (EOR) and miscible gas flooding operations. The 3.00 MPa discharge pressure is sufficient for injecting nitrogen into reservoirs at depths up to 2,000 meters, where the formation pressure requires high injection pressures to achieve effective displacement. The 13 m³/min capacity can serve multiple injection wells simultaneously through a centralized high-pressure distribution manifold. The oil-free design is critical in EOR applications because any oil contamination in the injected nitrogen would damage the reservoir formation, reduce permeability, and compromise oil recovery efficiency.
Gas Liquefaction & Cryogenic Process Booster
In nitrogen liquefaction plants and cryogenic process facilities, the LW-13/30 nitrogen booster compresses nitrogen from the liquefier cold end or storage vaporizer to the pressure required for distribution or further processing. The 3.00 MPa discharge pressure is adequate for feeding high-pressure nitrogen into cryogenic storage systems, driving nitrogen through multi-pass heat exchangers, and supplying high-pressure nitrogen for supercritical fluid extraction processes. The oil-free design prevents contamination of the cryogenic equipment, where even trace oil would freeze and block heat exchanger passages, causing costly shutdowns and equipment damage.
Petrochemical High-Pressure Reactor Inerting
In petrochemical and chemical synthesis operations, the LW-13/30 provides high-pressure nitrogen for reactor inerting, catalyst bed preservation, and emergency depressurization. The 3.00 MPa discharge pressure is sufficient to maintain positive inert gas blankets in high-pressure reactors operating at 2.00–2.50 MPa, preventing explosive vapor formation and protecting catalyst beds from oxidation during startup and shutdown. The 13 m³/min capacity can serve multiple reactors or process units through a centralized high-pressure nitrogen header. The oil-free certification is mandatory because any oil contamination would poison catalysts, degrade product quality, and create safety hazards in oxygen-sensitive processes.
High-Pressure Pipeline Testing & Commissioning
Natural gas pipelines, petrochemical process piping, and high-pressure vessel systems require nitrogen for hydrostatic testing, pneumatic testing, and commissioning purge operations. The LW-13/30’s 3.00 MPa discharge pressure is suitable for pressure testing systems rated up to 2.50 MPa design pressure (with appropriate safety margins per ASME B31.3). The 13 m³/min capacity allows rapid pressurization of large-diameter pipelines and vessels, reducing commissioning time. The oil-free design ensures that test nitrogen does not introduce contaminants that would require post-test cleaning or compromise the integrity of sensitive process systems.
자재 및 시공
The LW-13/30 is constructed from premium materials selected for extreme high-pressure nitrogen compatibility, thermal resistance, and extended operational life:
| 요소 | 재료 | 사양 |
|---|---|---|
| Cylinder Block (LP Stage) | 회색 주철 | GG25 / HT250, 표준 벽 두께 |
| Cylinder Block (IP Stage) | 회색 주철 | GG25 / HT250, 강화벽 + 리브 |
| Cylinder Block (HP Stage) | 회색 주철 | GG25 / HT250, heavy reinforced wall + ribbing |
| 크랭크 샤프트 | 단조 합금강 | 42CrMo4, Q&T, ISO 1940 G2.5 밸런스 |
| 피스톤 링 | PTFE-유리-청동 복합재 | High-pressure rated, self-lubricating, 185°C max |
| 라이더 밴드 | PTFE 복합재 | Piston guidance, anti-scuffing, wear rate <0.03 mm/1000h |
| 밸브 플레이트 | 스테인리스 스틸 | SS316, 고압 동심 링 설계 |
| Intercoolers (2 units) | 탄소강 쉘 / SS316 튜브 | ASME VIII Div.1, 1.5배 수압 시험, 30분 유지 |
| 애프터쿨러 | 탄소강 쉘 / SS316 튜브 | 고압 핀 튜브, 32°C 냉각수 |
| 고압 배관 | 이음매 없는 스테인리스 스틸 | SS316, ANSI Class 900 flanges |
모든 압력 지지 부품은 다음 사항에 따라 엄격하게 설계 및 제작됩니다. ASME BPVC 섹션 VIII 부문 1 or Chinese GB 150 standards. Every weld joint undergoes 100% radiographic inspection (RT) per ASME Section V, Article 2, and each completed pressure vessel is subjected to a hydrostatic pressure test at 1.5 times the maximum allowable working pressure (MAWP) for a minimum hold period of 30 minutes. High-pressure piping systems are fabricated from seamless SS316 with ANSI Class 900 flanged connections to ensure leak-tight integrity at 3.00 MPa operating pressure.
설치 및 유지 관리 지침
기초 및 구조 요구사항
The LW-13/30 has a dry weight of 6.60 tonnes and a center of gravity approximately 850 mm above the baseplate. Despite the three-row design, the opposed-cylinder arrangement provides reasonable force balance, permitting installation on a reinforced concrete inertia block of 10–12 tonnes. The block should be mounted on elastomeric vibration isolators (natural frequency 6–8 Hz). Minimum clearance requirements: 1.5 m on the non-drive side for valve access, 1.2 m on the drive side for motor maintenance, and 2.0 m overhead for crane access. The high-pressure discharge piping must be properly supported with spring hangers or flexible supports to prevent thermal expansion stress and vibration-induced fatigue at 3.00 MPa.
냉각수 시스템 설계
냉각수 수요는 대략 다음과 같습니다. 25 m³/h at an inlet temperature not exceeding 32°C. The water distribution circuit supplies the cylinder jackets and two intercoolers in parallel. Given the extreme pressure ratio, both intercoolers are critical for thermal management and must receive priority cooling water flow. Water quality specifications: pH 6.5–8.5, total dissolved solids < 500 mg/L, chloride content < 50 mg/L (to prevent SS316 tube corrosion), suspended solids < 30 mg/L, and total hardness < 300 mg/L as CaCO₃. A closed-loop cooling tower with side-stream filtration and chemical treatment is strongly recommended for all installations.
예방 정비 일정
| 간격 | 서비스 항목 | 조치 필요 |
|---|---|---|
| 일일 | 운영 점검 | Check vibration, abnormal noise, cooling water flow, discharge pressure, temperature, oil levels |
| 250시간 | Valve Plate Inspection (All Stages) | 흡입/배출 밸브를 분리하여 탄소 침전물, 스프링 피로, 균열 여부를 점검하십시오. |
| 1,000시간 | Piston Ring Wear Assessment (All Stages) | Measure groove clearance; replace rings if clearance exceeds 0.18 mm |
| 3,000시간 | 중간 정비 | Replace all piston rings, rider bands, and valve plate assemblies across all three stages |
| 6,000시간 | 대대적인 개편 | Inspect crankshaft journals, measure main bearing clearances, replace bearings if >0.06 mm |
The oil-free design of the LW-13/30 dramatically reduces maintenance complexity compared to lubricated alternatives. There are no oil changes, no oil analysis, no filter replacements, and no separator cartridge changes. The primary consumable wear items are the PTFE 피스톤 링 및 라이더 밴드, which typically achieve 3,000–5,000 hours of service life under clean nitrogen conditions at high pressure. The three-stage design distributes wear more evenly than two-stage configurations, reducing the frequency of major overhauls.
규정 준수 및 안전 인증
The LW-13/30 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:
ASME BPVC 섹션 VIII Div.1, GB 150-2011, PED 2014/68/EU 모듈 A
IEC 60034-1(IE3 효율), IEC 60204-1, ISO 12100 기계 안전
ISO 8573-1 0등급(유지 함량) 기준 충족, TÜV 라인란트에서 독립적으로 테스트 완료
ISO 9001:2015, ISO 14001:2015
Nitrogen is classified as a simple asphyxiant gas. At 3.00 MPa discharge pressure, the risk of rapid gas release and oxygen displacement is severely elevated. All LW-13/30 installations must incorporate continuous oxygen deficiency monitoring in the compressor room and all adjacent areas. High-pressure discharge piping must be equipped with pressure relief valves rated at 110% of MAWP and rupture discs as secondary protection. All high-pressure connections must be verified with ultrasonic leak detection before commissioning. Ventilation systems must maintain ambient oxygen above 19.5% per OSHA 29 CFR 1910.146. Emergency shutdown interlocks should activate at 19.5% O₂ (alarm) and trigger automatic isolation at 18.0% O₂ (hard shutdown). Personnel must be trained in high-pressure gas safety protocols and wear appropriate PPE before operating or maintaining this equipment.
성과 및 효율성 분석
The LW-13/30 achieves a specific power consumption of approximately 12.31 kW per m³/min of nitrogen delivered at 3.00 MPa discharge pressure. This specific power figure reflects the thermodynamic reality of ultra-high-pressure compression, where the work required increases substantially with pressure ratio. Within the high-pressure oil-free piston compressor segment (discharge pressure >2.50 MPa), this efficiency is highly competitive and significantly superior to diaphragm compressors, which are the primary alternative for oil-free high-pressure service. For comparison, oil-lubricated reciprocating compressors in similar ultra-high-pressure applications typically consume 13.0–15.0 kW/m³/min, while diaphragm compressors may exceed 18 kW/m³/min.
Over an 8,000-hour annual operating cycle, the LW-13/30’s efficiency advantage versus less efficient alternatives yields approximately 52,000–104,000 kWh of annual energy savings. At $0.08/kWh, this represents $4,160–$8,320 in direct electricity cost reduction per year. However, the primary economic justification for the LW-13/30 is typically the 석유 관련 소모품의 제거 및 하류의 오일 제거 장비의 불필요화 윤활유를 사용하는 대안의 경우 이는 필수적일 것입니다. total cost of ownership for ultra-high-pressure nitrogen compression 오일 없이 작동하는 시스템을 하류 정화 설비가 완비된 윤활 시스템과 비교할 때, 10년 작동 수명 동안 총 TP3T가 약 25~351개 감소하는 것으로 추정됩니다.
The absence of oil in the compression path is particularly valuable at 3.00 MPa because oil contamination becomes exponentially more concentrated and more difficult to remove as pressure increases. At this pressure level, even advanced coalescing filters and activated carbon systems struggle to achieve sub-ppm oil content, and the energy penalty of operating such systems becomes substantial. The LW-13/30’s native oil-free design eliminates this challenge entirely.
맞춤 제작 및 OEM 역량
We offer extensive customization options to adapt the LW-13/30 to specific site conditions, integration requirements, and end-user specifications:
- 스키드 장착형 턴키 패키지: Pre-assembled compressor, motor, intercoolers, aftercooler, high-pressure discharge piping, instrumentation, and control panel on a structural steel skid. Factory pre-testing of all systems reduces commissioning time by 60%.
- 위험 지역 구성: ATEX Zone 2 and IECEx compliant motor and electrical enclosures for petrochemical installations. Integrated gas detection and automatic ventilation interlocks.
- 고급 공정 제어: Siemens S7-1200 or Allen-Bradley CompactLogix PLC with 10-inch HMI touchscreen, remote monitoring via Modbus TCP/IP or OPC-UA, and DCS/SCADA integration. High-pressure safety interlocks including automatic unload on overpressure and emergency isolation valves.
- 환경 보호: C5-M marine-grade coatings for coastal installations; tropicalized electrical components for 55°C ambient; IP54-rated acoustic enclosures reducing noise from 85 dB(A) to 72 dB(A).
- OEM 및 자체 브랜드: 가스 장비 유통업체 및 시스템 통합업체를 위한 맞춤형 페인트 색상, 브랜드 명판 및 현지화된 문서.
사용자 지정 구성은 다음에서 이용 가능합니다. 최소 주문 수량 1개. Engineering proposals are typically delivered within 5–7 business days. Standard delivery time is 12–14 weeks; repeat orders are delivered in 8–10 weeks.
Case Study: LNG Plant Nitrogen Purge & Inerting System
고객: An LNG regasification terminal in Southeast Asia
도전: The terminal required a reliable high-pressure nitrogen supply for pipeline purging, storage tank inerting, and emergency nitrogen injection into the LNG vaporization system. The existing oil-lubricated compressor was experiencing oil carryover into the nitrogen stream, contaminating the cryogenic heat exchangers and requiring quarterly cleaning shutdowns. The 2.50 MPa discharge pressure was also insufficient for the new high-pressure pipeline purge requirements. Maintenance costs had reached $95,000/year and unplanned shutdowns were occurring every 3–4 months.
해결책: 우리는 공급했습니다 LW-13/30 oil-free nitrogen compressor as the primary high-pressure supply, configured on a custom skid with integrated dual intercoolers, aftercooler, and a Siemens S7-1200 PLC control panel with SCADA integration. The 3.00 MPa discharge pressure met all pipeline purge and tank inerting requirements. The oil-free design eliminated heat exchanger contamination. A 3 m³ surge vessel was installed upstream to buffer demand fluctuations from the intermittent purge operations.
24개월 후 정량화된 결과:
- 질소 오일 함량: Reduced from 2.8 mg/m³ to <0.01 mg/m³ISO 8573-1 클래스 0을 달성했습니다.
- Cryogenic heat exchanger cleaning frequency: Reduced from quarterly to annually, saving $45,000/year
- Unplanned shutdowns: 이벤트 없음 in 24 months versus 6 events in the previous 24 months
- 연간 유지 관리 비용: 48%만큼 감소 ($95,000 to $49,400)
- Pipeline purge capability: Enhanced from 2.50 MPa to 3.00 MPa, meeting new regulatory requirements
“The LW-13/30 has been the most reliable piece of equipment in our nitrogen system. The elimination of oil contamination has solved our heat exchanger fouling problem, and the 3.00 MPa pressure gives us the purge capability we need for regulatory compliance. Our operations team finally has confidence in the nitrogen supply.” — Operations Manager, LNG Terminal
자주 묻는 질문 및 선택 가이드
관련 제품 및 솔루션
DW 시리즈 고압 질소 압축기
Designed for discharge pressures from 0.40 MPa to 2.00 MPa, the DW series covers nitrogen injection, pipeline boosting, and chemical synthesis. Capacities from 2 to 130 m³/min.
ZW 시리즈 다단식 무오일 압축기
Vertical, multi-stage oil-free compressors for oxygen, nitrogen, hydrogen, and specialty gases. Discharge pressures up to 9.00 MPa for ultra-high-pressure applications.
MW Series Medium-Pressure Compressors
Medium-pressure oil-free compressors (1.0–4.0 MPa) for nitrogen recycle, gas liquefaction, and process gas compression in petrochemical operations.
저희에 대한 포괄적인 개요를 보시려면 산업용 질소 압축기 오일프리 산소 압축기, 수소 압축기, 이산화탄소 압축기 및 맞춤형 특수 가스 솔루션을 포함한 당사 제품 포트폴리오에 대한 자세한 내용은 애플리케이션 엔지니어링 팀에 문의하거나 온라인 제품 카탈로그를 참조하십시오.
Ready to Upgrade Your Ultra High-Pressure Nitrogen System?
당사의 애플리케이션 엔지니어는 고객의 질소 유량 요구 사항, 흡입 조건, 토출 압력 목표 및 통합 제약 조건을 평가하기 위해 대기하고 있습니다. 문의 접수 후 48시간 이내에 무료 기술 제안서, 기초 배치 도면, 배관 및 계측 다이어그램(P&ID) 및 상세한 총 소유 비용(TCO) 분석을 제공해 드립니다.
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