Sertco Solutions

Model 632AIO Flowchart (PDF)

DESIGN SERVICE CONDITIONS

Sertco Industries Model 632 Series compressors are designed to handle a wide variety of conditions in wellhead compression. Specific applications are designed using known well data such as suction and discharge pressures, suction temperatures, the anticipated amount of fluids and desired gas flow.

SUCTION SCRUBBER
ASME 500 PSI 24" O.D. X 70" SUCTION SCRUBBER / BLOWCASE

Suction Scrubber

  • ASME carbon steel code stamp vessel
  • Combination scrubber/blowcase handling up to 500 BPD fluids
  • Mesh pad type elements (304SS) installed
  • High fluid level shut-down switch
  • Kenco high pressure sight glasses with ball checks
  • Automated dump valve system
  • Manual drain valve

AIR COOLER
ASME OVERSIZED COOLER

Process Gas / Engine Water Cooler

Air Cooled Heat Exchanger Manufactured by AXH including:
EJW (Water) and AC (Gas) cooling sections supplied as follow:

  • Designed for 60 C cooler discharge temperature at 45 C
  • maximum ambient
  • Manual individual gas louvers
  • Tube Material –SA214 seamless steel tubes
  • ASME code stamped – gas sections
  • 350 PSI MAWP gas section
  • 50 PSI MAWP water section
  • Header Material - SA-516-70N – gas
  • Header Material – A500 – water
  • Approximately 11,026 FPM fan tip speed

UNIT ELECTRICAL

Wiring of all on-skid end devices included with package

Control Panel And Package Instrumentation
The following skid mounted instrumentation shall be provided:

  • Scrubber high level switch (Murphy or equal)
  • Suction pressure gauge (Altronic or equal)
  • Discharge pressure gauge (Altronic or equal)
  • Discharge temperature gauge and thermocouple, 1 per side. (Murphy or equal)
  • Compressor lube oil pressure gauge (Murphy or equal)
  • Compressor crankcase level controller (Murphy or equal)
  • Compressor vibration switch (Murphy or equal)
  • Engine crankcase level controller (Murphy or equal)
  • Engine lube oil pressure gauge (Murphy or equal)
  • Local skid mounted emergency stop push button included

Above control / monitoring points are each served with SINGLE end devices and associated single I/O points. Sertco has made NO provision for redundant instrumentation or I/O either on the skid or in the panel.

Altronic Control Panel

  • Panel is a weatherproof enclosure, NEMA 3, designed for outside use, with front access.
  • The front door has a clear viewing window. Enclosure is powder-coated steel ASA 61 gray.
  • Enclosure dimensions are 24" H x 24" W x 12" D with 32" H stand.
  • Altronic DD-40-NTV Series Annunciator - provides continuous monitoring of 40 each end devices, with automatic shut-down of equipment in the event of a fault.
  • Faults are indicated locally on a LCD display by numeric code.

DISCRETE INPUTS

CLASS B1

  • Low pressure - suction (DSG-1611DUPS set pt. gauge in panel)
  • Low pressure - discharge (DSG-1611DUPS set pt. gauge in panel)
  • High pressure - suction (DSG-1611DUPS set pt. gauge in panel)
  • Loss of speed signal (integral to annunciator) - signal from magnetic pick-up

CLASS B2

  • Low pressure - engine oil (A25P-100 set pt. gauge in panel)
  • Low pressure - compressor oil (A25P-100 set pt. gauge in panel)

CLASS A

  • High pressure - discharge (DSG-1611DUPS set pt. gauge in panel)
  • High temp - compressor discharge - left bank
  • High temp - compressor discharge - right bank
  • High temp - engine jacket water
  • High level - scrubber
  • Low level - engine oil
  • Low level - compressor oil
  • Low level - engine water
  • Vibration – compressor and cooler
  • Emergency stop - local (signal from separate ESD panel)
  • Overspeed (integral to annunciator) - signal from CD ignition G lead

DISCRETE ANNUNCIATOR CONTROL OUTPUTS

  • SW # 2-A - ignition cut-out - interrupt 12 VDC power to CD-1 ignition
  • LUBE - spare
  • Electronic speed control operator switch on panel insert:
  • Mode selector switch - idle / run
  • Manual speed potentiometer
  • Automatic speed signal is available from either DSG-1611DUPS gauge in the panel.
  • Unit panel power switch - off/on - on panel insert.
  • Tubing is 316 SS, seamless.
  • Tube fittings are 316 SS, Swagelock.

PACKAGE FEATURES

  • 3/8" plate structural skid with 765 liter fluid containment capacity
  • Flame arresting lifetime muffler
  • CNC machined skid brackets and details for perfect fit and interchangeability
  • Suction control valve with positive shut-off system when compressor shuts down
  • ASME code scrubber/blowcase with up to 500 bbl/day fluid handling capability with the ability to re-inject the fluids into the discharge gas stream. System designed for maximum efficiency adapting to fluctuating discharge pressure conditions with increased discharge pressure only when needed for the dump cycle. Engine jacket water heat trace system(if applicable prevents liquid from freezing in blow case.
  • Process piping constructed with S 80 A106 grade B seamless carbon steel pipe with carbon content < .43%
  • ASME code oversized gas aftercooler designed for 10 C maximum discharge temperature above ambient temperature under all operating conditions
  • Standard oversized engine jacket water cooler for ambient conditions up to 45 C
  • Driveshaft coupling between compressor and driver eliminates the need for alignment procedures and is designed to break and protect the compressor if it receives liquid in the suction. Also allows for compressor/driver replacement in the field in less than 4 hours.
  • Puller fan, roof and heat trace system(if applicable) prevent freezing of piping, tubing and vessels on skid with ambient temperature @ -34 C
  • 30 – 90 day service schedule based on load, RPM and gas composition
  • Heated 100 liter oil daytank and automatic level controllers provides make-up oil to both driver and compressor for 90 days
  • Optional custom powder coated trailer with dual-axel electric brake system and integrated leveling jacks eliminates site preparation and provides an easy method of transporting compressor with ½ ton truck.
  • Optional integrated, removable roof structure with hinged side panels protects all belts and hoses from UV rays and protects the skid from collecting rain water and potential oil spills
  • Optional low suction pressure make-up system prevents unnecessary shut-downs when gas flow rate fluctuates. System also prevents vacuum operation if desired.
  • Optional package bypass system allows gas production to continue if the compressor shuts down.

UNIT PAINT

Sertco Sherwin Williams Industrial Coating paint details:

  • Commercial Sandblast
  • Primer – 2 coats of red oxide high solid polyamide epoxy primer to 5.0 mils DFT
  • Top coat – coat acrylic, aliphatic polyurethane in any color combination to 3-4 mils DFT

MISCELLANEOUS

  • The following items are included in our Scope of Supply:
  • no-load spin test of compressor at Sertco works;
  • unit run test of main driver at Sertco works;
  • ONE (1) hour no-load mechanical run test of compressor system at Sertco works complete with loop check / continuity test of all unit instrumentation;
  • Sertco cannot guarantee sound levels
  • ONE (1) copy of the instruction manual in the English language;
  • ONE (1) CD copy
  • Sertco Standard drawings are offered and included as follows:
    • Vessel drawings (vendor standard); Cooler drawings (vendor standard); Process P&ID; Process Flow drawing (PFD); Service Flow P&ID's; Panel Drawing & Philosophy; Cause & Effect/shutdown key; Instrument I/O list; Sertco standard ITP;
  • open piping inlets covered (plywood covers)
  • loose instrumentation and spare parts boxed and labeled
  • preparation for shipment
  • loading on truck at Sertco facility is included

Driver Options

ONE (1) ORIGIN 10.3 Liter, Natural Gas Fueled Industrial Driver, 8 Cylinder, 200 HP Continuous @ 2100 RPM

General Data:

  • Type: 10.3L V-8
  • Displacement: 632 cid
  • Engine Orientation: Longitudinal
  • Compression Ratio: 10.5:1
  • Valve Configuration: Overhead Valves (2 valves per cylinder)
  • Assembly Site: USA
  • Valve Lifters: Hydraulic Roller
  • Bore x Stroke: 116.84mm x 120.66mm
  • Main Bearing Caps: 4-Bolt main
  • Balance Method: Internal
  • Intake Manifold: Dual Plane
  • Oil Pan Capacity: 16 qt with filter
  • Engine Rotation: Clockwise

Materials:

  • Block: Cast Iron
  • Cylinder Head: Cast Iron
  • Intake Manifold: Aluminum
  • Crankshaft: Forged Steel
  • Camshaft: Steel Billet Roller
  • Connecting Rods: Forged Steel
  • Pistons: Forged Aluminum Phosphate Coated
  • Exhaust Seat: Industrial Grade Super Alloy
  • Intake Seat: Industrial Grade Super Alloy
  • Intake Valves: Stainless Steel
  • Exhaust Valves: Stellite/Inconel

Features:

  • Hydraulic roller valve lifters for reduced friction and improved performance
  • Engines are balanced for minimal vibration and a smoother running engine
  • Piston oilers for cooler piston crown temperatures and increased wristpin lubrication
  • Large capacity oil pan features port and starboard drain plugs for easier maintenance
  • Stellite-faced exhaust valves; stainless steel intake valves ensure performance in extreme duty applications
    Hardened valve guides for longer life
  • Cylinder heads feature hardened exhaust and intake seats for outstanding durability
  • Hydraulic roller lifter camshaft, optimized for industrial applications
  • Coil-near-plug ignition includes crankshaft, camshaft, coolant, and oil pressure sensors; as well as eight ignition coils
  • Forged aluminum pistons designed specifically for extreme duty

Electric motor equivalent available upon request

Optional Features

  • Roof
  • Trailer
  • Dump to Discharge
  • C1D2
  • Common venting
  • Coalescing Scrubber
  • Liquid Flow Meter
  • Gas Flow Meter
  • Fuel Scrubber
  • Discharge Scrubber

 

Model 632

 

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Sertco Model 632 Compressor Features

  • 100% CNC machined
  • 356-T6 cast aluminum frame, cylinders and oil sump construction for rapid, even heat dissipation and corrosion resistance
  • 8 cylinder, balanced horizontally opposed cylinder arrangement provides high flow capacity, low vibration and even distribution of rod & crankshaft loads
  • Rotating assembly constructed from standard off-the-shelf components reduces initial and overhaul cost and provides for excellent availability
  • Rotating assembly internally balanced to 3 grams for vibration reduction and maximum efficiency
  • Cast aluminum alloy piston with chromoly "gapless" compression rings for blow-by control
  • Forged steel connecting rods balanced and fitted with ARP heat treated 8740 chromoly rod bolts
  • Clevite TriMetal low friction, high conformability main and rod bearings
  • Centrifugally spun-cast high nickel iron alloy replaceable cylinder sleeves
  • Hoerbiger 60RX valves with 0.047" suction lift and 0.039" discharge lift reduces impact velocity providing industry leading reliability and flow characteristics
  • Discharge valves placed at the bottom of the cylinder for moisture ejection
  • All metallic valves and piston rings increase compressor ratio capability beyond typical reciprocating compressors
  • Low (9.5%) fixed clearance billet aircraft aluminum head design allows for valve inspection and replacement without removal of piping
  • All fasteners are grade 8, coated for corrosion resistance
  • Inexpensive automotive oils acceptable (no need for synthetic)
  • External oil pump for ease of service and flow adjustment
  • Tolerant of limited impurities in the gas stream
    Quad discharge ports for pressure drop minimization
  • Standard size Viton o-ring seals throughout
    Dual automotive oil filters and 4.5 gallon oil sump for extended service interval
  • Forged 4340 steel crankshaft