Since 1977, more than 400 integrally geared centrifugal compressors have
been developed and built at the Berlin site – including 200 with in-house
gears. “With the Competence Center for Integrally Geared Compressors, we
represent the entire bandwidth of the supply chain, offering both development
and sales of machines from a single source. The main components are constantly
being further optimized by means of strategic partnerships,” says Ediz
Demirkapilar, Head of Procurement Berlin.
Gear and compressor form a single unit machine-side in the RG – a
Turbo specialty. As the compressor stages sit directly on the gear shafts, the
individual stages can run at different speeds, so they are at their optimum.
This makes the RG extremely efficient. Every stage can be operated separately,
facilitating interstage cooling. The RGs are powered by both engines and steam
Building integrally geared compressors demands precise manufacture in the
micron range, as virtually any vibration will put transmission at risk. “RGs
are used in PTA and the high-pressure CO2 field, for example. In air separation, they
are employed as booster air compressors (BACs) and fuel gas compressors. And
the RGs are pretty much predestined for the new LAES technology,” says Hanno
Wegner, Project Manager in Research & Development.
With the Competence Center for Integrally Geared
Compressors, we represent the entire bandwidth of the supply chain, offering
both development and sales of machines from a single source.
Alongside new equipment sales, service for integrally geared compressors
is also lucrative and important. With Omnicare, MAN PrimeServ Berlin offers
services for third-party machines as well. In addition to component
development, Berlin also develops its own bearings independently.
“Design-to-cost measures help us to prepare a cost-optimized quote for
customers, enhancing efficiency and boosting competitiveness. Thanks to
technological refinement, MAN ES has already won out over competitors like
Siemens and GE multiple times,” says Christian Mourier, Head of R&D and
The Berlin project team has successfully built
the first bull gear with a diameter of 3 meters. Weighing up to 19 metric tons, the bull gear
attains a peripheral speed of around 600 km/h, approximately half the speed of
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