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Breaking monopolies to forge heavy equipment: The "Chinese Heart" of ultra-deep gas Storage Facilities - A Record of the Research and Development of 40 mpa high-pressure Centrifugal Gas Injection Compressors by Shenyang Blower Group

On April 23rd, good news came from the Tarim Oilfield: China's largest ultra-deep gas storage facility, the Yaha Gas Storage Facility, officially started the gas injection mode. As the heart of this "underground energy bank", the first domestic 40-megapascal high-pressure centrifugal compressor unit developed by Shenyang Blower Group has been successfully debugged and put into operation. The addition of this "national heavyweight" has enabled the daily gas injection capacity of the gas storage facility to exceed 10 million cubic meters, completely breaking the long-term monopoly of foreign countries in the field of ultra-high pressure gas storage facilities.


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As the first in-service deep condensate gas reservoir in China, the Yaha Gas Storage Facility has extremely high requirements for the pressure level, displacement and stability of the gas injection compressor - 40 megapascals. It needs to withstand the pressure equivalent to 4,000 meters of deep sea, and the daily gas injection volume must match the energy storage needs of ultra-deep reservoirs. Moreover, it must adapt to the long-term stable operation under the extreme temperature difference and complex working conditions of the Gobi Desert. At that time, there were no mature technologies to draw upon domestically, no similar equipment to refer to, and the difficulty of research and development could be described as the "peak" of the industry. The road of research and development is destined to be full of thorns.


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"At that time, it was truly 'starting from scratch'. There was no record of 40MPa grade compressors in China, and even reference materials were scarce."; " Dong Hao, an engineer from the Turbine Design Institute, recalled. As the main designer of the project, he led the technical breakthroughs throughout the process: "We re-studied from all dimensions including performance, structure, materials, and skid-mounted design. The design plan alone went through more than ten iterations." To withstand ultra-high pressure, we innovatively adopted an ultra-high pressure cylindrical compressor structure, combined with a newly developed model-level impeller, and gradually optimized it through rotor dynamics analysis. The most challenging part was the thrust calculation. We optimized the program and calculated over a hundred working conditions. Finally, we overcame the tough problem of axial thrust." From drawing design to production and manufacturing, from shipment to on-site commissioning, Dong Hao closely monitored the entire process: "We dare not be careless about any parameter or structure. We aim to make 'China's first' world-class." In the end, all the tests of the unit were successfully passed and all the performance met the standards. At that moment, all the hard work was worth it.


The test pressure of 63MPa is the highest record in the history of Shengu Gas Storage equipment. If the pressure is not well controlled, risks may occur. Zhou Guisong, the head of the pressure testing group in the stator workshop, still couldn't hide his excitement when talking about the manufacturing breakthroughs. He led his team to face the most stringent test directly: "This unit has a complex structure and a particularly large number of ultra-high pressure sealing points. If the sealing is not in place even slightly, it will leak." It requires a stepwise and slow pressure increase. Flange deformation and shell stress overload are both major hidden dangers. We conducted dozens of simulation debugging sessions before and after, getting every detail stuck." To ensure absolute safety, the team introduced an intelligent monitoring system, combined with a new high-pressure sealing structure, and strictly implemented the three-level confirmation of "operation - review - proofreading". All members of the pressure test team worked in unison and in coordination, providing a solid guarantee for the high-quality and timely commissioning of the unit. Zhou Guisong said, "Our team takes turns to stand guard at the scene, our eyes fixed on the pressure curve, not daring to take a single step away." The final pressure test was successful, not only breaking the record but also solving the pain points of high risk and long time consumption in high-voltage tests in the industry. This is the confidence of Shengu Manufacturing!"


On the Gobi Desert, the wind and sand are strong, the temperature difference is large, and the working area is small. Multiple specialties carry out cross-construction, and every step is like ";dancing on the tip of a needle". Lu Wei, the on-site security inspection project manager, spent over three months tackling the tough task of installation. He introduced: "The installation accuracy of this unit is at the hairline level. From pipe purging, bolt tightening to unit alignment, not a single mistake is allowed."; We worked in shifts around the clock, braving the sandstorm and extreme temperature differences, breaking down the construction plan into the smallest units, strengthening multi-party collaboration, and meticulously refining the precision with meticulous care." From installation, commissioning to trial operation, Lu Wei and his team were on duty throughout: "Parameters were adjusted step by step, data was reviewed group by group, and problems were solved one by one." In the end, the unit was successfully put into operation at one go. Hearing the sound of the equipment running smoothly, all of us heaved a sigh of relief. This is Shengu Service. No matter how difficult the scene is, we can get through it and ensure success!"


From the Gobi Desert and wasteland to the front line of energy supply security, from the small blueprint to the major national equipment, Shenyang Blower Group has written a brilliant stroke in the picture of self-reliance and strength in China's equipment manufacturing industry. The successful development and application of the 40-megapascal high-pressure centrifugal gas injection compressor is not an end but a new beginning.


Looking to the future, Shenyang Blower Group will always keep in mind the "major issues of the country", adhere to its original aspiration and mission of "serving the country through science and technology and strengthening the nation through forging", continue to focus on the core technology research and development of large turbine compressor units, constantly break through the "bottleneck" technologies, and contribute to the high-quality development of China's energy equipment with more original and leading technological achievements. Contribute the strength of Shengu to ensuring national energy security and building a manufacturing power!