Breaking Monopoly & Forging Core Equipment: The "Chinese Heart" for Ultra-Deep Gas Storage Reservoirs —— Development Story of 40 MPa High-Pressure Centrifugal Gas Injection Compressor by SBW Group
On April 23, good news came from Tarim Oilfield: Yaha Gas Storage, China’s largest ultra-deep gas storage reservoir, officially commenced gas injection operations. As the core equipment of this "underground energy bank", China’s first complete set of 40 MPa high-pressure centrifugal compressor unit independently developed by Shenyang Blower Works Group (SBW) has completed commissioning and been put into service. Equipped with this state-of-the-art equipment, the daily gas injection capacity of the gas storage reservoir exceeds 10 million cubic meters, which has thoroughly broken the long-term foreign monopoly in the field of ultra-high pressure gas storage facilities.
As China’s first in-service deep condensate gas storage reservoir, Yaha Gas Storage sets stringent requirements for gas injection compressors in terms of pressure rating, displacement and operational stability. The equipment needs to withstand a pressure of 40 MPa, equivalent to the pressure 4,000 meters beneath the sea surface. Its daily gas injection volume must meet the energy storage demands of ultra-deep reservoirs, and it is required to operate stably for a long time under extreme temperature differences and harsh working conditions in the Gobi Desert. At that time, there were no mature technologies or similar equipment for reference domestically, making the R&D challenge the "Mount Everest" of the industry. The road to development was inevitably full of difficulties.
"We really started from scratch. There were no domestic operating records for 40 MPa compressors, and even reference materials were scarce," recalled Dong Hao, an engineer at the Turbine Design Institute and the chief designer of the project. He led the whole technical tackling work. "We conducted comprehensive research covering performance, structure, materials and skid-mounted design, and revised the design plan for more than a dozen times. To withstand ultra-high pressure, we innovatively adopted a barrel-type structure for the compressor and applied newly developed model impellers. We also made continuous optimizations through rotor dynamics analysis. The most challenging part was thrust calculation. We optimized calculation programs and simulated hundreds of working conditions, and finally solved the tough problem of axial thrust." From drawing design and manufacturing to delivery and on-site commissioning, Dong Hao kept a close watch on every link. "We dared not overlook any parameter or structural detail, for we aimed to build a world-class pioneering product made in China. When all tests were passed and performance indicators fully met the standards, all our efforts were worthwhile."
"The hydrostatic test pressure reached 63 MPa, a new record for gas storage equipment developed by SBW. Any improper pressure control would lead to potential risks," said Zhou Guisong, leader of the pressure testing team in the Stator Workshop. His team took on the toughest challenges head-on. "The unit features a complex structure with numerous ultra-high pressure sealing points, where even minor sealing defects would cause leakage. Stepped and slow pressure rise was required, while flange deformation and excessive casing stress posed major hidden dangers. We carried out dozens of simulated tests to refine every detail." To ensure absolute safety, the team adopted an intelligent monitoring system and new-type high-pressure sealing structures, and implemented a three-level verification mechanism of operation, review and inspection. All team members worked in full solidarity, guaranteeing the high-quality delivery of the unit on schedule. "We worked in shifts around the clock, keeping a close eye on the pressure curves without stepping away. The one-off successful pressure test not only set a new record, but also solved the industry-wide pain points of high risks and long cycles in high-pressure testing. This is the solid strength of SBW manufacturing."
"The Gobi Desert is characterized by strong wind, drastic temperature fluctuations and limited working space. Multi-disciplinary cross construction made every procedure as demanding as 'dancing on the tip of a needle'." Lu Wei, Project Manager for on-site safety supervision, spent more than three months completing the tough installation work. "The installation precision of this compressor is as fine as a hair’s breadth. Any mistake in pipeline purging, bolt tightening or unit alignment would affect the overall performance. We worked round the clock in shifts, braving sandstorms and extreme temperatures. We broke down the construction plan into detailed steps, strengthened multi-party coordination, and pursued ultra-high precision with meticulous craftsmanship." Lu Wei and his team stayed on site throughout installation, commissioning and trial operation. "We adjusted parameters step by step, analyzed every set of data and solved problems one by one. The successful one-off commissioning was a huge relief for all of us. With reliable SBW services, we are capable of delivering successful results no matter how tough the on-site conditions are."
From the desolate Gobi Desert to the frontline of energy supply guarantee, from blueprints to national core equipment, SBW has written a brilliant chapter in the journey of self-reliance and self-improvement of China’s equipment manufacturing industry. The successful R&D and application of the 40 MPa high-pressure centrifugal gas injection compressor is not an end, but a new starting point.
Looking ahead, SBW Group will always bear in mind the country’s major strategic needs and stay true to its original aspiration of serving the nation through science and technology and strengthening the country with superior equipment. The Group will continue to make breakthroughs in core technologies for large turbine compressor units, break through technological bottlenecks that restrict industrial development, and deliver more original and leading technological achievements. It will contribute to the high-quality development of China’s energy equipment sector, safeguard national energy security, and fuel the development of a manufacturing powerhouse with solid SBW strength.
