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Pression 270415
Pression 270415
CONTENT
COMPRESSION
● The gas flow enters the impeller in an axial direction and exits in a radial direction
● Well adapted to medium and high gas flowrates, but not suitable for low flowrates
● Most frequently used in the oil and gas processing units
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● The characteristic feature of an axial compressor is the axial direction of flow through
the machine
● Generallyy smaller and significantly
g y more efficient than comparable
p centrifugal
g
compressors
● Requires more stages than a centrifugal due to the lower pressure rise per stage
● The axial compressor’s capital cost is usually higher than centrifugal compressor
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● Having a casing with one or more rotating elements that either mesh with each other
such as lobes or screws, or which displace a fixed volume with each rotation.
● Because of their limited discharge
g ppressure p
performance these compressors
p are not
frequently used in the oil and gas industry, notwithstanding certain special applications
and the fact that their reliability factor and flow regularity is generally higher than for a
reciprocating machine
● Can propel gases at a wide range of flowrates,
flowrates but are not suitable for high pressures
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Discharge
HP Motive
Fluid
Fluid
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LP Suction
Fluid
● 1st step
● 2nd step
● 3rd step
● 4th stepp
DRIVER TYPES
● Electric motor
- Limits the operation of the compressor due to constant and low speed
- Not recommended in remote areas
● Gas engine
- Limited power capacity. Their use is thus restricted to small compressors (not
recommended to drive centrifugal compressors)
● Gas turbine
- Power output is limited at a reduced speed. It is not recommended to drive reciprocating
compressors because of speed-reducing gears
● Steam turbine
- Variable speed capability that allows more control of the compressor capacity or
discharge pressure
● Turboexpander
- Generally linked to low temperatures process. High pressure gas is expanded to lower its
temperature
p and pproduce work that can be used to drive the compressor
p
● Efficiency
Efficiency is defined as the ratio of work output to the work input to
d
develop
l th
the required
i dhhead.
d
- Polytropic Efficiency
• Only used for centrifugal or axial-flow compressors
• If no manufacturer information, can be estimated as follow:
COMPRESSION TERMINOLOGY
- Adiabatic Efficiency
• The work of a compressor under ideal conditions (at constant entropy)
• Correlation between adiabatic and polytropic efficiency:
• In any case,
• Typical adiabatic efficiency of
a screw compressor will be in
the range of 70 to 80%
- Reciprocating Efficiency
• ηR = 0.8 may be considered as a first estimate if no manufacturer information
available
• For centrifugal compressors ηR = 1
● Surge
- Condition of minimum flow where the developed pressure is insufficient to
overcome the discharge system resistance,
resistance results in a flow reversal and
unstable operation
- Centrifugal compressor: the surge usually occurs below 50% to 70% of
rated flow at a given speed
- Axial compressor: the surge point is around 80% - 90% of rated flow
● Stonewall / Choke
- Occurs when the compressor is operating at very high flowrates and sonic
velocity is reached at any point in the compressor, hence the flow through
the compressor cannot be increased further
- Usually would not occur below 115% - 120% of rated capacity
COMPRESSION TERMINOLOGY
● Critical Speed
- The speed of the shaft which coincides with the natural frequency of the
system.
system
- A shaft that operates above its critical speed is known as a flexible shaft,
while a shaft operating below its critical speed is known as a rigid shaft.
- The operating speed of the shaft must be at least 15% away from its
critical speed.
- The maximum continuous speed (generally equal to 105 % of the nominal
speed)
- The first critical speed (between 70 to 80 % of nominal speed)
● Seal System
- Shaft seals are provided on all centrifugal compressors to limit, or completely
eliminate, ggas leakage g along g the shaft where it p
passes through
g the casing
g
- Types of seal:
1. Labyrinth (gas)
A stream of “seal gas” is injected into each labyrinth shaft seal at a pressure
hi h th
higher than th
thatt off th
the process gas.
2. Liquid (oil)
The seal consists in two sleeves which run at close clearance to the shaft
with a liquid injected between the sleeves to flow to the seal extremities
3. Mechanical seal
A mechanical gas seal uses the process gas as working fluid to eliminate the
seal oil system.
4. Lubrification and seal-oil systems
Lubrication and seal-oil systems may be furnished as combined into one
system, or as one lubrication system having booster pumps to increase the
pressure of only the seal oil to the required sealing level.
COMPRESSION TERMINOLOGY
● Seal Leakage
- Depending on the seal type and operating pressure, gas seal leakage can
be between 62 to 480 NL/min
- Typical figures of gas seal leakage versus rotational speed
speed, seal size or
operating pressure for centrifugal compressor
● Compressors
● Drivers
● Scrubbers
● Air Coolers
● Skid
● Pressure Relief Valve for each stage
● Blowdown Valve
● Bl k V
Block Valves
l (S
(Suction
ti and
d Di
Discharge)
h )
● Check Valves
● Design Criteria
- Design Flowrate
- Gas Characteristic
- Suction and Discharge Condition (Pressure, Temperature)
● Calculation Procedure
- Determine suction condition (gas composition, pressure, temperature,
flowrate)
- Compression type selection and number of stage
- Determine approximate discharge gas temperature
- Determine approximate compression power
- Determine design condition of system
• Design Temperature : based on GS-EP-ECP-103
• Design Pressure : based on Settle Out Pressure
Note (*):
- The minimum allowable flowrate of a
centrifugal compressor is a function of the
diffuser width of the last wheel. The latter
shall be greater than 2.8 m/s
- The maximum allowable flowrate of a
centrifugal compressor is limited by the gas
velocity at compressor flange main
connection. The latter shall be lower than
28 m/s
● Compression Stages
- Compression ratio CR is defined by the relation:
where
● Iteration step
- “n” method
With the "n" method the compression power is calculated with the following
relations:
l ti
where
● Shaft Power
- Considering the mechanical power losses due to friction in bearings, seals
and speed increasing gears
gears.
where
• η is the mechanical efficiency.
m
where
• K = 0.04
API
• K = 0.015
0 015 tto 0
GB 0.04
04 ((when
h ththere iis a gearbox)
b )
● Calculation Step:
- Determine the equivalent compressibility factor of the system
● Heat Exchangers
- No special requirement. The design of heat exchangers and aircoolers is
further described in PRODEM chapters XIX-B
XIX B and XIX-D
XIX D
OPERATIONAL ASPECTS
2. Surge control
Surge can be avoided by maintaining the flow above the surge point.
Flow - ∆P control is the most widely used protection systems
It is recommended that bypass line take off to be located between the
compressor outlet and the discharge check valve.
The
Th antisurge
i valve
l iis d
designed
i d to meet the
h ffollowing
ll i criteria:
i i
• Fast opening valve
• No shutdown valve or emergency shutdown valve must be present on the
antisurge line,
line so as to make sure the antisurge valve can open and protect the
compressor in case of shutdown
OPERATIONAL ASPECTS
SAFETY ASPECTS
RECIPROCATING
● Prevention?
A process engineers,
As i we shall
h ll iindicate:
di t
- The expected pressures and flowrates throughout equipment life, so as to
foresee possible restaging
- Minimum and maximum molecular weight of the gases to be compressed,
because of the impact of this parameter on the absorbed power
OTHER TECHNOLOGY
● CO2 reinjection is one the major steps in the Carbon Capture and
Storage (CCS) process (refer to Prodem chapter XXXIII. Capture of
CO2).
CO2)
● Before being reinjected, CO2 needs to be compressed from slightly
above atmospheric pressure (2 bar abs) to around 150 bar abs. This
can usually be performed with one of the two following schemes:
- A 5 stages centrifugal compressor
- A 4 stages centrifugal compressor, compressing gas, plus a fifth stage
consisting in a pump increasing the supercritical CO2 pressure to its final
pressure before injection
● For clean gas applications such as CO2 reinjection, the maximum
discharge temperature of a centrifugal compressor shall be limited to
200°C (which is above typical maximum discharge temperature for
hydrocarbon applications)
3 MMscfd
7-8 MMscfd
7-8 MMscfd
10 11 MMscfd
10-11
Max. 1 L/MMscf
Liquid
3 MMscfd supplied
pp from ASV ≈ 3 bbl/day
y liquid
q ≈ 47 L/MMscf
CASE STUDY
● Problem identification:
- Bekapai TEK-3000 LP Compressor Frequent Shutdown due to Liquid Carry
Over
● Findings:
- No suction scrubber for LP Compressor
- Anti surge valve continuously open
● Recommendation:
- Minimize the inlet fluctuation flow therefore anti surge valve will not
continuously open
- Provide
P id suction i scrubber
bb ffor LP CCompressor (if possible)
ibl )
- Modification to tap anti surge line source from the common discharge of HP
Suction Scrubber (V-3010/V-3040)
• Drawback:
- Additional load to HP suction scrubber
• Way Forward: Further review on anti surge control system logic might be required
once the proposed modification has been implemented and to be confirmed by
compressor vendor
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i i off the
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MINUTES OF MEETING Sheet 1 of 3
No Description Action By
Meeting Objective and Background
This meeting is intended to share knowledge related to process engineering aspect of
INFO
Compression to ECP/PRO and other related entities based on PRODEM Chapter XXI. The
materials which have been presented in the meeting are available in attachment. This MoM
aims to summarize the highlights of the question-answer session of the knowledge sharing.
Meeting Discussion
2. How the compressor operates in vacuum condition (slide no. 27) INFO
Compressors can operate below atmospheric pressure (as in vacuum pump) or above
atmospheric pressure (as for major process applications) to low, medium, or high discharge
pressure. Ejectors and vacuum pumps are the most common type of compressor to be used in
vacuum condition.
Depending on the type of vacuum pumps (positive displacement or kinetic), air is either carried
away in a flow by a rotating impeller on the suction side or compressed using vaned chambers.
Positive displacement pumps use a mechanism to repeatedly expand a cavity, allow gases to
flow in from the chamber, seal off the cavity, and exhaust it to the atmosphere. This allows a
very high vacuum to be achieved at a very low flow rate. In kinetic type, Air is forced to flow
through the application of additional mechanical force. This method achieves only a relatively
low vacuum level despite a high suction rate.
Ejectors have a much simpler design compared with other vacuum generators. They are driven
purely pneumatically according to venturi principle as explained in slide 10-12.
3. Why the discharge temperature of the compressor shall not exceed 160 °C INFO
It is recommended to limit the gas temperature at compressor discharge to prevent mechanical
problems as well as safety problems. Limited discharge temperatures also reduce the fouling
tendency of the compressed gas. Besides that, less work required for a given pressure ratio by
reduction of compressor stage inlet temperature.
When discharge temperature is around 160 °C (or even less at high C6+ content), it is
recommended to consult the machinery specialist to check the compression feasibility.
4. Why CO2 needs to be compressed from slightly above atmospheric pressure (2 bar abs) INFO
to around 150 bar abs in CO2 Capture Process
CO2 capture consists of separating CO2 from combustion flue gases and also from the process
of CO2 removal using amine process so that it can be compressed and transported to a
storage site, or reinjected to the wellhead.
The CO2 is compressed in order to reach the pressure required for transport or injection. CO2
compression and transport will largely depend on injection conditions at the wellhead. The
wellhead pressure governs choice of the type of transport. There are 3 alternatives type of
transport, which are low pressure transport, multi phase transport, and dense phase transport.
LP transport, consists of initial compression of the flue gases leaving the treatment units of the
capture section at a pressure lower than the critical pressure, for example 20-25 bara, followed
by drying the flue gases before low pressure transport by pipe. At the well head, the flue gases
are compressed to the conditions required for injection at the well head. Therefore, this option
requires an installation of a wellhead compressor.
In multi phase transport, flue gases are in a two-phase state at intermediate pressures, for
example between 30 and 95 bara. The option of multiphase transport of oxy-combustion flue
gases may be considered if wellhead pressures are below this pressure level. In this pressure
range, there are uncertainties about the thermodynamics of the flue gases, and their physical
properties.
Major projects for CO2 injection use the dense phase transport of CO2 (at pressures above the
critical point for CO2 : 73.8 bara, injection at pressures above 150 bara). Dense phase
transport is frequently chosen because the dense phase has intermediate properties between
those of a liquid and a gas, in particular very low head losses due to friction, which are very
advantageous in the case of transport over long distances (several hundred km).
After compression to pressures above the critical pressure, the gas is dewatered and then
transported to the well head by a pipe. At the well head, the gas is reheated and then (if
necessary) depressurised in such a way as to reach the conditions required for gas phase
injection. The dense phase flue gas transport system makes it possible to avoid installation of
compressor at the well head.
The main disadvantages of dense phase flue gas transport are:
• The pressure required for transport which is very much greater than that actually required for
injection at the well head,
• Installation of a reheating system at the well head to compensate for thermal losses along the
pipe and a depressurisation at the well head, if necessary,
• More flue gas in the pipeline than the case of LP transport. This factor has a major impact on
calculations of dispersion in the event of a leak from the pipeline and on operational aspects
during start-up and shut-down, pressurisation and depressurisation of the pipe,
• A hydrostatic head loss associated with the profile of the pipe, which can sometimes
counteract the expected benefits of dense phase transport.
Attachment :
Attendance list
Presentation slides