FOXTROT

COMPRESSOR
STUDY
FOXTROT
Compressor
System
Review Study
May 7th,2015

TABLE OF CONTENT
Background
Objectives
Production Profile
Case Study
Block Diagram
Liquid Carry Over
Adequacy Check Vessel
Adequacy Check Fin-fan Cooler
Trim Cooler Reactivation or Refrigerant
Replacement
Fuel Gas System Review
Compressor System Review
Summary & Recommendation

BACKGROUND
To check and review existing FOXTROT
Compressor system any issue regarding:
1. Stripping Down and Bearing Capsule
Replacement due to ingress liquid carry
over
to compressor in ECHO and LIMA.
2. Future flowrate condition and changes S.G.

OBJECTIVE
a.Check Liquid Carryover to compressor system.
b.Adequacy Check of Vessel and Fin-fan Cooler.
c.Review Reactivation of Trim Cooler/Refrigerant
regarding Corrosion Issue.
d.Review the Compressor Performance.
e.Review Fuel Gas System.

PRODUCTION PROFILE

Future Case Train B

Reactivation

Max production
of total fluid

CASE STUDY
1) Current Case

a.Current Operating based on site survey data (29-Jan-2015)

b.1 Train Compressor Running
c.Trim Cooler is inactive

2) Future Case

a.Maximum Gas flowrate refer to Production Profile

b.2 Trains Compressor running
c.Trim Cooler is inactive or Trim Cooler Reactivation and or
Replaced Refrigerant

Train
Flowrate,
MMSCFD
SG, (-)

CurrentCase FutureCase
(*)

(**)

DesignCase

19.07

20.77

21.94

22.66

20.42

0.970

1.076

1.076

1.016

0.947

(*) 1 Train Compressor is running

(**) 2 Trains Compressor are running

BLOCK DIAGRAM

FFB,FN

CURRENT

9.89 MMSCFD

FUTURE

31.70 MMSCFD

CURRENT

1.48 MMSCFD (*)

FUTURE

2.84 MMSCFD (**)

Fuel Gas
FOXTRO
T

Gas Lift

FA,FG &
FK
CURRENT

9.17 MMSCFD

CURRENT

17.58 MMSCFD (*)

FUTURE

8.56 MMSCFD

FUTURE

37.82 MMSCFD

Note:
*)
One train compressor is running
**)
Two trains compressor are running

LIQUID CARRY OVER

LIQUID CARRY OVER

Liquid Carry Over issue to compressor for Current and Future Case

There are liquid

coming from HAL200 and MBF-300,
400 to 2nd stage
scrubber

There is liquid coming

from liquid outlet 2nd
stage scrubber to 1st
scrubber.

Current case:
- 1 train running
- Anti-surge
valve is open
5%.
Future case:
- 2 trains running
-Recycle and
Anti-surge
valve closed.

Mitigation : Liquid content

can be separated by mist
extractor at 1st and 2nd stage
scrubber
No Liquid Carry Over
to compressor for
Current & Future Case

10

VESSEL ADEQUACY CHECK

11

VESSEL ADEQUACY CHECK

Parameter

Unit

FP-V7

FP-V1B

MBF
100/110

MBF
200/210

MBF
300/310

MBF
400/410

Gasflowrate

MMscfd

241

21.6

21.11

21.94

21.6

18.76

Liquidflowrate

BFPD

273.7

1278

142.1

1371

327

1821

OperatingP/T

psig/0F

82/120

85/67

69/87

400/145

700/115

700/115

Existing

lb/ft-s2

201.7

442

421.8

1928

2310

2652

Maximu
m

lb/ft-s2

4000

4000

10002

10002

10002

10002

Existing

in

20

16

16

Required

in

9.5

8.9

12.9

12.1

7.4

7.7

Existing

in

20

16

16

Required

in

10.5

9.4

10.2

7.03

5.9

5.9

Existing

in

Required

in

0.5

1.6

Required

in/ft2

5.81

12.58

45.38

30.18

3.95

3.95

Available

in/ft2

47.52

19.24

60

42

9.62

9.62

Adequate

Adequate

Adequate

Nozzle inlet
is undersized

Nozzle inlet
is
undersized

Nozzle inlet
is
undersized

Inlet
Momentum

InletNozzle

GasOutlet
Nozzle

Liquid
Outlet
Nozzle

ID/Area

Remarks

The possibility of liquid carry

over to compressor can be
reduced by the presence of
Mist extractor in scrubber.
In order to meet momentum
criteria, it is suggested to make
sure the existing inlet device
type.

Note:
1. Gas flowrate based on Max.
flowrate (Future Case).
2. Inlet device and internal
device are assumption (half
open pipe).

12

FIN-FAN COOLER ADEQUACY

CHECK

13

Adequacy Check HAL-100

Parameter
GasRate

Unit

Current
(existing1)

Current(new Future(New Design(New

cooler)
Cooler)
Cooler)

MMscfd

19.07

19.07

21.68

28.7

(1000) lb/hr

65.123

65.123

74.23

98.69

336

336

269

375

158

158

115

115

PressureDrop

psi

21.2

3.47

3.69

6.65

AllowablePressDrop

psi

10

10

10

10

Temperaturein

Temperatureout

1. Scale and leakage

at tube side is
indicated from
high pressure drop
2. The outlet
temperature is still
high.

Consider to install
new cooler.

(1000) lb/hr

500.7

500.7

500.7

500.7

98

98

98

98

141

141

141.5

182.4

inH2O

0.64

0.62

0.62

0.65

Duty

MMBtu/hr

5.164

5.172

5.233

10.164

Uactual

Btu/ft2-hr-F

3.067

2.848

2.989

3.330

Urequired

Btu/ft2-hr-F

0.826

0.831

2.374

2.988

Airflow
Temperaturein

Temperatureout

PressureDrop

Note: 1. Datasheet existing fin-fan cooler is assumed based on NEW cooler except for tube diameter & thickness.
Tube diameter & thickness is adjusted based on Pressure drop.

14

Adequacy Check HAL-200

Parameter

GasRate

Unit

Current
(existing1)

Current(new
cooler)

Future(New
Cooler)

Design(New
Cooler)

MMscfd

19.07

19.07

21.68

28.7

(1000) lb/hr

65.123

65.123

74.23

98.69

Scale and leakage at

tube side is indicated
from high pressure
drop.
Consider to install new
cooler

Temperaturein

235

234.9

203.2

240

Temperatureout

100

100

115

115

PressureDrop

psi

30.1

4.89

5.35

10.9

Airflow

(1000) lb/hr

522.3

522.3

522.3

522.3

Temperaturein

98

98

98

98

Temperatureout

129

130

125.7

148

inH2O

0.69

1.15

1.15

1.179

Duty

MMBtu/hr

3.923

3.994

2.738

6.272

Uactual

Btu/ft2-hr-F

4.345

3.922

4.142

4.472

Urequired

Btu/ft2-hr-F

3.501

2.992

2.28

4.094

PressureDrop

Note: 1. Datasheet existing fin-fan cooler is assumed based on NEW cooler except for tube diameter & thickness.
Tube diameter & thickness is adjusted based on Pressure drop.

15

TRIM COOLER REACTIVATION OR

REFRIGERANT REPLACEMENT

16

TRIM COOLER REACTIVATION

Background:
1. Trim Cooler had
been demolished (inactive condition) for
Current condition.
2. High risk corrosion
due to CO2 partial
pressure at 164 psia
(current condition).

Trim Cooler is inactive condition

FA
FG
FK

17

Trim cooler location

Past

Current (Trim Cooler had been

demolished)

18

TRIM COOLER (Sea Water ) REACTIVATION STUDY

Trim Cooler reactivation using

sea water

FA
FG
FK

19
TRIM COOLER (Refrigerant) REACTIVATION STUDY
Trim Cooler reactivation using
Refrigerant supply:
Refrigerant type is
using R14 or CF4 or
Tetrafluoromethane.

FFB
FN

Trim Cooler
equipment will be
replaced with the
new one to come up
with R14 fluid
characteristic.

Trim Cooler is replace

using Refrigerant
FA
FG
FK
Trim Cooler is active
using Seawater

20

REFRIGERATION SYSTEM PACKAGE

Compressor

GasFrom
MBF
300/310

Compressor
Oil Separator

Suction
Scrubber

Compressor
Oil Cooler
Compressor
Oil Filter
Compressor
Oil Pump

ToFlare

FOXTROT Platform has limited space and already crowded, Not

Available to Install additional Refrigerant system package.

21

TRIM COOLER REACTIVATION

CurrentCase
Parameter
Gas Flowrate
Gas Pressure
Gas Temp. inlet /
outlet
Cooler Supply
Flowrate
Cooler Supply
Temp. In/out
Cooler Duty
Temperature at
Pipeline
Water Content

Unit

CO2Partial Corrosion
Press.,psia Category

FutureCase

InactiveTrim
Cooler

Re-activation
TrimCooler

Refrigerant

MMSCFD
psig

19.07
700

40.26
721

40.26
721

100 / 100

115 / 95

115 / 80

Lb/h

330200

967400

85 / 95

70 / 81

MMbtu/hr

3.394

6.146

80

80

80

lb/MMscf

82.13

24.7

0.22

Water Dew Point

99

113

113

HC Dew Point

100

115

115

CO2 Partial
Pressure

psia

164.8

157

139

Corrosion
category

High Corrosion Risk High Corrosion Risk High Corrosion Risk

Reactivating Trim Cooler or Refrigerant will decrease water content, but the potential
corrosion impact is still high. Therefore, reactivation Trim Cooler/Refrigerant is not
recommended.

<7
7-20
>20

Low
Medium
High

22

Pros and Cons

Reactivation Trim Cooler
Refrigerant Replacement
Advantages
Disadvantages
Advantages
Disadvantages
Temperature can
be reduce to 95 F
Temperature can
Temperature
(as closed as
be reduce to 80 F
ambient
temperature)
Reduce water
Reduce water
content from
content from
Water Content
82.13 to 24.7
82.13 to 0.22
lb/MMscf
lb/MMscf
CO2 partial
CO2 partial
pressure is not
pressure is not
significantly
significantly
CO2 Partial
reduced (from
reduced (from
Pressure
164.8 to 157
164.8 to 139
psia). Corrosion
psia). Corrosion
rate is still high.
rate is still high.
Need additional
Re-install Trim
Constructability
space since the
Cooler.
area is limited
Re-install Sea
Additional
Water Pump
Equipment need
(existing Sea
to be installed to
Utility
Conclusion:
Water pump
support
In order to minimize corrosion impact, it is suggested to provide
already
refrigerant
corrosion inhibitor injection.
Parameter

23

FUEL GAS SYSTEM REVIEW

24

FUEL GAS SYSTEM REVIEW

Schematic Fuel Gas System (Current Case)

25

FUEL GAS SYSTEM REVIEW

Schematic of New Fuel Gas System (Future Case)

Consider to install new

Electric Superheater at
downstream of Fuel gas
Filter to raise the
temperature above dew
point requirement.

26

FUEL GAS SYSTEM REVIEW

Unit

Current
Case

FutureCase
(Reactivation
TrimCooler)

MMSCFD

1.464

2.928

2.928

2.928

100

95

80

80

psig

700

721

716

716

kW

36.7

68.22

35.58

23.42

60.39

26.1

11.4

6.8

7.1

psig

136

136

136

136

Not
adequat
e

Not adequate

Not adequate

Adequate

Parameter

MassFlowRate

FutureCase
(Refrigerant)

FutureCase
(UsingElectric
SuperHeater)

InletFuelGasSystem
Temperaturein
Pressurein

NewElectricSuperheater
RequiredDuty
FuelGasControlValve
Temperature
DownstreamFGCV

HCDewPoint
Temperature

Pressure
DownstreamFGCV

FUELgasQuality

Gas temperature is
not adequate as fuel
gas requirement.
Consider to install
new Electric
Superheater at
downstream of Fuel
gas Filter to raise
the temperature
requirement above
dew point
temperature.

27

ADVANTAGES AND DISANDVANTAGES

ElectricSuperheaterActivating
Advantages

Disadvantages
Limited space to install new Electric
Superheater.

Improve Fuel Gas quality (at least gas

temperature 50 0F above Dew point
temperature).

Need additional cost for purchasing of new

Electric Superheater.
Increase
operational
consumption).

cost

(power

28

COMPRESSOR SYSTEM REVIEW

29

PERFORMANCE RESULT
C2A-1/C2B-1

Parameter

Unit

Current

Future

Design

Capacity
Actual
capacity
Specific
gravity
Speed

MMscfd

19.06

20.77

22.66

ACFM

2300

2363

3373

0.9702

1.076

1.016

13569
54903

12066
44644

13640
55100

1858/2492

1683/2258

2148/2881

SuctionP/T

rpm
ft
kW/hp
%
psig/ 0F

66.77
69/85

71.99
67/38.6

72.16
50/46.7

DischargeP/T

psig/ 0F

422/336

422/267

395/328

Adequate

Adequate

Head
Power

Flow (ACFM )=
2300
Head (ft) =
5.4903e+4
Eff (%) = 66.77

Flow (ACFM )=
3373
3Head (ft) =
5.51e+4
Eff (%) = 72.16

Efficiency

Remarks

1st Stage Compressor (C2A1/C2B-1) performance is still

adequate (power requirement
less than power design) to
handle current and future case.
Re-staging is not needed.

Flow (ACFM )=
2363
Head (ft) =
4.464+4
Eff (%) = 71.99

30

PERFORMANCE RESULT
C2A-2/C2B-2
Flow (ACFM )= 507.7
Head (ft) =
1.8919e+04
Eff (%) = 71.00
Flow (ACFM )=
478.6
Head (ft) =
1.769e+04
Eff (%) = 71.85

Flow (ACFM )= 486.1

Head (ft) =
1.6105e+04
Eff (%) = 70.49

Parameter

Unit

Capacity
Actual
capacity

MMscfd
ACFM

S.g.

Speed

rpm

Head

ft

Power

kW/hp

Efficiency

Future

Design

19.06

21.94

20.42

478.6

486.1

507.7

0.9833

1.077

0.947

17328
17693
563/756
71.85

17168
16105
585/826
70.49

18919
21859
717/962
71.99

SuctionP/T

psig/ 0F

400/136

400/97.12

385/110

DischargeP/T

psig/ 0F

736/184

736/182

815/222

Adequate

Adequate

Remarks

Current

2nd Stage Compressor (C2A2/C2B-2) performance is still

adequate (power requirement
less than power design) to
handle current and future case.
Re-staging is not needed.

31

SUMMARY & RECOMMENDATION

32

SUMMARY
There is no liquid carry over to compressor.
Reactivating trim cooler or install refrigerator is not recommended.
Therefore, keep the existing configuration and inject the corrosion
inhibitor to prevent the corrosion issue.
Install new electric superheater at downstream of Fuel Gas Filter
(MAJ-700/710) to achieve the temperature as fuel gas requirement.
Since the operating point is still in the performance curve, there is
no need compressor re-staging.
Both compressors are still adequate to accommodate the changes
of future flowrate and S.G.

33

RECOMMENDATION
No.

Action

Cleaning the internal device of scrubber (MBF-200/210, MBF-300/310, & MBF400/410) to ensure has good separation performance.

Check vibration monitoring at inlet & outlet piping of scrubber & compressor to
ensure no liquid carry over.

Replaced HAL-100 with new one since outlet HAL-100 is still high temperature due to
some of tube has plugged by leakage and pressure drop is high.

Replaced HAL-200 with new one due to outlet HAL-200 under monitoring as per site
survey, some of tube has plugged by leakage and high pressure drop.

Reactivating trim cooler or install refrigerator is not recommended. Consider to use

corrosion inhibitor injection to prevent the corrosion issue.

Install new electric superheater at downstream of Fuel Gas Filter to maintain the
temperature is enough as fuel gas requirement.

PIC

Due Date

34

ATTACHMENT

35

PFD FPRO PLATFORM

Compressor System
P= 422
P= 120
psig
T = 83 oF
P= 72
psig
T = 85
o
F

P= 67
psig
TP=
= 69
77
o
F
psig

T = 85
o
F

psig
T=
P= 422
o
337
psigF

P= 415
psig
T 400
=
P=
o
115
psig F

T = 336
o
F

T = 158
o
F

C2A-1

P= 67
psig
T = 85
o
F

P= 67 psig
T = 85 oF

P= 736
psig
T=
P= 736
207 oF

psig
T = 184
o
F

P= 726
psig
T=
P= 700
115 oF

psig
T = 100
o
F

HAL-100

C2A-2

P= 675
psig
T=
P= 700
113oF

psig
T = 100
o
F

CAC

HAL-200
MBF-300

MBF-400

MBF-310

MBF-410

MBF-200

MBF-100

1st Station Recycle

2nd Station Recycle

CAC

CAC

C2B-1
FA
FG
FK

T = 136
o
F

CAC

FFB
FN
V-7

P= 400
psig
T=
P=
400
113.7
o
psig
F

C2B-2

HAL-110

V-1B
MBF-110

MBF-210

HAL-210

P= 675
psig
T=
P= 700
o
113
psigF
T = 100
o
F
Gas Lift
Fuel Gas

36

PFD FPRO PLATFORM

Compressor System
P= 422
P= 120
psig
T = 83 oF
P= 72
psig
T = 85
o
F

P= 67
psig
TP=
= 69
39
o
F
psig

T = 85
o
F

psig
T=
P= 422
o
266
psigF

P= 415
psig
T 400
=
P=
o
115
psig F

T = 336
o
F

T = 158
o
F

T = 136
o
F

CAC

C2A-1

FFB
FN

P= 736
psig
T=
P= 736
184 oF

psig
T = 184
o
F

P= 67
psig
T = 85
o
F

HAL-100

psig
T = 100
o
F

C2A-2

P= 675
psig
T=
P= 700
113oF

psig
T = 100
o
F

HAL-200
MBF-300

MBF-400

MBF-310

MBF-410

MBF-200

MBF-100

P= 67 psig
T = 85 oF

P= 726
psig
T=
P= 700
115 oF

CAC

2nd Station Recycle

V-7

1st Station Recycle

CAC

CAC

C2B-1
FA
FG
FK

P= 400
psig
T = 96
P=o 400
F
psig

C2B-2

HAL-110

V-1B
MBF-110

MBF-210

HAL-210

P= 665
psig
T=
P= 700
o
80
F
psig
T = 100
o
F
Gas Lift
Fuel Gas

37

Temperature out HAL-200

38

Adequacy Check HAL-100

Parameter

GasRate

Unit

Current
(existing1)

Current
(newcooler)

Current
(newcooler)2

MMscfd

19.07

19.07

19.07

(1000) lb/hr

65.123

65.123

65.123

1. Scale and leakage

Design
at tube side is
(newcooler)
indicated from
28.7
high pressure drop
2. The outlet
98.690
temperature is still
high.

Temperaturein

336

336

297

375

Temperatureout

158

158

115

115

PressureDrop
AllowablePress
Drop

psi

21.2

3.47

6.927

6.65

psi

10

10

10

10

Airflow

(1000) lb/hr

500.7

500.7

500.7

500.7

Temperaturein

98

98

98

98

Temperatureout

141

140.9

155

182.4

inH2O
MMBtu/hr
Btu/ft2-hr-F
Btu/ft2-hr-F

0.64
5.164
3.067
0.826

0.62
5.172
2.848
0.831

0.586
8.128
5.269
4.747

0.65
10.164
3.330
2.988

PressureDrop
Duty
Uactual
Urequired

Note: 1. Datasheet existing fin-fan cooler is assumed based on NEW cooler except for tube diameter & thickness.
Tube diameter & thickness is adjusted based on Pressure drop.
2. Trim cooler in-active.

Consider to install
new cooler.

39

DESIGN POINT OF COMPRESSOR

COMPRESSOR C2A-1/C2B-1 (Solar Centaur 40)

COMPRESSOR C2A-2/C2B-2 (Solar - Saturn 10)

40

Recycle Line entering Scrubber

From 1st Stage Comp.
Anti-surge Line

41

TRIM COOLER

42

REFRIGERANT

Compressor Control System

Located at Main Deck FPRO

Vibration Analyzer

Location

44

Finding (site visit)

2nd Stage Compressor (C2A-2)
Compressor Train A
at 2nd Stage is in
highly vibration at
2.12 mils (alarm 2.0
mils) due to rotor
imbalance (cause of
misalignment).

45

Gas Composition Analysis (current)