Natural Gas

Compression Course

Revised: 20th May 2004

Section 2

NG Compressor Course Content

Process Description and PFD

Equipment Data

Process
Mechanical

Chemistry and Thermodynamics

Specific Hazards, Safety and Environmental Issues
Design Features
Pre-commissioning
Commissioning
P&ID
Operation
Measurements and Performance Assessments
Controls / Trips
Normal Conditions and Flowrates
Trouble Shooting

Process Description & PFD

The natural gas compressor has two duties.
During Start-up it recycles nitrogen around the reformer start up loop so
as to heat up the front end of the reformer.

Allow steam to be added without it condensing particularly on the

catalysts

Bring the catalyst well into its operating temperature range

During normal operation it compresses the natural gas feed at times of

low supply pressure.
The compressor is steam turbine driven.

Equipment Data

Process & Mechanical

All Mechanical Data is to be taken from Nuovo Pignone

During Start up the compressor drives ca 35,000 NM3/H of Nitrogen at about

12 barg (discharge) around the Refomer startup loop

The compressor takes natural gas at down to 17.4 Barg and compresses it to a
maximum of 30.5 barg

Run the antisurge cooler fans at all times when the compressor is runing

Specific Hazards, Safety &

Environmental

One hazard could be a leak.

There are two possibilites with a leak:

A fire

The presence of H2S. This can usually be smelt. But note at higher
concentrations you may get a sharp smell after that it cannot be smelt.

An operational hazard would arise if reformed gas alone is recycled back to the
Hydrodesulphuriser D1102. Reformed gas will methanate with a very large
heat release and damage the vessel.

Expanding natural gas for fuel use causes it to go cold if it rains possibly ice
could form on the valve

Chemistry & Thermodynamics

There is no chemistry.

Compressing a gas causes it to heat up. The energy required is the energy
required to heat it up:

Tin ( Kelvin) Pout

Tout ( Kelvin)
efficiency Pin

Molar specific heats of gases during compression (say 50-150 O C): monatomic
gases about 5.5, diatomic gases about 8, triatomic about 9, and methane
about 12 Kcal/KgMol

Gamma is the ratio of Specific heats (for air = 1.28, For Natural gas 1.367)

Typical Efficiencies (Isentropic) : Recips. 75%, Centrifugal 78%, Axial 86%

Changeover on Rising or Falling NG

Pressure
Use the antisurge to effect a smooth changeover
Note the compressor suction pressure must not cause the casing
design pressure of the discharge to be exceeded.
If the compressor is running and the natural gas pressure is
rising use the antisurge to keep the compressor running until
control has been taken over by 11 PIC 219 b
If the compressor is not running and the natural gas pressure is
falling, start the compressor with the antisurge open

Pre-Commissioning
It is important that the anti-surge is set up correctly for each duty
The anti-surge limits will be different for nitrogen and natural gas
because their characteristics are different.

Commissioning
Nuovo Pignone - Use Vendor Documentation
After the compressor starts the suction pressure will go down and more
nitrogen can be added to give more mass flow around the start-up loop

Natural Gas Compressor Trips

Natural Gas Compressor Shutdown - Interlock No. 2

Any one of these Possible Causes:

Push button on trip panel

High compressor discharge temperature

High Compressor speed

Vibration

Lube oil / Seal / Mechanical Failure

Cause all of these Effects:

Natural Gas feed goes through the by-pass

Anti surge line opens

Isolate natural gas feed, suction and discharge of the compressor

Desaturator set pressure lowered C1401 should speed up.

At high capacities- May lead to partial shut down of reformer 80-115%?

Normal Conditions & Flowrates

Nitrogen at Startup:

Pressure (Suction / Discharge): N2 Utility Pressure ca 6 / 12 Barg

Temp: About 45 C

Flow: 35,000 NM3/H

After compressor starts, the suction pressure will go down and more
nitrogen can be added to give more mass flow around the start up loop

Natural Gas MAXBOL Operation

Pressure (Suction / Discharge): 18 Barg min / 30.5 Barg

Temp. min / max: 0 C (with expansion cooling)/ 35 C

Flow: 101,000

NM3/H

Troubleshooting 1
General Vibration Limits
NOTE: Use Nuovo Pigones Figures

Vibrations Frequency Cycles per

Minutre

Vibration Displacement peak to peak

Troubleshooting - 2

Most troubles are instrument troubles

Compressors/pumps High Vibration- monitor carefully shut down before

the trip condition is reached

High Oil Temperature:

Check that the cooling water flow is per specification

Check the flow of oil is correct

Check and clean oil filters

Check water content of the oil

Shut down before any trip condition is reached

On shutdown check piping

Springs still connected

shoes on sliders

Piping not against its stops

NG Compressor Course Summary

Process Description and PFD

Equipment Data

Process
Mechanical

Chemistry and Thermodynamics

Specific Hazards, Safety and Environmental Issues
Design Features
Pre-commissioning
Commissioning
P&ID
Operation
Measurements and Performance Assessments
Controls / Trips
Normal Conditions and Flowrates
Trouble Shooting