Gas Compressor

NATURAL NATURAL GAS GAS Compression Compression – NTNU 2013

Gas Compressor Compressors Compre ssors used in OIL OIL & GAS Industr Industry y Emphas Emp hasis is on Cen Centri trifug fugal al com compre presso ssorr Thor Owe Johansen Johansen Dresser-Rand AS

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Agenda 1.

Compressor in Natural gas production production & transport

2.

Types and Principles

3.

Centrifu Centrifugal gal Compres Compressor sor Selection Selection process process

4.

Compress Compressor or Compone Components nts

5.

Latest developments

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Customer Training Training

Page: 1 ©Dresser -Rand A/S


Since 1840

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3

Kongsberg

Where are we . . . . ?

DRAMMEN

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Since 1840

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3

Kongsberg

Where are we . . . . ?

DRAMMEN

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What Wh at do does es a Co Comp mpre ress ssor or do ?



Redu Re duce ce volu olume of gas gas

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Incr Increa ease se pres pressu sure re of gass gass

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Control pressure pressure in process

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GAS FROM RESERVIOR TO LAND

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NATURAL GAS Compression – NTNU 2013

TYPICAL OIL PLATFORM

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DRIVER

Compressor

ASDS -EM

Gear

Compressor

GT

Gear

Compressor

ST 3 1 0 2 t h g i r y p o C ©

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COMPRESSOR ON KOLLSNESS VSD- electric motor

Gearbox

DATUM Compressors

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COMPRESSOR TRAIN GE LM2500+ Gas Generator D-R VECTRA Powerturbine Gearbox DATUM Compressors

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Gas turbine Driven Generator (30 MW)

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Gas turbine Driven Compressor(30 MW)

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Gas turbine Driven Compressor (30 MW)

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Gas turbine Driven Compressor (30 MW)

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Compressor train (reinjection)

60,3 b 63,5 b 285 b

282 b

131 b 20,5 b 134 b

485 b 3 1 0 2 t h g i r y p o C ©

Centrifugal compressor

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2 TYPES AND PRINCIPLE

• Compressor Type

• Centrifugal - principle

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Compressor Types

• Axial - large flow, low pressure • Centrifugal - large to medium flow, high presssure • Helical Screw - low flow, low pressure • Reciprocating - medium to low flow, high pressure

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Application parameters Outlet pressure bars a

• Offshore North Sea - large flow, high pressure

Reciprocating

Centrifugal Axial

Inlet flow m3 / h

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Axial Compressor

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Centrifugal Compressor

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Centrifugal Compressor

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Reciprocating Compressor

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Reciprocating compressor

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Helical Screw Compressor

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Basic Principles

• Centrifugal Action

• A Centrifugal Stage • Energy Conversion

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Centrifugal Action

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Centrifugal Action

Velocity Relationship

A

Exit Path B

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Centrifugal Action Cover

Blades

Disk

High Velocity, Higher Pressure Gas Outlet

Low Velocity, Low Pressure Gas Inlet

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Impellers

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DIFFUSOR From impellers gas flows in to diffuser

Diffusor

Diffuser converts kinetic energy to pressure energy

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How A Centrifugal Works Centrifugal Stage

Return Bend

Return Bend

Diffuser Reduces Velocity Increases Static Pressure

Return Channel

Impeller Increases Velocity Increases Static Pressure

Guide Vanes

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A Centrifugal Stage 

IMPELLER

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Transfer energy - pressure and speed

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DIFFUSOR

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Converts kinetic energy to pressure

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GAS COMPRESSOR

3 – Centrifugal Compressor Selection process

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Compression Process from study to startup 

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Study: “need for Compression”: (4 years) 

Gate 1: - Concept and selection of Compressor and Driver

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Gate 2: - Pre-FEED (Front-End Engineering Design)

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Gate 3: - FEED

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Gate 4: - Post- FEED and RFQ

Production: (42 – 52 weeks) 

Production of Compressor and test, delivered to Shipyard

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Installation on Module at ship-yard (1 year)

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Whole module to Site (1-2 years)

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Comissioning at Site (1 year)

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Target Production normally after 8-10 years.

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• Total cost approx. 8M EURO 35

Selection Process 

Inputs required for centrifugal compressor selection 

Typically Know: • Ts inlet • Ps inlet • Pd outlet • Flow (Q) • Gas composition • Driver type (Gas Turbine, Steam Turbine, Motor)

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Selection Process 

Selection Process 

Aerodynamic Selection and Optimization • Impeller Requirements (including Stress)

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Mechanical Design • Coupling size • Bearing and Seal sizes

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Rotordynamic Design • Could reselect coupling, bearings, seals

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Polytropic Work (Head)

COURTESY OF BILL FORSTHOFFER

Customer Training

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Basic Thermodynamic Equations   P  m    d  − 1    Ps   Head =   × R × T s × Z avg m      

m=

[(k − 1) / k ] η

z = compressibility R = Universal Gas Constant

Redlich Kwong equation used to calculate compressibility(z)

(1545.3/Mw) Mw = Mole Weight k = Isentropic Exponent (Cp/Cv) Cp = Specific Heat at constant pressure Cv = Specific Heat at constant volume 3 1 0 2 t h g i r y p o C ©

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Customer Training



Some Rotor dynamic terminology: Axial vibrations Torsional vibrations

y

z

x

Lateral vibrations

Concepts used in Rotor Dynamics: • Basic principles of vibrations • Knowledge of how a fluid film bearing works • Influence of bearings on the dynamics of the machine • Influence of labyrinth and damper seals on the dynamics of the machine

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Some Rotor dynamic terminology: • Rotor: rotating element consisting of shaft, impellers/disks, shrunk-on components like sleeves, balance piston, etc. • Bearings: Journal bearings support the rotor in the lateral direction. (Thrust bearings support the axial load of the rotor while in operation.)

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Customer Training



Some Rotor dynamic terminology (Contd.): Natural frequency: Frequency at which the system vibrates. The frequency of vibration of a system (e.g. rotor-bearing system) with damping is called the damped natural frequency.

• Critical speed: Is a natural frequency with an ‘active enough’ response that the natural frequency should be designed around.

• Stability: The stability of a system is defined as the “reaction” to any external perturbation. 3 1 0 2 t h g i r y p o C ©

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Customer Training



Compressor Control Recycle Valve

Recycle Increases Suction Flow

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Surge!

t n e i c i f f e o C e r u s s e r P c i p o r t y l o P

SURGE LINE

COMPRESSOR DESIGN POINT

105% Speed 100% Speed

90% Speed

Flow

Customer Training

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ASC

FT

PDY

PDT

Compressor 3 1 0 2 t h g i r y p o C ©

GAS COMPRESSOR

4 – Centrifugal Compressor components

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Rotor Assembly Balance Piston Impellers Drive Coupling Mount

Shaft Thrust Rotor

Bearing Journals

Impeller Spacers Seal Area

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STRAIGHT THROUGH FLOW DATUM D10R5S

Thrust Bearing

bearing

Gas seals

Balance piston

Gas seal

Customer Training

bearing

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Centrifugal Flowpaths

P5

P3

P7

P9

Balance Piston P1

Straight-Through or Series Flow

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Centrifugal Flowpaths SS In

P3

SS Out

P5

P7

P9

Balance Piston P1

Series Flow with Sidestreams 3 1 0 2 t h g i r y p o C ©

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Centrifugal Flowpaths P7

P3

P9

Balance Piston

P5

P1

Compound Flow

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P5

P3

P1

P1

Parallel or Double Flow

Customer Training

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P9

P5

P1

Back to Back Flow with No Cooler

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P9

P5

P1

Back to Back Flow with a Cooler

Customer Training

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APPLICATIONS Application parameters Applications / Services 3 1 0 2 t h g i r y p o C ©

Application parameters

Gases - All types of gases Speed - 3,500 to 26,500 RPM Pressure - Vacuum to 724 bars (10,500 PSI) Flow - 1300 to 900,000 m3 /h Number of stages - 1 to 10 impellers

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Customer Training



Designation of centrifugal compressors

Horizontal split

Vertical split 3 1 0 2 t h g i r y p o C ©

Types of multi-stages centrifugals

Radially split

Axially split 3 1 0 2 t h g i r y p o C ©

Customer Training



Types of multi-stages centrifugals

Axially split compressor on test

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Sizes of compressors

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Different scales

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Designation of centrifugal compressors The name DATUM is an acronym of : Dresser-Rand Advanced Turbo Machine. The name is made of 5 components as follows : DXYNZ 3 1 0 2 t h g i r y p o C ©

Customer Training



Designation of centrifugal compressors DXYNZ D : always ‘ D ’ for Datum X : frame size, one or two digits, 2 through 28 in step of 2 Y : case split design as follows : ‘ R ’ for Radial (Barrel type) ‘ A ’ for Axial (Horizontal type) N : total number of impellers, one or two digits Z : casing configuration as follows : ‘ S ’ for straight through , compound or side stream ‘ B ’ for back to Back arrangement ‘ D ’ for double flow arrangement

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Size of Datums

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COMPRESSOR ACESSORIES - COMPONENTS 

Compressor

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Lube oil system

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Gasseal system – gas or oil

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Gear and Couplings

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Driver - el. motor, gasturbine, steam turbine

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Foundation skid

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Prosess- anti-surge valve, scrubber and cooler

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Instrumentation and control system

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GAS COMPRESSOR

5 – Centrifugal Compressor latest develoments

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Latest Developments 

Compact integral Motor driven compressor

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Latest Developments 

Compact integral Motor driven compressor - High speed Electrical motors - No gearbox - Magnetic bearings that eliminate need for oil lubrication - Reduced footprint - digital controls instead of analog controls - Emission-free design

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Latest Developments Integrated Compression System(ICS)

DATUM I Compressor package

Customer Training

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