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Gas Compressors used in the Oil and Gas Industries
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Page: 1Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training
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Gas CompressorCompressors used in OIL & GAS Industry
Emphasis on Centrifugal compressor
Thor Owe JohansenDresser-Rand AS
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Agenda
1. Compressor in Natural gas production & transport 2. Types and Principles3. Centrifugal Compressor Selection process4. Compressor Components5. Latest developments
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NATURAL GAS Compression NTNU 2013
Customer Training
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3
Since 1840
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Kongsberg
Where are we . . . . ?
DRAMMEN
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NATURAL GAS Compression NTNU 2013
Customer Training
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Reduce volume of gas
Increase pressure of gass
Control pressure in process
What does a Compressor do ?
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GAS FROM RESERVIOR TO LAND
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NATURAL GAS Compression NTNU 2013
Customer Training
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TYPICAL OIL PLATFORM
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DRIVERASDS -EM
Compressor
Gear CompressorGT
Gear Compressor
ST
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NATURAL GAS Compression NTNU 2013
Customer Training
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COMPRESSOR ON KOLLSNESS
VSD- electric motor DATUM CompressorsGearbox
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COMPRESSOR TRAINGE LM2500+ Gas GeneratorD-R VECTRA Powerturbine
GearboxDATUM Compressors
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NATURAL GAS Compression NTNU 2013
Customer Training
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Gas turbine Driven Generator (30 MW)
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Gas turbine Driven Compressor(30 MW)
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NATURAL GAS Compression NTNU 2013
Customer Training
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Gas turbine Driven Compressor (30 MW)
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Gas turbine Driven Compressor (30 MW)
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NATURAL GAS Compression NTNU 2013
Customer Training
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Compressor train (reinjection)
20,5 b
63,5 b
60,3 b
134 b
131 b
285 b 282 b
485 b
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Centrifugal compressor
Page: 9Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training
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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
Page: 10Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training
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Reciprocating CentrifugalAxial
Inlet flow m3/h
Outlet pressure bars a
Application parameters
Offshore North Sea - large flow, high pressure
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Axial Compressor
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NATURAL GAS Compression NTNU 2013
Customer Training
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Centrifugal Compressor
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Centrifugal Compressor
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NATURAL GAS Compression NTNU 2013
Customer Training
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Reciprocating Compressor
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Reciprocating compressor
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NATURAL GAS Compression NTNU 2013
Customer Training
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Helical Screw Compressor
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Basic Principles
Centrifugal Action A Centrifugal Stage Energy Conversion
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NATURAL GAS Compression NTNU 2013
Customer Training
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Centrifugal Action
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A
B
Velocity Relationship
Exit Path
Centrifugal Action
Page: 15Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training
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Low Velocity, Low Pressure
Gas Inlet
High Velocity, Higher Pressure
Gas Outlet
Cover Blades Disk
Centrifugal Action
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Impellers
Page: 16Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training
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DIFFUSOR
Diffusor
Diffuser converts kinetic energy to pressure energy
From impellers gas flows in to diffuser
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How A Centrifugal WorksCentrifugal Stage
Return Bend
Guide Vanes
Return Channel
Return Bend
ImpellerIncreases Velocity
Increases Static Pressure
DiffuserReduces Velocity
Increases Static Pressure
Page: 17Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training
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A Centrifugal Stage
IMPELLER Transfer energy
- pressure and speed
DIFFUSOR Converts kinetic energy to
pressure
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3 Centrifugal Compressor Selection process
GAS COMPRESSOR
Page: 18Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training
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CompressionProcess from study to startup
Study: need for Compression: (4 years) Gate 1: - Concept and selection of Compressor and Driver Gate 2: - Pre-FEED (Front-End Engineering Design) Gate 3: - FEED Gate 4: - Post- FEED and RFQ
Production: (42 52 weeks) Production of Compressor and test, delivered to Shipyard
Installation on Module at ship-yard (1 year) Whole module to Site (1-2 years) Comissioning at Site (1 year) Target Production normally after 8-10 years.
Total cost approx. 8M EURO
35
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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)
Page: 19Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training
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Selection Process Selection Process
Aerodynamic Selection and Optimization Impeller Requirements (including Stress)
Mechanical Design Coupling size Bearing and Seal sizes
Rotordynamic Design Could reselect coupling, bearings, seals
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COURTESY OF BILL FORSTHOFFER
Polytropic Work (Head)
Page: 20Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training
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avgs
m
s
d
ZTRm
PP
Head
=
1 [ ]
kkm
/)1( =
Basic Thermodynamic Equations
z = compressibility
R = Universal Gas Constant (1545.3/Mw)
Mw = Mole Weight
k = Isentropic Exponent (Cp/Cv)Cp = Specific Heat at constant pressure
Cv = Specific Heat at constant volume
Redlich Kwong equation used to calculate compressibility(z)
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40
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NATURAL GAS Compression NTNU 2013
Customer Training
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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
x
y
z
Torsional vibrationsAxial vibrations
Lateral vibrations
Some Rotor dynamic terminology:
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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.)
Page: 22Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training
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Some Rotor dynamic terminology (Contd.):
Stability: The stability of a system is defined as the reaction to any external perturbation.
Critical speed: Is a natural frequency with an active enough response that the natural frequency should be designed around.
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.
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45
Page: 23Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training
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Compressor ControlRecycle Valve
Recycle Increases Suction Flow
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Surge!
Flow
Poly
tro
pic
Pres
sure
C
oef
ficie
nt SURGE LINE
COMPRESSORDESIGN POINT
100% Speed
105% Speed
90% Speed
Page: 24Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training
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Compressor
PDT
PDYFT
ASC
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4 Centrifugal Compressor components
GAS COMPRESSOR
Page: 25Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training
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Rotor Assembly
Thrust Rotor
Impellers
Balance Piston
SealArea
Shaft
Bearing Journals
ImpellerSpacers
Drive Coupling
Mount
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STRAIGHT THROUGH FLOW DATUM D10R5S
Gas sealsbearingThrust Bearing Gas seal
Balance pistonbearing
Page: 26Dresser -Rand A/S
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Customer Training
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Centrifugal Flowpaths
Straight-Through or Series Flow
P1
P3 P5 P7 P9
BalancePiston
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Centrifugal FlowpathsSS In
Series Flow with Sidestreams
P1
P5
SS Out
P7 P9P3
BalancePiston
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NATURAL GAS Compression NTNU 2013
Customer Training
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Centrifugal Flowpaths
Compound Flow
P1
P5
P3 P9P7
BalancePiston
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Centrifugal Flowpaths
Parallel or Double Flow
P1 P1
P5 P3P3
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NATURAL GAS Compression NTNU 2013
Customer Training
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Centrifugal Flowpaths
P1 P5
Back to Back Flow with No Cooler
P5 P9
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Centrifugal Flowpaths
P1
P9P5
P5
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NATURAL GAS Compression NTNU 2013
Customer Training
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APPLICATIONS
Application parameters Applications / Services
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Gases - All types of gases Speed - 3,500 to 26,500 RPMPressure - Vacuum to 724 bars (10,500 PSI) Flow - 1300 to 900,000 m3/hNumber of stages - 1 to 10 impellers
Application parameters
Page: 30Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
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Horizontal split Vertical split
Designation of centrifugal compressors
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Axially split
Radially split
Types of multi-stages centrifugals
Page: 31Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training
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Axially split compressor on test
Types of multi-stages centrifugals
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Sizes of compressors
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NATURAL GAS Compression NTNU 2013
Customer Training
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Different scales
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The name DATUM is an acronym of :
Dresser-Rand Advanced Turbo Machine.
The name is made of 5 components as follows :
D X Y N Z
Designation of centrifugal compressors
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NATURAL GAS Compression NTNU 2013
Customer Training
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D : always D for DatumX : frame size, one or two digits, 2 through 28 in step of 2Y : case split design as follows :
R for Radial (Barrel type) A for Axial (Horizontal type)
N : total number of impellers, one or two digitsZ : casing configuration as follows :
S for straight through , compound or side stream B for back to Back arrangement D for double flow arrangement
Designation of centrifugal compressors D X Y N Z
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Size of Datums
Page: 34Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training
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Compressor Lube oil system Gasseal system gas or oil Gear and Couplings Driver - el. motor, gasturbine, steam turbine Foundation skid Prosess- anti-surge valve, scrubber and cooler Instrumentation and control system
COMPRESSOR ACESSORIES- COMPONENTS
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Page: 35Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training
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5 Centrifugal Compressor latest develoments
GAS COMPRESSOR
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Compact integral Motor driven compressor
Latest Developments
Page: 36Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training
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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
Latest Developments
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Latest DevelopmentsIntegrated Compression System(ICS)
DATUM I Compressor package
Page: 37Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training
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Dresser-Rand ASKirkegrdsveien 45 / P.O.Box 1010,
NO-3601 KONGSBERGwww.dresser-rand.com
Thanks for your attention..