SSome new insights to efficient design ome new insights to ...research.nigc.ir/Portal/images/images_research/files/8thcongress/... · Gas Turbines •Nuovo Pignone M5238C ... •Zorya

RIPI: RIPI: 26 26 February February 20132013

Some new insights to efficient design Some new insights to efficient design of gas processing and transmission of gas processing and transmission

plantsplants

NigcNigc R&D symposiumR&D symposium

Some new insights to efficient design of gas processing and transmission plants

Overview

New design of compressor stations

Power generation in GPRS of compressor stations

Energy integration in existing compressor stations

Active control of surge in gas compressors


Industrial Gas Turbine

Fuel Gas

Centrifugal Compressor

Station Inlet

Station Outlet

Recycle sy

stem

1- NEW DESIGN OF COMPRESSOR STATIONS

J-T valve

Heater


GT3 GC3

GT2 GC2

GT1 GC1

Heat Recovery Steam Generator

GC4ST

condenser

Stand byStand by





ParameterNG saving per

annumBudget price

CO2

reduction

Unit MMSCM MUS$ Ton/year

KHONJ 47.73 45 94135

JAHROM 45.6 43 89058

ARSANJAN 44.71 43 87355

ARDESTAN 36.36 36 68906

DEHSHIR 36.34 37 71271

NODOOSHAN 40.67 43 78840

KASHAN 40.59 44 78525

Total 292 291 568090

Note: Net investment for IGEDC is about 136 MUS$Note: Net investment for IGEDC is about 136 MUS$



Note: Net investment for IGEDC is about Note: Net investment for IGEDC is about 136 136 MUS$MUS$

ParameterIGEDC net

Investment costSaved NG worth Reduced CO2 worth

Total

income

Unit MUS$ MUS$ /Year MUS$/Year MUS$/Year

KHONJ 20 14.319 0.94135 15.26035

JAHROM 18 13.68 0.89058 14.57058

ARSANJAN 18 13.413 0.87355 14.28655

DEHSHIR 17 10.902 0.71271 11.61471

NODOOSHAN 23 12.201 0.7884 12.9894

ARDESTAN 16 8.7264 0.551248 9.277648

KASHAN 24 9.7416 0.6282 10.3698

The most optimistic economic outlook-full load operation



2- POWER GENERATION IN GPRS OF COMPRESSOR STATIONS


Gas Composition Based on IGS-CH-033(0):2004

Gas Turbines

• Nuovo Pignone M5238C

• Siemens SGT600

• Zorya UGT25000

•Zorya UGT16000

Compressor Stations

• Gathered Data

Capacity – Inlet & Exit Pressure – Height – Gas Turbine

• Data from Simulation

Gas Turbine Power, Load, Efficiency and Fuel consumption

Gas Turbine Type

Fuel

Pressure

(bar)

Fuel

Temperature

(°C)

Nuovo Pignone M5238C 19 25

Siemens SGT600 24.5 10

Zorya UGT25000 35 20

Zorya UGT 16000 24.5 20



Compressor Stations Data; A Sample Case: FARASHBAND-2

Nominal

Capacity

(MSCMD)

Inlet

Pressure

(bar)

Exit

Pressure

(bar)

Height

(m)

Gas

Turbine

Type

Arrange

-ment

Gas

Turbine

Fuel Gas

Pressure

(bar)

Gas Turbine

Fuel Gas

Temperature

(°C)

79 48 84 762.3 M5238C 4+1 19 25

A

B

Gas Compressor

Gas compressor

Gas Compressor

Gas Compressor

AFTER COOLER

Ambient pressure 0.9251 barAmbient temperature 15 CAmbient RH 40 %Gross power 0 kWGross electric efficiency(LHV) 0 %

2

17°

18°

19°

20°

21°

22

235

6

7

24

26

25

8GE M5382C

9GE M5382C

10GE M5382C

27GE M5382C

11

12

13

28

29

14

15

16

30

31

1

33

34

3536

37

38

3

13

14

15

16

174

5

6

18

20

19

7

8

9

21

10

11

12

22

231

2

26

27

28

29

30

31

32

33

34

Each Gas

Turbine Power

Generation

(kW)

Each

Gas

Turbine

Load

(%)

Each Gas

Turbine

Efficiency

(%)

Each Gas

Turbine Fuel

Consumption

(kg/s)

Total Fuel

Consumption /

Turboexpander Flow

(kg/s)

20516 81.23 28.39 1.607 6.428



Electrical Network Data

Compressor Stations Existing Substations

20 kV to 400 V

Turboexpander Power Generation Level

LV → 400 V

Connection to Grid

• 400 V (through the existing substation)

• Automatic

- Export to Grid

- Import from Grid


Assume η = 0.8

Calculate SHP;

SHP = 1.41ṁΔhη

Determine N

(From Diagram I)

Calculate NS;

Look up New η

(From Diagram II)

Diagram I

Diagram II



A Sample Case: FARASHBAND-2

Parameter Symbol Unit Value

Station / Turboexpander Inlet Pressure P1 bar 48

Station / Pre-heater Inlet Temperature T0 °C 24

Pre-heater Exit / Turboexpander Inlet Temperature T1 °C 75

Gas Turbines Fuel / Turboexpander Flow mf kg/s 6.428

Gas Turbines Fuel / Turboexpander Discharge Pressure P2 bar 19

Gas Turbines Fuel / Turboexpander Discharge Temperature T2 °C 25

Required Input Heat to Gas Q0 kW 839.9

Input Heat Considering Pre-heater Efficiency Q kW 1199.9

Turboexpander Speed N rpm 31125

Turboexpander Specific Speed NS - 40.78

Turboexpander Efficiency ηTE % 78.87

Electrical Power Generation W kW 631.3

First-Law Thermal Efficiency ηth % 52.61



Power Generation Calculations

Rank Station Name Power HeatThermal

Efficiency

W

(kW)

Q

(kW)

ηth

(%)

1 FARASHBAND-2 631.3 1199.9 52.61

2 NOORABAD-3 567.7 1091.3 52.02

3 PATAVEH-2 528.6 1008.6 52.41

4 DORAHAN-2 474.7 915.1 51.87

5 DAHAQ-2,3 398.8 554.3 71.95

6 SAFASHAHR 389.3 582.0 66.89

7 KHONJ 382.8 592.9 64.56

8 FARASHBAND-3 352.9 512.4 68.87

9 ESFAHAN-2 333.8 578.3 57.72

10 SHAHREZA 320.7 487.9 65.73

11 NOORABAD-2 303.0 533.3 56.82

12 QOM-3 295.8 387.9 76.26

13 KHAVARAN 267.5 507.6 52.70

14 QOM-2 265.0 504.6 52.52

15 PATAVEH-3 256.3 353.4 72.52

16 ESFAHAN-3 255.6 346.1 73.85

17 DORAHAN-3 252.5 348.4 72.47



Why Using Gearbox?

Case Study; FARASHBAND-2

Heater Turboexpander Gearbox Generator

Heat (kW)Speed

(rpm)

Specific

Speed

(-)

TypeEfficiency

(%)

Mechanical

Power

(kW)

Efficiency

(%)

Efficiency

(%)

Electrical

Power

(kW)

Thermal

Efficiency

(%)

1119.9 31125 40.78 Radial 78.87 671.0 97 97 631.3 52.61

715.4 3000 3.93 Axial 42 331.6 - 97 321.7 44.97



Total Fuel Saving PotentialSummary of Power Generation and Heat Consumption

Turboexpander

(New Design)

Expansion Valve

(Current Situation)

Station NamePower

(kW)

Heat

(kW)

Power

(kW)

Heat

(kW)

FARASHBAND-2 631.3 839.9 0 321.9

NOORABAD-3 567.7 763.9 0 310.7

PATAVEH-2 528.6 706 0 294.8

DORAHAN-2 474.7 640.6 0 263.0

DAHAQ-2,3 398.8 388.0 0 86.16

SAFASHAHR 389.3 407.4 0 98.15

KHONJ 382.8 415.0 0 105.6

FARASHBAND-3 352.9 358.1 0 84.30

ESFAHAN-2 333.8 404.8 0 172.5

SHAHREZA 320.7 341.5 0 86.74

NOORABAD-2 303.0 373.3 0 155.4

QOM-3 295.8 271.5 0 57.75

KHAVARAN 267.5 355.3 0 145.4

QOM-2 265.0 353.2 0 142.9

PATAVEH-3 256.3 247.4 0 54.30

ESFAHAN-3 255.6 242.3 0 52.84

DORAHAN-3 252.5 243.9 0 53.53



Economic OUTLOOK

Investmen

t cost

(MUS$)

Water Bath Heater for

Expansion Valve Case

Electrical Heater for

Expansion Valve Case

Station NameNG Saving

(MSCM/year)

Saved NG price

(MUS$/year)

NG Saving

(MSCM/year)

Saved NG price

(MUS$/year)

FARASHBAND-2 1.471902 1.053390 0.316017 1.617315 0.485195

NOORABAD-3 1.334991 0.961775 0.288533 1.505990 0.451797

PATAVEH-2 1.251125 0.908120 0.272436 1.424595 0.427379

DORAHAN-2 1.135330 0.805920 0.241776 1.266550 0.379965

DAHAQ-2,3 0.972248 0.694960 0.208488 0.845705 0.253712

SAFASHAHR 0.952039 0.661380 0.198414 0.833295 0.249989

KHONJ 0.938095 0.644225 0.193268 0.829280 0.248784

FARASHBAND-3 0.873832 0.606995 0.182099 0.754820 0.226446

ESFAHAN-2 0.832607 0.605170 0.181551 0.907390 0.272217

SHAHREZA 0.804517 0.544945 0.163484 0.696785 0.209036

NOORABAD-2 0.766727 0.541295 0.162389 0.813585 0.244076

QOM-3 0.750964 0.527060 0.158118 0.628530 0.188559

KHAVARAN 0.690339 0.457345 0.137204 0.712115 0.213635

QOM-2 0.684971 0.450410 0.135123 0.700800 0.210240

PATAVEH-3 0.666291 0.447490 0.134247 0.542755 0.162827

ESFAHAN-3 0.664674 0.450045 0.135014 0.542755 0.162827

DORAHAN-3 0.658207 0.440920 0.132276 0.534725 0.160418

Total 15.44886 10.80145 3.240437 15.15699 4.547102



3- Energy integration in existing compressor stations

Industrial Gas Turbine

Fuel Gas

Centrifugal Compressor

Station Inlet

Station Outlet

Kick

Back

Sy

stem

0.85$

1$

0.15$

More than More than 62 62 units older than units older than 35 35 years years (already retired) with such a performance:(already retired) with such a performance:


3- Energy integration in existing compressor stations


4- surge active control in gas compressors

Gas compressor has to follow the downstreamGas compressor has to follow the downstream



-50 0 50 100 150 200 250 300 350 4001

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

Mass flow (kg/s)

Pre

ssu

re r

atio

Generatedspeed lines

Surge Line

Existing speed lines

-100 0 100 200 300 400 5001.6

1.65

1.7

1.75

1.8

1.85

1.9

Mass flow (kg/s)

Pre

ssu

re R

ise

operating condition

Surge Line

40 50 60 700

1

2

3

4x 10

4

t (s)

To

rqu

e (

N.m

)

0 20 40 60 80 100700

800

900

1000

t (s)

spe

ed

(ra

d/s

)

0 50 100

1.55

1.6

t (s)

Pre

ssu

re R

ise

0 20 40 60 80-200

0

200

400

600

t (s)

Ma

ss

Flo

w (

kg/s

)



50 100 150 200 250 300 350 4001.3

1.35

1.4

1.45

1.5

1.55

1.6

1.65

1.7

1.75

1.8

Mass flow (kg/s)

Pre

ssure

Ris

e

Design Speed

Max. Speed

Maximum turn down ratio: Customized for refrigeration circuits (LNG) and injection to wells


Thanks for your attention

Documents

SSome new insights to efficient design ome new insights to ...research.nigc.ir/Portal/images/images_research/files/8thcongress/... · Gas Turbines •Nuovo Pignone M5238C ... •Zorya