Gas Compressor

Page: 1Dresser -Rand A/S

NATURAL GAS Compression NTNU 2013

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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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3

Since 1840

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Kongsberg

Where are we . . . . ?

DRAMMEN



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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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TYPICAL OIL PLATFORM

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DRIVERASDS -EM

Compressor

Gear CompressorGT

Gear Compressor

ST



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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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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)

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



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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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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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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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A

B

Velocity Relationship

Exit Path

Centrifugal Action



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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



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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



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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



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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

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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)



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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)



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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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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.)



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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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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



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Compressor

PDT

PDYFT

ASC

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4 Centrifugal Compressor components

GAS COMPRESSOR



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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



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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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Compound Flow

P1

P5

P3 P9P7

BalancePiston

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Parallel or Double Flow

P1 P1

P5 P3P3



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P1 P5

Back to Back Flow with No Cooler

P5 P9

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P1

P9P5

P5



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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



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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



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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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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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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



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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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5 Centrifugal Compressor latest develoments

GAS COMPRESSOR

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Compact integral Motor driven compressor

Latest Developments



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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



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Dresser-Rand ASKirkegrdsveien 45 / P.O.Box 1010,

NO-3601 KONGSBERGwww.dresser-rand.com

Thanks for your attention..

Gas Compressor

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