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Dresser -Rand A/S

NATURAL GAS Compression NTNU 2013
Customer Training

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Gas Compressor
Compressors used in OIL & GAS Industry
Emphasis on Centrifugal compressor
Thor Owe Johansen
Dresser-Rand AS

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Agenda
1. Compressor in Natural gas production & transport
2. Types and Principles
3. Centrifugal Compressor Selection process
4. Compressor Components
5. Latest developments
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Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training

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Since 1840

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Kongsberg
Where are we . . . . ?
DRAMMEN
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Dresser -Rand A/S
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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Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training

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TYPICAL OIL PLATFORM

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DRIVER
ASDS -EM
Compressor
Gear Compressor
GT
Gear Compressor
ST
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Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training

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COMPRESSOR ON KOLLSNESS
VSD- electric motor DATUM Compressors Gearbox

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COMPRESSOR TRAIN
GE LM2500+ Gas Generator
D-R VECTRA Powerturbine
Gearbox
DATUM Compressors
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Dresser -Rand A/S
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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Dresser -Rand A/S
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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Dresser -Rand A/S
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
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Dresser -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
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Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training

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Reciprocating Centrifugal
Axial
Inlet flow m
3
/h
Outlet pressure bars a
Application parameters
Offshore North Sea - large flow, high pressure

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Axial Compressor
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Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training

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Centrifugal Compressor

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Centrifugal Compressor
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Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training

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Reciprocating Compressor

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Reciprocating compressor
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Dresser -Rand A/S
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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Dresser -Rand A/S
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
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Dresser -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
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Dresser -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 Works
Centrifugal Stage
Return Bend
Guide Vanes
Return Channel
Return Bend
Impeller
Increases Velocity
Increases Static Pressure
Diffuser
Reduces Velocity
Increases Static Pressure
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Dresser -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
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Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training

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Compression
Process 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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Dresser -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)
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Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training

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avg s
m
s
d
Z T R
m
P
P
Head

=
1
[ ]

k k
m
/ ) 1 (
=
Basic Thermodynamic Equations
z = compressibility
R = Universal Gas Constant
(1545.3/Mw)
Mw = Mole Weight
k = Isentropic Exponent (Cp/Cv)
C
p
= Specific Heat at constant pressure
C
v
= Specific Heat at constant volume
Redlich Kwong equation used to calculate
compressibility(z)

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Dresser -Rand A/S
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 vibrations
Axial 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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Dresser -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
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Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training

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Compressor Control
Recycle Valve
Recycle Increases Suction Flow

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Surge!
Flow
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P
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SURGE LINE
COMPRESSOR
DESIGN POINT
100% Speed
105% Speed
90% Speed
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Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training

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Compressor
PDT
PDY FT
ASC

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4 Centrifugal Compressor components
GAS COMPRESSOR
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Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training

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Rotor Assembly
Thrust
Rotor
Impellers
Balance
Piston
Seal
Area
Shaft
Bearing
Journals
Impeller
Spacers
Drive
Coupling
Mount

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STRAIGHT THROUGH FLOW
DATUM D10R5S
Gas seals
bearing
Thrust Bearing
Gas seal
Balance piston
bearing
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Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training

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Centrifugal Flowpaths
Straight-Through or Series
Flow
P1
P3 P5 P7 P9
Balance
Piston

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Centrifugal Flowpaths
SS In
Series Flow with Sidestreams
P1
P5
SS Out
P7
P9
P3
Balance
Piston
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Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training

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Centrifugal Flowpaths
Compound Flow
P1
P5
P3 P9 P7
Balance
Piston

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Centrifugal Flowpaths
Parallel or Double Flow
P1 P1
P5 P3
P3
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Dresser -Rand A/S
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
P9 P5
P5
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Dresser -Rand A/S
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 RPM
Pressure - Vacuum to 724 bars (10,500 PSI)
Flow - 1300 to 900,000 m
3
/h
Number of stages - 1 to 10 impellers
Application parameters
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Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training

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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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Dresser -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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Dresser -Rand A/S
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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Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training

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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
Designation of centrifugal
compressors
D X Y N Z

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Size of Datums
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Dresser -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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Dresser -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
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Dresser -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 Developments
Integrated Compression System(ICS)
DATUM I Compressor package
Page: 37
Dresser -Rand A/S
NATURAL GAS Compression NTNU 2013
Customer Training

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Dresser-Rand AS
Kirkegrdsveien 45 / P.O.Box 1010,
NO-3601 KONGSBERG
www.dresser-rand.com
Thanks for your attention..