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(5.1)
where;
P1, P2 = gas pressures at states 1 and 2, respectively
V1, V2 = gas volumes at states 1 and 2, respectively
C = constant
5.1.2 Isoentropic Compression
The compression process is adiabatic reversible or isoentropic if the gas behaves as an ideal gas, no
heat is added to or removed from the gas during compression, and the process is frictionless. The
pressure-volume behavior of a gas under isoentropic compression or expansion is given by:
58
k
k
P1V 1 = P 2 V 2 = C
(5.2)
where;
k = the isoentropic exponent, which is equal to the ratio of the specific heat at constant
pressure (Cp) and the specific heat at constant volume (Cv) for the gas:
k=
Cp
Cv
(5.3)
(5.4)
where;
R = universal gas constant.
Cp and Cv are functions of temperature only for ideal gases. For real gases, however, Cp and Cv are
functions of both pressure and temperature.
P 2
)
T v
C p - C v = -T P
(
)
V T
(
(5.5)
(5.6)
where;
W = work done by the compressor on the gas,
P = pressure,
V = volume of a unit mass of gas,
z = elevation above a datum plane,
lw = lost work due to friction and irreversibility,
g = gravitational acceleration,
gc = conversion constant relating mass and weight,
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(5.7)
Neglecting frictional losses, and the changes in kinetic and potential energies, the energy balance of
Equation 5.7 can be written as:
W = P12 Vdp
P
(5.8)
W = C k P12 p k dP
P
(5.9)
1
(k -1)
(k -1)
k
C k [ P 2 k - P1 k ]
k -1
(k -1)
k
k
C k P2
W=
P1 ( ) [( )
k -1
P1
P1
- 1]
(5.10)
(5.11)
k
P2 k
W=
P1V 1 [( ) - 1]
k -1
P1
(5.12)
(5.13)
W = R T1
k -1
k
( r k - 1)
k -1
(5.14)
where;
r = compression ratio (P2/P1)
This analysis assumed an ideal gas. Where deviation from ideal gas behavior is significant, Equation
5.14 empirically modified in several different ways. One such modification is:
k -1
k
P2 k
z1 + z 2
W = R T1
[( ) - 1](
)
k - 1 P1
2 z1
60
(5.15)
where;
z1 and z2 = compressibility factors of the gas at inlet and outlet conditions.
During compression the discharge temperature of the gas changes and can be estimated by the
following formula.
k -1
P2 k
T2
=( )
P1
T1
(5.16)
where;
T1 and T2 = temperature of the gas at the inlet and outlet conditions.
5.1.5 Multi-staging
There are practical limits to the permissible amount of compression for a single compression stage.
The limitations vary with the type of compressor, and include the following:
- Discharge temperature.
- Compression efficiency.
- Mechanical stress problems.
- Compression ratio.
Whenever any limitation is involved, it becomes necessary to use multiple compression stages (in
series). Furthermore, multi-staging may be required from a purely optimization standpoint. For
example, with increasing compression ratio r, compression efficiency decreases and mechanical
stress and temperature problems become more severe. Inter-coolers are generally used between the
stages to increase compression efficiency as well as to lower the gas temperature that may become
undesirably high.
Theoretically minimum power requirement is obtained with perfect inter-cooling and no pressure
loss between stages by making the ratio of compression the same in all stages. The following
formula uses the overall compression ratio,
1
P final s
)
rs = (
Pinitial
(5.17)
where;
s = number of stages
rs = theoretically best compression ratio per stage
5.1.6 The reciprocating compressor
The basic reciprocating compression element is a single cylinder compressing only on side of
the piston (single acting). A unit compressing on both sides of the piston (double acting)
consists of two basic single acting elements operating in parallel in one casting.
The reciprocating compressor uses automatic spring-loaded valves that open only when the
proper differential pressure exists across the valve. Inlet valves open when the pressure in the
cylinder is slightly below the intake pressure. Discharge valves open when the pressure in the
cylinder is slightly above the discharge pressure.
Figure 5.1, diagram A, shows the basic element with the cylinder full of atmospheric air. On
the theoretical PV diagram (indicator card), point 1 is the start of compression. Both valves are
closed.
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Diagram B shows the compression stroke, the piston having moved to the left, reducing the
original volume of air with an accompanying rise in pressure. Valves remain closed. The PV
diagram shows compression from point 1 to point 2, and that the pressure inside the cylinder
has reached that in the receiver.
Diagram C shows the piston completing the delivery stroke. The discharge valves opened just
beyond point 2. Compressed air is flow out through the discharge valves to the receiver.
After the piston reaches point 3, the discharge valves will close leaving the clearance space
filled with air at discharge pressure. During the expansion stroke, diagram D, both the inlet and
discharge valves remain closed and air trapped in the clearance space increases in volume
causing a reduction in pressure. This continues, as the piston moves to the right, until the
cylinder pressure drops below the inlet pressure at point 4 .The inlet valves now will open and
air will flow into the cylinder until the end of the reverse stroke at point 1. This is the intake or
suction stroke, illustrated by diagram E. At point 1 on the PV diagram, the inlet valves will
close and the cycle will repeat on the next revolution of the crank.
In a simple two-stage reciprocating compressor, the cylinders are proportioned according to
the total compression ratio, the second stage being smaller because the gas, having already
being partially compressed and cooled, occupies less volume than at the first stage inlet.
Looking at the PV diagram (Figure 5.2), the conditions before starting compression are points
1 and 5 for the first and second stages, respectively; after compression, points 2 and 6, and,
after delivery, 3 and 7. Expansion of air trapped in the clearance spaces as the pistons reverse
brings points 4 and 8, and on the intake stroke the cylinders are again filled at points 1 and 5
and the cycle is set for repetition. Multiple staging of any positive displacement compressor
follows the above pattern.
Compression Cycles
Two basic compression cycles that are applicable to all compressors are isothermal
compression and adiabatic compression. A third process, polytropic compression, is widely
used, but, since it is a modification involving an efficiency to more nearly represent actual
conditions, it is not a true basic cycle.
Figure 5.3 shows the theoretical zero clearance isothermal and adiabatic cycles on a PV basis.
The area ADEF represents the work required when operating on the isothermal basis; and
ABEF, the work required on the adiabatic basis. Obviously the isothermal area is considerably
less than the adiabatic and would be the cycle for greatest compression economy. However, it
is never commercially possible to remove the heat of compression as rapidly as it is generated.
Therefore, this cycle is not as logical a working base as the adiabatic although it was used for
many years. Compressors are designed, however, for as much heat removal as possible.
Adiabatic compression is likewise never exactly obtained, since with some types of units there
may be heat losses during part of the cycle and a gain in heat during another part. For this
reason, polytropic compression cycle is generally used.
The polytropic exponent, n, is experimentally determined for a given type of machine and may
be lower or higher than the adiabatic exponent, k. In positive displacement and internally
cooled dynamic compressors n is usually less than k. In uncooled dynamic units it is usually
higher than k due to internal gas friction. Although n is actually a changing value during
compression, an average or effective value, as calculated from experimental information is
used.
62
In addition to the isothermal and adiabatic compression curves shown in Figure 5.3, the dotted
lines show typical polytropic curves for a water-cooled reciprocating cylinder (AC) and for a
non-cooled dynamic unit (AC').
Although the exponent n is seldom required, the quantity n-l/n is frequently needed. This can
be obtained from the following equation, although it is necessary that the polytropic efficiency
P be known from prior test. The k value of any gas or gas mixture is either calculable or
known.
n 1 k 1 1
=
n
k
P
(5.18)
where P is the polytropic compression efficiency. Figure 5.4 solves this equation in curve
form.
If, either n or n-l/n is known, the discharge temperature can be estimated from the following
equation. Figure 5.5 will be useful for this purpose.
T2 P2
=
T1 P1
n 1
n
=r
n 1
n
(5.19)
2
g
+
X = q w
2g c g c
(5.20)
where AH is the increase in enthalpy between initial and final states, 2nd term of the left hand
side is the difference in kinetic energy and 3rd term is the change in potential energy . Q is the
heat absorbed by system from surroundings and w is work done by the fluid while in flow.
63
Kinetic energy and potential energy due to differences in elevation are usually neglected,
leaving
H = q w
(5.21)
(5.22)
or
w = H TS
(5.23)
(5.24)
where H is in Btu per pound mole and S is in Btu peer pound mole per degree Rankine.
By following a line of constant temperature on an enthalpy-entropy diagram between initial and
final pressure conditions, H and S can be determined.
In the case of adiabatic compression, q of Equation 5.21 is also zero; so
w = H
(5.25)
That is, at adiabatic or constant-entropy conditions for a single stage of compression, the work
necessary to compress the gas is equal to the difference in enthalpy between the initial and final
stages of compression.
Expressing the adiabatic theoretical work necessary to compress 1 MMscf/day at 60 F and 14.
7 psia results in
w = 0.0432H
(5.26)
where H is expressed in Btu per pound mole. For multistage compression the H must be
calculated separately for each stage and totaled.
In addition to the horsepower, the final temperature of compression and the heat removed in
the intercoolers can be obtained from enthalpy-entropy diagrams.
The procedure for calculating horsepower from an enthalpy-entropy diagram can be best
shown diagrammatically. Point 1 in Figure 5.13 is the initial state of the gas as it enters the
compressor. Path l-2 shows the first stage of compression (constant entropy). The gas is then
cooled in the intercoolers at constant pressure (path 2-3); the difference in enthalpy along this
path is equal to the heat removed in the intercooler. Path 3-4 shows the second stage of
compression. The temperatures at points 2 and 4 are the temperatures of the gas at the end of
64
the first and second stages of compression. The temperature at point 3 is the temperature to
which the gas is cooled in the intercooler.
5.2 GAS FLOW MEASUREMENTS
Because of the evident importance of accurate measurement of the quantity of gas delivered,
various technical societies have combined their efforts to arrive at standards and procedures for
quantitative measurement of gas that are mutually acceptable to both purchasers and sellers of gas
products. Also, there is interest in the orifice meter throughout industry in general.
Two general classes of metering devices are available for measuring gas rates: dynamic and
volumetric meters (Table 5.1). For measuring large volumes, the orifice flow meter is the primary
type. In these meters, the pressure drop occurring at a restriction indicates the flow rate. With the
exception of domestic or space heating sales, essentially all measurements are based on orifice meter
The second class of meter, which is used for domestic sales, is the volumetric meter; this meter
receives mechanically a definite volume of gas from an upstream source, counts the volume, and
discharges it downstream. However, to make this volumetric measurement more meaningful, base
or standard pressure and temperature conditions are defined that yield measurement in standard
cubic feet. The most common basis is the AGA and API recommended pressure of 14.73 psia and
o
temperature of 60 F.
Table5.1 Principal Types of Gas Flow Meters
Dynamic measurement
Orifice meter
Venturi meter
Flow nozzle
Critical-flow prover
Pitot tube
Rotameter
Choke
Volumetric Measurement
Diaphragm meter
Laboratory wet-test meter
Gas is most commonly measured in terms of volume because of the simplicity of such a procedure.
However, to make this volumetric measurement more meaningful, base or standard pressure and
temperature conditions are defined that yield measurement in standard cubic feet. This volumetric
rate can be converted to mass flow rate by multiplying with the gas density at the standard pressure
and temperature conditions. Since the gas density at the standard pressure and temperature is a
constant for the particular gas under consideration, measurements in standard cubic feet are
synonymous to mass flow rate measurements.
Flow is one of the most difficult variable to measure, because it cannot be measured directly like
pressure and temperature. It must be inferred by indirect means, such as pressure differential over a
specified distance, speed of rotation of a rotating element, displacement rate in a measurement
chamber, etc.
5.2.1 Attributes of Flow Devices
A flow-meter or measurement device is characterized using the following parameters:
- Accuracy
- Rangeability
- Repeatability
- Linearity
Accuracy: This is a measure of a flow-meter's ability to indicate the actual flow rate within a
65
specified flow-rate range. It is defined as the ratio of the difference between the actual and measured
rates to the actual rate.
ABS [Actual rate - Measured rate]
Accuracy = 100 (%)
Actual rate
Accuracy is reported in either of two ways: percent of full scale, or percent of reading. For example,
for a 100 MMscfd flow-meter, a 1% of full scale accuracy means that the measured flow rate is
within 1 MMscfd of the actual flow rate, regardless of the value of the flow rate. Thus, for a
measured flow rate of 10 MMscfd, the actual flow rate is between 9 and 11 MMscfd, and for a
measured rate of 100 MMscfd, it is between 99 and 101 MMscfd. An accuracy of 1 % of reading,
however implies that the measured flow rate is within 9.9 to 10.1 MMscfd for a measured rate of 10
MMscfd, 49.5 to 50.5 for a measured rate of 50 MMscfd, 99 to 101 MMscfd for a measured rate
of 100 MMscfd, etc. Thus, the percent reading results in a better overall performance because the
error is proportional to the magnitude of rate. Orifice meters and rotameters have a percent of fullscale accuracy in their specifications.
Rangeability: A flow-meter's rangeability is the ratio of the maximum flow rate to the minimum
flow rate at the specified accuracy.
Maximum flow rate that can be measured
Rangeability =
Minimum flow rate that can be measured
Rangeability is usually reported as a ratio X:1. For example, a meter with maximum and minimum
rates of 10 and 50 MMscfd, respectively, for a specified accuracy of 1%, has a rangeability of 5:1.
Thus, it is important to know the flow rate range over which a quoted rangeability applies.
Repeatability: Also known as reproducibility or precision, repeatability is the ability of a meter to
reproduce the same measured readings for identical flow conditions over a period of time. It is
computed as the maximum difference between measured readings, sometimes expressed as a
percent of full scale. Note that repeatability does not imply accuracy; a flow-meter may have a good
repeatability, but a lower overall accuracy.
Linearity: This is a measure of the deviation of the calibration curve of a meter from a straight line.
It can be specified over a given flow rate range, or at a given flow rate. A calibration curve is
desirable because it leads to a constant metering accuracy, with no portion of the scale being
relatively more or less sensitive than the other. Note that a flow-meter could have a good linearity,
but poor accuracy if its calibration curve is offset (shifted).
5.2.2 Measurement by Orifice Meters
This is by far the most commonly used device for metering natural gas. It consists of a flat metal
plate with a circular hole, centered in a pair of flanges in a straight pipe section (Figure 5.14). The
pressure differential is measured across this plate to yield the flow rate.
The relationship for orifice meters can be derived from the general energy equation, written between
two points in the flowing stream- Point 1 being some point upstream of the orifice plate, and point 2
representing the orifice throat:
2
1 VdP +
1 2
g 2
1 vdv + 1 dz = ws - l w
gc
gc
where;
66
(5.27)
1 Vdp +
1 2
vdv + l w = 0
gc 1
(5.28)
Incorporating the friction loss term lw in the compression-expansion term to avoid the complexity of
referring to the friction factor, and multiplying both sides by fluid density , we get :
2
C 2 1 dP +
1 2
vdv = 0
gc 1
(5.29)
C 2 ( P2 - P1 )+
av 2 2
( v 2 - v1 ) = 0
2 gc
(5.30)
P1 - P 2
av
(5.31)
(5.32)
Substituting for v in Equation 5.31, recognizing that v1 is measured at area A1, the pipe, and v2 at
A2, the orifice; and defining b = Dorifice / Dpipe, one obtains Equation 5.33.
m = C A2
2 g c av ( P1 - P2 )
4
1-
(5.33)
The value of C in Equations 5.31 and 5.33 varies with the area ratio b as well as with the flow rate.
Figure 5.15 shows values of C, based on data with liquids, with the variation in flow rate given as a
67
Reynolds number through the orifice. For liquids at appreciable velocities, the orifice coefficient
becomes 0.610.
Equation 5.31 may be reduced to a single velocity v1 or v2 by inserting a function of b as follows.
2 g c ( P1 - P 2 )
4
(1- ) av
(5.34)
2 g c ( P1 - P 2 )
4
(1- ) av
(5.35)
v1 = v pipe = C
v 2 = v orifice = C
29G P
zRT
(5.36)
The average values of pressure, temperature, and compressibility factor from points 1 to 2 in the
meter should be used. It is customary to use either the upstream pressure or the downstream
pressure, the flowing temperature, and the compressibility factor at the temperature and the
pressure selected.
In using an orifice formula for thousands of measurements each day, it is necessary to devise
calculation procedures that can be followed easily in a routine manner. This has been done for the
orifice formula, with the development of a series of factors or corrections that can be taken from
tables.
To convert Equation 5.33 into units and form similar to those used for natural gas, the following
conversions will be made.
Q=
(379)(3600)m
29G
(5.37)
where;
Q = gas flow at standard conditions, cuft/hr
G = gas gravity
m = mass velocity, lb/sec
Combining Equations 5.33, 5.36, and 5.37,
Q=
( P1 - P2 )29GP
(3600)(379) C A2
g
2
c
4
29G
zRT
1-
68
(5.38)
Q=
(3600)(379) 64.34C A2
29 R G T z 1-
( P1 - P2 )P
(5.39)
Since the differential pressure h is measured in inches of water and (P1 - P2) is in pounds per square
foot,
h=
( P1 - P2 )12
62.43
(5.40)
62.43h
12
(5.41)
P1 - P 2 =
Q=
(5.42)
This equation gives the flow volumes computed at base conditions of 60 F and 14.7 psia. Since
other base conditions may be used on occasion, factors are used to convert base conditions.
F pb =
14.7
Pb
(5.43)
F tb =
Tb
520
(5.44)
for Tb in R.
o
It is customary to establish the value to give Q, for a flowing temperature of 60 F, a gas gravity of
1.0 and a compressibility factor of 1.0. To do this, the standard values are inserted.
1
520 1 1 1
=
T G z 520
GTz
(5.45)
Therefore;
Q=
(5.46)
The numerical constants C, b, A2 are grouped as a single constant Fb. The other factors are defined:
69
520
T
(5.47)
Fg =
1
G
(5.48)
F pv =
1
z
(5.49)
F tf =
where;
Ftf = The flowing temperature factor
Fg = The gas gravity factor
Fpv = The supercompressibility factor
Equation 5.37 thus becomes,
Q = F b F tb F pb F tf F g F pv hP
(5.50)
where;
Q = gas flow rate, cuft/hr
h = orifice differential, in. of water
P = pressure of gas at orifice, psia.
The flowing pressure and temperature are taken normally as upstream values. The expansion of the
gas through the orifice is essentially adiabatic. Under these conditions, the density of the stream
changes because of the pressure drop and the adiabatic temperature change. An expansion factor Y,
computed for the adiabatic and reversible case, is included in the formula to correct for this variation
in density.
The values of C, and hence of Fb, vary with the Reynolds number and the diameter ratio b.
Correction factors for variations in Reynolds numbers are given as Fr, with Fb considered to be a
constant for a given meter installation.
The density of the gas opposite the mercury influences the differential indicated. Since the
calibration is normally made at or near atmospheric pressure, corrections should be used for the gas
density at high pressures. This correction factor is Fm is
Fm =
Hg - f
Hg
where;
Hg= the density of mercury
f= the density of the fluid opposite the mercury column in the meter.
The complete orifice equation recommended by AGA is
70
(5.51)
Q = F b F r Y F pb F tb F tf F g F pv F m hP
(5.52)
1
Tables of the above factors are provided by the AGA and are given by Katz et. al .
To obtain the quantity of gas flowing through an orifice meter from the above equation and the
AGA tables, the following data are required:
- Diameter of pipe
- Diameter of orifice
- Differential across meter
- Pressure on meter
- Flowing temperature
- Gas gravity
- Carbon dioxide and nitrogen content of gas
- Type of meter, pipe or flange taps.
REFERENCE
1. Katz, D,L., D.Cornell, R. Kobayash , F.H. Poettmann, J.A. Vary, J.R. Elenbaas, and C.F.
Weinaug, Handbook of Natural Gas Engineering, McGraw-Hill Publishing Co., New York, pp.
751-763 (1959).
71
72
Figure 5.3 Theoretical indicator card showing various gas compression processes.
73
75
76
77
78
Figure 5.13 Example of use of enthalpy-entropy diagram to find adiabatic work of compression.
79
80