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Research Article
Gas Compressor Station Economic Optimization
Rainer Kurz,1 Matt Lubomirsky,1 and Klaus Brun2
1 Solar
2 Southwest
1. Introduction
The economic success of a gas compression operation
depends to a significant extent on the operation of the
compressors involved. Important criteria include first cost,
operating cost (especially fuel cost), life cycle cost, and
emissions. Decisions about the layout of compressor stations
(Figure 1) such as the number of units, standby requirements, type of driver, and type of compressors have an
impact on cost, fuel consumption, operational flexibility,
emissions, as well as availability of the station.
3. Maintenance Cost
Maintenance cost includes the parts and labor to keep the
equipment running at or above a certain power level. This
includes routine maintenance (like change of lube oil and
spark plugs in gas engines) and overhauls. Maintenance
events can be schedule or condition based. A cost related to
maintenance eort is the cost due to the unavailability of the
equipment (see below). Maintenance aects availability in
two ways. Many, but not all, maintenance events require the
shut down of the equipment, thus reducing its availability.
Scheduled maintenance has usually less of an eect than
unscheduled events. For example, a scheduled overhaul of
a gas turbine may keep the equipment out of operation for
only a few days if an engine exchange program is available.
On the other hand, insucient or improper maintenance negatively aects the availability due to more rapid
performance degradation and higher chance of unplanned
shutdowns.
5. Emissions
6. Availability
Availability is the ratio between the hours per year when the
equipment is supposed to operate and actually can operate
and the hours per year where the equipment is supposed to
7. Compressor Operation
The relationship between pressures and flows in any given
application that employs gas compressors as well as some
other factors may influence the arrangement of compressors
in a station as well as the type of equipment used. The
question about series or parallel arrangements in a station
has to be considered both in the light of steady-state
aerodynamic performance, as well as regarding transient
behavior, spare strategy, and growth capabilities. Not only
the full load behavior of the driver, but also its part-load
characteristics influence areas like fuel consumption and
emissions. Since greenhouse gas emissions from CO2 for a
given fuel gas are only influenced by the overall eciency
of the operation, there is a strong tie between eciency and
emissions.
Dierent concepts such as the number of units installed,
both regarding their impact on the individual station and
the overall pipeline and the necessity of standby units are
discussed. The number of compressors installed in each
compressor station of a pipeline system has a significant
impact on the availability, fuel consumption, and capacity of
the system. Depending on the load profile of the station, the
answers may look dierent for dierent applications.
The operating point of a compressor is determined by
a balance between available driver power, the compressor
82%
85%
A
85%
82%
78%
Sur
ge
lim
it
Isentropic head
87%
74%
82%
85%
Pipeline
characteristic
85%
Sur
ge
lim
it
Isentropic head
82%
78%
87%
Available
power
74%
Cold day
Hot day
Max. power
Inlet volume flow
Before After
looping
84%
86%
86%
84%
Sur
ge
lim
it
81%
Isentropic head
In case of a pipeline, the operating point of the compressor is always determined by the power available from
the driver (Figure 3). In the case of a gas turbine driver, the
power is controlled by the gas producer speed setting and the
pipeline characteristic. We find this point on the compressor
map at the intersection between the pipeline characteristic
and the available power. Increasing the flow through a
pipeline will require more power and more compressor head.
The change of operating conditions over time is due to
many reasons, such as drop in field pressure, the pipeline gets
looped or has to meet an increase in capacity. Looping the
pipeline will change the characteristic of the pipeline to allow
more flow at the same head requirement. So, any change
in the pipeline operation will impact power requirements,
compressor head or pressure ratio, and flow. Operational
changes may move the compressor operating point over time
into regimes with lower eciency. Fortunately, centrifugal
compressors driven by gas turbines are very flexible to
automatically adapt to these changes to a degree.
As indicated, variable speed drivers allow for ecient
operation over a large range of conditions. If a constant speed
driver has to be used, the adjustment of the compressor
to the required operation usually has to rely on the use of
recycling and suction or discharge throttling. Either method,
while eective, is not very ecient: throttling requires the
compressor to produce more head than required by the
process, thus consuming more power. On a compressor
speed line, throttling will move the compressor to a point
at lower flow than the design point. Recycling forces the
compressor to flow more gas than required by the process
and thus also consumes more power. It thus allows the
compressor to operate at a lower head than the design
head. In general, an electric motor for a constant speed
drive has to be sized for a larger power than a motor for a
variable speed drive under otherwise the same conditions.
Furthermore, starting of constant speed motors requires
to oversize the electric utilities, especially if a start of a
pressurized compressor is desired.
77%
Sur
ge
lim
it
Isentropic head
Steady state
before
shutdown
(time 1)
82.46%
83.18%
82.52%
80.7%
71.2%
14300
14000
13000
Immediately
12000
after
10000
shutdown
(time 7.6)
Inlet volume flow
1.2
Load variation
1
0.8
0.6
0.4
100
95
90
85
80
75
70
65
60
55
50
50
0.2
60
70
80
90
100
Load (%)
0
0
96
192
288
384
480
Hours
Series 1
Series 2
Series 3
the relative load, that is, what percentage of gas turbine full
power PGT,max available at the given ambient conditions and
the required compressor speed is required by the centrifugal
compressor (Kurz and Ohanian [6]):
Pcompr = W
Hs
+ Pmech .
s
(1)
Load(%) =
Pcompr
100.
PGT,max
(2)
PGT
.
GT
(3)
7
Present value, including fuel, 500 MM
2000
1900
100
Present value ($MM)
120
80
60
40
1800
1700
1600
1500
1400
1300
1200
1100
20
1000
9
10
11
0
72
74
76
78
80
82
12
13
14
15
16
Number of stations
1000 psi-34 in
1500 psi-28 in
2200 psi-24 in
Figure 9: Optimum number of stations and optimum maximum operating pressure (MAOP) for the 3220 km (2000 mile),
560000 Nm3 /h sample pipeline. The lowest cost configurations for
each MAOP solution are marked (from [7]).
82% 85%
85%
Sur
ge
lim
it
Isentropic head
Design
Point
Pipeline
Resistance
82%
78%
87%
74%
4 smaller
units
2 larger
units
Max. power
Inlet volume flow
Figure 10: Impact of loss of one unit for the 4 unit and the 2 unit
scenarios.
9
much higher overall eciency. Thus, shutting both units
down reduces the pipeline fuel consumption compared to
the scenario with only one unit shut down in station 2. The
point of this example is, the failure of one of two large units
in a compressor station has more significant consequences
than the failure of a smaller unit in a station with three or
more operating units. Or, in other words, scenarios with 3
ore more units per station without spare units tend to have a
higher flow if one of the units fails or has to be shut down for
maintenance, than scenarios with 2 units per station without
spare units.
15. Conclusion
The paper has illustrated the dierent influence factors
for the economic success of a gas compression operation.
Important criteria include first cost, operating cost (especially fuel cost), capacity, availability, life cycle cost, and
emissions. Decisions about the layout of compressor stations
such as the number of units, standby requirements, type
of driver and type of compressors have an impact on cost,
fuel consumption, operational flexibility, emissions, as well
as availability of the station.
References
[1] J. H. Lotton and M. Lubomirsky, Gas Turbine Driver Sizing and
Related Considerations, Bratislava Publishers, Slovakia, 2004.
[2] S. P. Santos, Transient analysis- a must in gas pipeline
design, in Proceedings of the Pipeline Simulation Interest Group
Conference, Tucson, Ariz, USA, 1997.
[3] S. Ohanian and R. Kurz, Series of parallel arrangement in a
two-unit compressor station, Journal of Engineering for Gas
Turbines and Power, vol. 124, no. 4, pp. 936941, 2002.
[4] W. Wright, M. Somani, and C. Ditzel, Compressor station
optimization, in Proceedings of the 30th Annual Meeting,
Pipeline Simulation Interest Group, Denver, Colo, USA, 1998.
[5] M. Pinelli, A. Mazzi, and G. Russo, Arrangement and
optimization or turbocompressors in o-shore natural gas
extractions station, Tech. Rep. GT20005-68031, ASME, 2005.
[6] R. Kurz and S. Ohanian, Modelling turbomachinery in
pipeline simulations, in Proceedings of the 35th Annual Meeting,
Pipeline Simulation Interest Group, Berne, Switzerland, 2003.
[7] R. Kurz, S. Ohanian, and K. Brun, Compressors in high
pressure pipeline applications, Tech. Rep. GT2010-22018,
ASME, 2010.
[8] S. P. Dos Santos, M. A. S. Bittencourt, and L. D. Vasconcellos,
Compressor station availabilitymanaging its eects on gas
pipeline operation, in Proceedings of the Biennial International
Pipeline Conference (IPC 07), vol. 1, pp. 855863, 2007.
[9] S. P. Santos, Monte Carlo simulationa key for a feasible
pipeline design, in Proceedings of the Pipeline Simulation
Interest Group Conference, Galveston, Tex, USA, 2009.
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