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Thispageprovidesanoverviewoftheprimarycategoriesofnaturalgascompressorservicesandadescriptionofthedifferentclassificationsandtypesofcompressorsavailabletothe
industry.Adiabaticandpolytropiccompressiontheoryarediscussedwithsupportingdefinitionofterminology.
Contents
1Compressiontheory
2Oilandgascompressoruses
2.1Flashgascompressors
2.2Gasliftcompressors
2.3Reinjectioncompressors
2.4Boostercompressors
2.5Vaporrecoverycompressors
2.6Casingheadcompressors
3Classificationandtypes
3.1Positivedisplacementcompressors
3.2Dynamicorkineticcompressors
4Compressiontheory
4.1Isentropic(adiabatic)compression
4.2Polytropiccompression
4.3Head
4.3.1Isentropic(adiabatic)head
4.3.2Polytropichead
4.4Adiabaticorisentropicefficiency
4.5Polytropicefficiency
4.6Compressibilityfactory
4.7Floworcapacity
4.7.1Massorweightflow
4.7.2Standardvolumeflow
4.7.3Actualinletvolumeflow
4.8Compressionratio
4.9Intercooling
4.10Powerrequirement
4.11Compressorselection
4.12Numberofstagesofcompression
5Nomenclature
6References
7NoteworthypapersinOnePetro
8Externallinks
9Seealso
Compressiontheory
Specifictopicsrelatingtocompressiontheoryinclude:
Powerrequirement
Isentropicexponent
Compressibilityfactor
Intercooling
Adiabaticandpolytropicefficiency
Actualandstandardvolumeflowrates
Massflowrates
Inletanddischargepressures
Inletanddischargetemperatures
Adiabaticandpolytropichead
Majorcomponentsandconstructionfeaturesofcentrifugal(/Centrifugal_compressor)andreciprocatingcompressors(/Reciprocating_compressor)areemphasized.Installation,
safety,andmaintenanceconsiderationsalsoarediscussedintheirerspectivepages.
Oilandgascompressoruses
Compressorsusedintheoilandgasindustryaredividedintosixgroupsaccordingtotheirintendedservice.Theseare:
Flashgascompressors
Gasliftcompressors
Reinjectioncompressors
Boostercompressors
Vaporrecoverycompressors
Casingheadcompressors
Flashgascompressors
Flashgascompressorsareusedinoilhandlingfacilitiestocompressgasthatisflashedfromahydrocarbonliquidwhentheliquidflowsfromahigherpressuretoalowerpressure
separator.Flashgascompressorstypicallyhandlelowflowratesandproducehighcompressionratios.
Gasliftcompressors
Gaslift(/Gas_lift)compressorsarefrequentlyusedinoilhandlingfacilitieswherecompressionofformationgasesandgasliftgasisrequired.Gasliftcompressordutyisfrequently
oflowtomediumthroughputwithhighcompressionratios.Manygasliftcompressorsareinstalledonoffshorefacilities.
Reinjectioncompressors
Thereinjectionofnaturalgasisemployedtoincreaseortomaintainoilproduction.Reinjectioncompressorscanberequiredtodelivergasatdischargepressuresinexcessof10,000
psi.Reinjectioncompressorsalsoareusedforundergroundstorageofnaturalgas.Compressors,appliedtotheseservices,havelargecompressionratios,highpowerrequirements,
andlowvolumeflowrates.
Boostercompressors
Gastransmissionthroughpipelinesresultsinpressuredropbecauseoffrictionlosses.Boostercompressorsareusedtorestorethepressuredropfromtheselosses.Selectionofthese
compressorsinvolvesevaluatingtheeconomictradeoffofdistancebetweenpipelineboostingstationsandlifecyclecostofeachcompressorstation.Boostercompressorsalsoare
usedinfieldsthatareexperiencingpressuredecline.Mostcentrifugalpipelineboostercompressorsaregasturbinedriven,althoughtheuseofvariablespeedmotordrivesis
becomingmoreprevalent.Lowspeedintegralgasenginereciprocatingcompressorsalsoareusedforgastransmissionapplications.Boostercompressorstypicallyaredesignedfor
highthroughputratesandlowcompressionratio.Manyboosterapplicationscanbeconfiguredinasinglestagecentrifugalcompressor.
Vaporrecoverycompressors
Vaporrecoverycompressorsareusedtogathergasfromtanksandotherlowpressureequipmentinthefacility.Oftenthegasfromavaporrecoverycompressorisroutedtoaflash
gas,gaslift,orboostercompressorforfurthercompression.Lowsuctionpressures,highcompressionratios,andlowgasthroughputratescharacterizethesecompressors.
Casingheadcompressors
Casingheadcompressorsareusuallyusedwithelectricsubmersiblepumpsandrodpumpswhereformationgasisrequiredtobeseparateddownholeandthentransportedthroughthe
annulus.Oftenthecompressordischargeisroutedtoeitheraboosterorflashgascompressorortoalowpressuregatheringsystem.Likevaporrecoverycompressors,casinghead
compressorsoperatewithlowsuctionpressures,highcompressionratios,andlowgasthroughputrates.
Classificationandtypes
Compressorsareclassifiedintotwomajorcategories:
Positivedisplacementcompressors
Positivedisplacementcompressorsarefurtherdividedinto:
Reciprocating(/Reciprocating_compressor)
Rotarytypes(/Rotary_positive_displacement_compressors)
Dynamicorkineticcompressors
Dynamiccompressorsarecontinuousflowmachinesinwhicharapidlyrotatingelementacceleratesthegasasitpassesthroughtheelement,convertingthevelocityheadinto
pressure,partiallyintherotatingelementandpartiallyinstationarydiffusersorblades.Dynamiccompressorsarefurtherdividedinto:
Centrifugal(/Centrifugal_compressor)
Axialflow
Mixedflowtypes
Compressiontheory
Bothpositivedisplacementanddynamiccompressorsaregovernedbyafewbasicprinciplesderivedfromthelawsofthermodynamics.Thissectiondefinesterminologyand
discussestheoperatingprinciplesessentialforunderstandingcompressordesign,operation,andmaintenance.
Isentropic(adiabatic)compression
Anadiabaticprocessisoneinwhichnoheatisaddedorremovedfromthesystem.Adiabaticcompressionisexpressedby
(/File%3AVol3_page_265_eq_001.PNG)................(1)
wherek=Cp/Cv=ratioofspecificheats,dimensionless.
Althoughcompressorsaredesignedtoremoveasmuchheataspossible,someheatgainisinevitable.Nevertheless,theadiabaticcompressioncycleisrathercloselyapproachedby
mostpositivedisplacementcompressorsandisgenerallythebasetowhichtheyarereferred.
Polytropiccompression
Apolytropicprocessisoneinwhichchangesingascharacteristicsduringcompressionareconsidered.Dynamiccompressorsgenerallyfollowthepolytropiccycleasdefinedbythe
formula
(/File%3AVol3_page_266_eq_001.PNG)................(2)
wheren=polytropicexponent.
Thepolytropicexponentnisexperimentallydeterminedforagiventypeofmachineandmaybelowerorhigherthantheadiabaticexponentk.Becausethevalueofnchangesduring
thecompressionprocess,anaveragevalueisused.
Wheninletanddischargepressuresandtemperaturesareknown,thepolytropicexponentcanbedeterminedfromtherelationship
(/File%3AVol3_page_267_eq_001.PNG)................(3)
Head
HeadissimplytheworkexpressedinfootpoundsperpoundofgasorNm/kg.Atagivencompressorspeedandcapacity,theheaddevelopedbyacentrifugalcompressoristhesame
regardlessofthenatureofthegasbeingcompressed.Thepressureriseproducedbythegivenamountofheadvarieswiththedensityofthegas.
Isentropic(adiabatic)head
Inanisentropiccompressionprocess,headiscalculatedbyEq.4.
(/File%3AVol3_page_267_eq_002.PNG)................(4)
where
His = isentropichead,ftlbf/lbm,
zavg = averagecompressibilityfactor,dimensionless,
Ts = suctiontemperature,R,
S = gasspecificgravity(standardatmosphericair=1.00),
Pd = dischargepressure,psia,
and
Ps = suctionpressure,psia.
Polytropichead
Inapolytropiccompressionprocess,headisdefinedby
(/File%3AVol3_page_267_eq_003.PNG)................(5)
where
Hp = polytropichead,ftlbf/lbm,
and
p = polytropicefficiency.
Adiabaticorisentropicefficiency
Adiabaticefficiencyisdefinedastheratioofworkoutputforanidealisentropiccompressionprocesstotheworkinputtodeveloptherequiredhead.
Foragivencompressoroperatingpoint,theactualorpredictedisentropicefficiencycanbecalculatedwithEq.6.
(/File%3AVol3_page_268_eq_001.PNG)................(6)
where
is = isentropicefficiency,
Ts = suctiontemperature,R,
Td = dischargetemperature(actualorpredicted),R,
and
k = ratioofspecificheats,Cp/Cv.
Polytropicefficiency
Theefficiencyofthepolytropiccompressionprocessisgivenby
(/File%3AVol3_page_268_eq_002.PNG)................(7)
wherep=polytropicefficiency.
Compressibilityfactory
TheperfectgasequationderivedfromCharlesandBoyleslawsmakesitpossibletodeterminetheweightofagivengasasdeterminedbytheequation
(/File%3AVol3_page_269_eq_001.PNG)................(8)
where
P = pressure,
V = volume,
N = numberofmoles,
R = constantforaspecificgas,
and
T = temperature.
Inreality,allgasesdeviatefromtheidealgaslawstosomedegree.Thisdeviationisdefinedasacompressibilityfactor,z,appliedasamultipliertothebasicformula.Therefore,Eq.
8ismodifiedtoincludethecompressibilityfactorasshownnext.
(/File%3AVol3_page_269_eq_002.PNG)................(9)
Floworcapacity
Compressorflow(capacity)canbespecifiedinthreeways:
Mass(weight)flow
Standardvolumeflow
Actual(inlet)volumeflow
Massorweightflow
Massflowisexpressedasmassperunitoftime,mostoftenpoundsmassperminute(lbm/min)orkilogramsperminute(kg/min).Massflowisaspecificvalueindependentofgas
propertiesandcompressorinletconditions.Massflowcanbespecifiedoneitherawet(watervaporincluded)ordrybasis.
Standardvolumeflow
Standardvolumeflowisthemostcommontermusedbytheindustrytodescribevolumetricflowbecauseitisindependentofactualgaspressuresortemperatures.Itisthevolume
perunitoftimeusingpressuresandtemperaturesthathavebeencorrectedto"standard"conditions.Theseconditionsapplytopressure,temperature,molecularweight,and
compressibility.Thestandardsmustbeknownandheldconstant.Forpurposesofthistext,thestandardconditionsusedare
pressure = 14.7psia,
temperature = 60F,
compressibility = 1.00,
and
molecularweight = MWofsubjectgas.
Standardvolumeflowisusuallydryandexpressedinmillionsofstandardcubicfeetperday(MMScf/D).
Actualinletvolumeflow
Actualvolumeflowisdefinedastheamountofvolumeperunitoftimeattheinlettothecompressor.Actualvolumeflowisnormallyexpressedinactualcubicfeetperminute
(ACFM)oractualcubicmetersperhour(m3/hr).Whengascompositionandpressureandtemperatureareknown,thespecificationofactualvolumeisappropriatebecausethe
fundamentalperformancecharacteristicofthecompressorissensitiveonlytoactualvolumeflowattheinlet.
MassflowcanbeconvertedtoactualvolumeflowwithEq.10.
(/File%3AVol3_page_269_eq_003.PNG)................(10)
where
W = massflow,lbm/min.,
R = universalgasconstant=1,545,
MW = molecularweight,
Ts = suctiontemperature,R,
zs = compressibilityatinlet,
and
Ps = absolutesuctionpressure,psia.
StandardvolumeflowcanbeconvertedtoactualvolumeflowwithEq.11.
(/File%3AVol3_page_270_eq_001.PNG)................(11)
whereQg=standardvolumeflow,MMscf/D.
Compressionratio
Compressionratio,Rc,issimplytheabsolutedischargepressuredividedbytheabsolutesuctionpressure.AsexpressedinEq.3,temperatureratioincreaseswithpressureratio.
Temperaturelimitsrelatedtothemechanicaldesignofcompressorsoftenwilldictatethemaximumpressureratiothatcanbeachievedinastageofcompression.(Refertosectionon
intercoolingbelow.)
Intercooling
Wherelargepressureratiosareneeded,splittingthecompressiondutyintooneormorestageswithintercoolingbetweenstagescanbethemostenergyefficientarrangement.The
energysavingsmustbecomparedwiththecapitalandmaintenanceinvestmentnecessarytoprovidethecooling.Inadditiontothethermodynamicbenefit,intercooledcompression
systemsresultinlowerdischargetemperatures,whichreducetheneedforspecialcompressormaterials.
Powerrequirement
Thetotalpowerrequirementofacompressorforagivendutyisthesumofthegaspowerandthefrictionpower.Thegaspowerisdirectlyproportionaltoheadandmassflowand
inverselyproportionaltoefficiency.Mechanicallossesinthebearingsand,toalesserextent,inthesealsaretheprimarysourceoffrictionpower.
Forcentrifugalcompressors,thegaspowercanbecalculatedas
(/File%3AVol3_page_270_eq_002.PNG)................(12)
where
GHP = gaspower,horsepower,
W = massflow,lbm/min.,
and
Hp = polytropichead,ftlbf/lbm.
Forreciprocatingcompressors,thegaspowercanbecalculatedas
(/File%3AVol3_page_270_eq_003.PNG)................(13)
where
P1 = inletpressure,psia,
V1 = inletvolume,ACFM,
P2 = dischargepressure,psia,
and
CE = compressionefficiency(assume0.85forestimatingpurposes).
Compressorselection
Properselectionofthecompressortypeandnumberofstagescanbeaccomplishedonlyafterconsideringanumberoffactors.(Forthepurposesofthischapter,discussionislimited
tocentrifugalvs.reciprocatingcompressors.)Basicinformationneededfortheproperselectionincludes:
Volumeandmassflowofgastobecompressed
Suctionpressure
Dischargepressure
Suctiontemperature
Gasspecificgravity
Availabletypesofdrivers
Therequiredvolumeflowanddischargepressuredefineapointonagraphicrepresentationofcompressorcoverage,asshowninFig.6.Examinationofthischartrevealsthat,in
general,centrifugalcompressorsareappropriateforhighflowapplications,andreciprocatingcompressorsarebettersuitedtolowflowrates.
(/File%3AVol3_Page_271_Image_0001.png)
Fig.6Compressorselection.Areasindicate
regionsofbestperformance(courtesyofDresser
Rand).
Numberofstagesofcompression
Usingthespecifiedoverallpressureratioandsuctiontemperature(andanassumedefficiency),thedischargetemperatureforcompressionofgaswithaknownkvalueinasingle
stagecanbeestimatedbyrewritingEq.7.
(/File%3AVol3_page_271_eq_001.PNG)................(14)
where
T2 = estimatedabsolutedischargetemperature,R,
T1 = specifiedabsolutesuctiontemperature,R,
P1 = specifiedabsolutesuctionpressure,psia,
P2 = specifiedabsolutedischargepressure,psia,
k = ratioofspecificheats,
p = assumedpolytropicefficiency,
0.72to0.85forcentrifugalcompressors,
and
1.00forreciprocatingcompressors.
Ifthesinglestagedischargetemperatureistoohigh(typicallimitis300to350F),itisnecessarytoconfigurethecompressionequipmentinmorethanonestage.Calculatingthe
compressionratioperstagewithEq.15doestheevaluationofamultistagedesign.
(/File%3AVol3_page_272_eq_001.PNG)................(15)
where
Rsect = compressionratiopersection,
and
n = numberofsections.
Usingthepreviousequationsandprudentassumptions,itispossibletodeterminetheminimumnumberofstagesrequiredtoaccomplishagivenoverallcompressionratiowithout
exceedingtemperaturelimits.
Nomenclature
k = Cp/Cv
Cp/Cv = ratioofspecificheats,dimensionless
n = polytropicexponent
His = isentropichead,ftlbf/lbm,
zavg = averagecompressibilityfactor,dimensionless,
Ts = suctiontemperature,R,
S = gasspecificgravity(standardatmosphericair=1.00),
Pd = dischargepressure,psia,
Ps = suctionpressure,psia
Hp = polytropichead,ftlbf/lbm,
p = polytropicefficiency
is = isentropicefficiency,
Ts = suctiontemperature,R,
Td = dischargetemperature(actualorpredicted),R,
k = ratioofspecificheats,Cp/Cv
p = polytropicefficiency
P = pressure,
V = volume,
N = numberofmoles,
R = constantforaspecificgas,
T = temperature
W = massflow,lbm/min.,
R = universalgasconstant=1,545,
MW = molecularweight,
Ts = suctiontemperature,R,
zs = compressibilityatinlet,
Ps = absolutesuctionpressure,psia
Qg = standardvolumeflow,MMscf/D
GHP = gaspower,horsepower,
W = massflow,lbm/min.,
Hp = polytropichead,ftlbf/lbm
P1 = inletpressure,psia,
V1 = inletvolume,ACFM,
P2 = dischargepressure,psia,
CE = compressionefficiency(assume0.85forestimatingpurposes)
T2 = estimatedabsolutedischargetemperature,R,
T1 = specifiedabsolutesuctiontemperature,R,
P1 = specifiedabsolutesuctionpressure,psia,
P2 = specifiedabsolutedischargepressure,psia,
k = ratioofspecificheats,
p = assumedpolytropicefficiency,
0.72to0.85forcentrifugalcompressors,
and
1.00forreciprocatingcompressors
Rsect = compressionratiopersection,
n = numberofsections
References
Usethissectionforcitationofitemsreferencedinthetexttoshowyoursources.[Thesourcesshouldbeavailabletothereader,i.e.,notaninternalcompanydocument.]
NoteworthypapersinOnePetro
UsethissectiontolistpapersinOnePetrothatareaderwhowantstolearnmoreshoulddefinitelyread
Externallinks
UsethissectiontoprovidelinkstorelevantmaterialonwebsitesotherthanPetroWikiandOnePetro
Seealso
PEH:Compressors(/PEH%3ACompressors)
Centrifugalcompressor(/Centrifugal_compressor)
Reciprocatingcompressor(/Reciprocating_compressor)
Rotarypositivedisplacementcompressors(/Rotary_positive_displacement_compressors)
Category(/Special%3ACategories): 4.1.6Compressors,engines,andturbines(/Category%3A4.1.6_Compressors,_engines,_and_turbines)
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