Valerus

September 26, 2013
Compression
Split Technical Seminar
Tom Birney,
Director of Business Development
2012 Valerus. Confidential and proprietary. All rights reserved.
OVERVIEW
2012
2012 Valerus.
Valerus. Confidential
Confidential and
and proprietary.
proprietary. All
All rights
rights reserved.
reserved.
OUTLINE
1.
Selection Of A Reciprocating Or Centrifugal Compressor

a. Parameters
b. Drivers
c. Centrifugal Compressors
d. Reciprocating Compressors
d. Recip. vs. Centrifugal Comparison
- Examples
e. Conclusion
OUTLINE
2.
High/Medium Speed Vs. Slow Speed

Comparison of API 11P (ISO-13631): High/medium speed
compressors and API 618 slow speed compressors
3.
Sizing, Selection and Applications
4.
Packaging Considerations
COMPRESSION
1. Selection of a Reciprocating or Centrifugal Compressor
2012
2012 Valerus.
Valerus. Confidential
Confidential and
and proprietary.
proprietary. All
All rights
rights reserved.
reserved.
COMPRESSOR TYPES
Dynamic
Positive Displacement
Reciprocating
Radial
Screw
Vane
Rolling Lobe (Roots)

Axial
Liquid Ring
Single Screw
HISTORY
DEFINE THE QUESTION
Plant or Site Parameters
Project Parameters
Process Parameters
Machinery Parameters
PLANT OR SITE PARAMETERS
Onshore / Offshore
Elevation/Barometric Pressure
Ambient Temperature - design/range
Fuel Available - type, pressure, cost
Soil/Foundation conditions
Enclosure Required - open, partial, full

Manpower/Staffing Plans
Utilities - water, power, air

Environment - noise, air, effluents
PROJECT PARAMETERS
Anticipated life
Required start up date & equipment deliveries
Economic evaluation criteria
PROCESS PARAMETERS
Gas analysis
Suction pressure - design/range
Discharge pressure - design/range
Suction temperature - design/range
Flow rate - design/range
Extra process heat requirement

Operating flexibility required
Operating reliability required
MACHINERY PARAMETERS
Initial cost
Transportation/installation cost & time
Compressor efficiency - kw/m3
Specific fuel consumption over range
Power avail/power required match
Actual emissions/emissions allowed

Operation & maintenance cost
Flexibility to handle range of conditions
ELECTRIC OR GAS DRIVER
Fuel gas availability & quality

Electricity availability
Speed control
Fuel gas vs electric cost
Maintenance vs initial cost

Emissions
Lead time
ELECTRIC DRIVER
Fuel gas availability & quality Not Required
Electricity availability - Required
Speed control Additional VFD and Torsional Analysis
Fuel gas vs electric cost varies
Maintenance vs initial cost Maintenance Low / (high failure cost)

Initial cost comparable
Emissions - None
Lead time Long, built to order
COMBUSTION GAS TURBINE
Two types of gas turbines

Industrial
steam turbine technology
in-situ repair
Aero-derivative
replace - dont repair
TURBINE DRIVER
Fuel gas availability & quality Required / high quality
Electricity availability - No
Speed control Usually ran at constant speed
Maintenance vs initial cost Maintenance Low / (high failure cost)

Higher Initial cost
Emissions - High
Lead time Long
GAS TURBINE CONTROLS
Complex start-up/stop sequencing

Complex controls required for fuel scheduling and emissions
controls
Many critical monitoring points for gas turbine
Complicated surge control
RECIPROCATING ENGINE DRIVER
Fuel gas availability & quality Required / low quality
Electricity availability - No
Speed control Included
Maintenance vs initial cost Maintenance medium / Low Initial cost
Emissions - medium
Lead time short
RECIPROCATING DRIVERS
Industry did not have a large industrial gas engine until 1995.
Caterpillar G3616 in 1995
(4500 HP)
Caterpillar G16CM34 in 2001
(7670 HP)
Waukesha 16V-AT27 in 2000
(4500 HP)
Wartsila 18V34SG in 1997
(8000 HP)
Wartsila 20V34SG in 1998
(10600 HP)
RECIPROCATING ENGINE VS. GAS TURBINES DRIVERS

Turbine
Engine
Available HP
>30,000
>10,000
Temp.
22C
37.8C
Altitude
Sea Level
1500m
Intake Loss
None allowed
1500mm WC
Exhaust Loss
None allowed
300mm WC
Degradation
Allow up to 10%
0%
Weight / Footprint Low
High
CENTRIFUGAL COMPRESSORS
WHY Centrifugal?
Mature Technology Since 1940s

Handles large capacities
High Horsepower
Small footprint
99% Availability
Minimal Maintenance
CENTRIFUGAL CHARACTERISTICS
Dynamic compressor
Achieves pressure increase by controlling gas velocities
Narrow operating range
Precise matching to design point
Minimal degree of capacity control\
Large Volumetric flow rates
CENTRIFUGAL COMPRESSOR APPLICATION LIMITATIONS
Flow:
Minimum flow is approx. 3 m3/min (100 acfm) into any impeller.
As flow decreases toward this limit efficiency falls off dramatically.
Pressure:
Lower limit, none with proper seals.
Upper limit, high discharge pressure not itself a limiting factor, just
thicker components. This may reduce number of stages possible.
Most applications are below 350 bar.
Higher suction pressure are more difficult to seal. Most applications
below 200 bar.
Temperature:
Low temps. down to -75C handled using higher cost materials of
sufficient ductility. Special seals required. Upper limit set by shaft
seals.
Temps. of 195C are common & can be increased to 230C with
cool buffer gas.
Compression Ratio or Head:

Determines the number of stages required.
For dynamic compressors this is a function of pressure ratio, MW,
temperature, compressibility and ratio of specific heats.
Due to rotor stability 10 impellers is normal max. At 4,600 m kg/kg
polytropic head per impeller this limits methane to 7.92 ratios in one
casing and propane to 200 ratios. Correct MW is critical to proper
selection.
Horsepower:
Applications less than 750 kw (~1000 hp) usually have some other
limiting factor such as low flow or poor efficiency.
Upper limits are typically set by available drivers.
Centrifugal compressors can handle high powers.
Rotative Speed:
With dynamic compressors higher speed results in improved
performance. Work per stage and flow increases with speed.
Mechanical considerations limit tip speeds to 335 m/sec for open
impellers and 425 m/sec for closed impellers.
Efficiency:
Polytropic efficiency per stage of 85% is normal for quantity constant
of 100 to 300 and declines to 70% as quantity constant drops to 35.
Quantity Constant = ICFM X 1000 X 1728
RPM X IMP. DIA. (in)
RECIPROCATING COMPRESSORS
WHY Reciprocating?
Large, operating range / flow / pressure / variations in gas

+95% Availability
Portability
Ease of Start Stop
Re-Application
Cost
RECIPROCATING CHARACTERISTICS
Positive Displacement compressor

Achieves pressure by reducing the volume
Wide operating range
Infinite capacity control
Efficiency improves with decreasing flow
RECIPROCATING COMPRESSOR APPLICATION LIMITATIONS
Flow:
No minimum flow. Maximum flow limited by piston displacement of
available cylinders.
Pressure:
No minimum limit, can attain high vacuums. Maximum pressures

can be ultra high for special processes. Separable applications are
normally limited to 415 bar (6000 psi), at reduced rotative speeds.
Temperature:
Minimum limit is -30C with standard material and -40C with special alloys.
Maximum limit is normally 175C and preferably below 150C.
Compression Ratio:
Normally limited by one of following;

Max. discharge temp.
Allowable rod load
Low cylinder volumetric efficiency
Practical limits on natural gas are 4 - 5 on first stage and 3.5 - 4.5 on
succeeding stages.
Horsepower:
Limited by frame ratings or driver ratings. Reciprocating (aka Separable)

frames of 7500kw and gas engines of 6100 kw (8000 Bhp) are available.
Rotative Speed:
Smaller compressors operate at speeds up to 1800 rpm with larger units in

the 750 - 1200 rpm range. Speed is normally determined by available driver
speed.
SEPARABLE / CENTRIFUGAL COMPARISION
Comparing the most abundant combination in the upstream gas field.
Reciprocating Compressor
driven by a Gas Engine : Separable
Radial Compressor
driven by a Gas Turbine : Centrifugal
Coverage:
Separable vs. Centrifugal Coverage:
POWER COMPARISON:
Point
Separable
Centrifugal
5182kW
5660kW
5138kW
6129kW
4016kW
4685kW
1
3
POWER COMPARISON:
Point
Separable
Centrifugal
5182kW
5660kW
5138kW
6129kW
4016kW
4685kW
DRIVER RATINGS:
Derate
Temperature
37C
18%
Altitude
260m
4%
GT intake losses
100mm
0.7%
GT exhaust losses
100mm
Gas Turbine Derate:

Gas Engine Derate:
22% + 10% degradation

0%
SEPARABLE / CENTRIFUGAL COMPARISON
POWER COMPARISION:
Required Driver Rating (from Point 1):
Gas Engine rating required:
5182 kw
ISO Gas Turbine rating required:

5660 0.68 = 8323 kw
Turbine rating needs to be 60%
more than gas engine rating to
meet design flows
Solar Titan 130
SEPARABLE / CENTRIFUGAL COMPARISON
OPERATING COSTS:
Fuel:
Cost of fuel is the single largest operating cost.
Reciprocating
Turbine
Site Rating
8.44 Mj/Kwh
10.09 Mj/Kwh
Total
43736 Mj/hr
57109 Mj/jr
Reciprocating uses 23% less fuel than the Gas Turbine.
EFFICIENCY COMPARISON
Turbine / Centrifugal Engine / Reciprocating

Driver Heat Rate
Btu / (hp-hr)
8239
6400
29%
Compressor
Hp / MMSCFD
26.5
24.7
+7%
Decreasing Driver
Speed
Increased Fuel Rate
No Change or Decrease
Total Difference
+36%
MAINTENANCE COMPARISON
Reciprocating Compressor:
piston rings and wear bands
valve overhaul
packings
complete
Engine
spark plugs
top end
complete
Estimated cost
Centrifugal Compressor:
minimal with high quality gas
Gas Turbine
major overhaul
Estimated Cost
16000 hr
8000 hr
16000 hr
70000 hr
2000 hr
30000 hr
60000 hr
$7.2/MWh
32000 hr
$6.4/MWh
AVAILABILITY
Reliabilit y
Actual Production
100%
(Actual Production Losses from Unschedule d Downtime)
Availabili ty
Actual Production
100%
(Actual Production Losses Unschedule d Losses scheduled)
AVAILABILITY
Reciprocating
Rental fleet operators guarantee 97 - 99% availability for
separable units
Rotating
99% expected for gas turbine / centrifugal
PIPELINE APPLICATION EXAMPLE

ASSUMPTIONS
7500 Bhp installed

Heat rates (btu / (hp-hr))
CAT 3616TA: 6810
Wartsila 34SG: 6400
Solar Taurus: 8239
Fuel Cost: $2.5 / MM btu
Interest rate: 10%
Project life: 18 years
SOLAR
Installed Cost
CAT
Wartsilla
$6,091,000
$5,642,000
$5,834,000
25
40
45
Yearly O&M ($)
$200,000
$320,000
$360,000
Yearly Fuel ($)
$1,160,000
$841,000
$909,000
NPV - O&M ($)
$1,640,000
$2,624,000
$2,952,000
NPV - Fuel ($)
$9,511,000
$6,896,000
$7,454,000
$17,242,000
$15,162,000
$16,240,000
14%
0%
7%
O&M ($/hp)
Life Cycle Cost ($)

% Difference

During Engineering / Design:
350
Flow (MMSCFD)
300
250
200
150
100
50
0
Jan
Mar
May
July
Sept
Nov

Flow
MMSCFD
Suction Pressure
PSIA
Discharge Pressure
PSIA
305
550
900
300
564
900
290
590
900
280
615
900
250
678
900
225
722
900

2.5
2.4
2.3
Reciprocating
Compression Ratio
2.2
2.1
2.0
1.9
1.8
Centrifugal
1.7
1.6
1.5
1.4
1.3
1.2
1.1
1.0
0
20
40
60
80
Percent Flow
100
120
140

ACTUAL Operating Conditions:

Design vs Actual:
2.5
2.4
2.3
Reciprocating
Compression Ratio
2.2
2.1
2.0
1.9
1.8
Centrifugal
1.7
1.6
1.5
1.4
1.3
1.2
1.1
1.0
0
20
40
60
80
Percent Flow
100
120
140

Design vs Actual:
2.5
2 Reciprocating
Units
2.4
Reciprocating
2.3
Compression Ratio
2.2
1 Reciprocating Unit
2.1
2.0
1.9
Centrifugal
1.8
1.7
1.6
1.5
1.4
1.3
1.2
1.1
1.0
0
20
40
60
80
Percent Flow
100
120
140
OTHER CONSIDERATIONS
operating
pressure
flow capacity
gas gravity
modification
gas turbine driven

centrifugal compressor
not flexible, has very limited pressure
ratio
typical 100%-60% with variable guide
vanes Large Capacity
gas engine driven reciprocating

compressor
very flexible, can be designed to
cover broad range of pressures
typically 100% - 50% with clearance
control
100%-0% with recycle
100%-0% with recycle
pressure ratio is sensitive to the gas

gravity
not practical to modify for changing
gas conditions
pressure ratio is not affected by the

gas gravity
can be modified for # stages and
changing gas types and flows
can be designed as 1 stage / 2
stage or 2 stage/3 stage, etc
cannot readily change pressure ratio

size, weight
small and compact
larger and heavier than centrifugal
available in large powers but similarly Above about 4700 hp would require
sized standby needed if the service is multiple units but costs and
critical
flexibility are improved
cost
gas turbine driven centrifugal

compressor

compressor
usually higher capital cost
usually lower capital cost
fuel consumption 3 - 4 times higher than gas engine
reliability
maintenance
parts
as low as 6800 - 8000 btu/bhp/hr
usually requires fuel conditioning

for field gases
tolerant of field gases
typically 99 - 99.8%
typically 95-98.5%
needs sophisticated controls and

instrumentation
requires special shop repair and
skilled technicians
usually requires special synthetic
lubricants
requires special tools and
assembly fixtures
off the shelf control and

instrumentation
common tools and oil-field
mechanics
Uses locally available engine
crankcase lubricants
common tools and assembly
techniques
low usage, high cost
predictable usage, low cost
special parts, expensive insurance

spares
common parts, no insurance spares
gas turbine driven centrifugal
compressor
failure modes
delivery
can be unexpected and catastrophic

compressor
usually with early symptoms and
limited to replaceable components
Can be very long 9 - 18 months
Can be very short 14 - 36 weeks
small footprint and close centerlines
larger footprint
unbalance and vibration are nil
unbalanced forces and moments

are low
typically 4 - 8 weeks
typically a few days to a week
portability
usually not portable since the

compressor is designed
for a
specific set of conditions and gas
below about 2,000 hp can operate

without foundation
site rating
turbines lose power generally above

500 ft
installation
turbocharged gas engines

maintain power up to about 5,000
ft
RECIPROCATING / CENTRIFUGAL COMPARISON
Compare a natural gas engine driven separable compressor to a gas turbine

driven centrifugal compressor.
1 = best
2 = not quite as good
3 = worst
Compressor Type
kw/m3
Installed cost
Lead time
Fuel consumption
Waste heat avail.
Availability
O & M cost
Low emissions
Operating flexibility
Separable
1
1
1
1
3
2
2
2
1
Centrifugal
3
2
3
2
1
1
1
2
3
CONCLUSIONS
Best compressor choice depends on:

Plant or site parameters
Project parameters
Process parameters
Machinery parameters
CONCLUSIONS
Gas Turbine driven Centrifugal compressors are best when:

Large horsepower is required
Waste heat is required
Limited range of process conditions
Minimal foundation is required
Light weight is desired

Low fuel gas cost
Long lead time is possible
CONCLUSIONS
Separable compressors are best when:

High fuel cost
No waste heat required
Minimum initial cost required
6000 kw or less increments required
Medium project life is required

Relocation or conversion may be required
Minimum shipping/construction schedule

Maximum operating flexibility

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September 26, 2013

Split Technical Seminar

2012 Valerus. Confidential and proprietary. All rights reserved.

Selection Of A Reciprocating Or Centrifugal Compressor

2012 Valerus. Confidential and proprietary. All rights reserved.

High/Medium Speed Vs. Slow Speed

Sizing, Selection and Applications

2012 Valerus. Confidential and proprietary. All rights reserved.

Rolling Lobe (Roots)

2012 Valerus. Confidential and proprietary. All rights reserved.

DEFINE THE QUESTION

Plant or Site Parameters

2012 Valerus. Confidential and proprietary. All rights reserved.

PLANT OR SITE PARAMETERS

Enclosure Required - open, partial, full

Utilities - water, power, air

2012 Valerus. Confidential and proprietary. All rights reserved.

2012 Valerus. Confidential and proprietary. All rights reserved.

Extra process heat requirement

Operating reliability required

2012 Valerus. Confidential and proprietary. All rights reserved.

Actual emissions/emissions allowed

Flexibility to handle range of conditions

2012 Valerus. Confidential and proprietary. All rights reserved.

ELECTRIC OR GAS DRIVER

Fuel gas availability & quality

Maintenance vs initial cost

2012 Valerus. Confidential and proprietary. All rights reserved.

Fuel gas availability & quality Not Required

Electricity availability - Required

Speed control Additional VFD and Torsional Analysis

Fuel gas vs electric cost varies

Maintenance vs initial cost Maintenance Low / (high failure cost)

Lead time Long, built to order

2012 Valerus. Confidential and proprietary. All rights reserved.

COMBUSTION GAS TURBINE

Two types of gas turbines

2012 Valerus. Confidential and proprietary. All rights reserved.

Fuel gas availability & quality Required / high quality

Speed control Usually ran at constant speed

Fuel gas vs electric cost varies

Maintenance vs initial cost Maintenance Low / (high failure cost)

Lead time Long

2012 Valerus. Confidential and proprietary. All rights reserved.

GAS TURBINE CONTROLS

Complex start-up/stop sequencing

2012 Valerus. Confidential and proprietary. All rights reserved.

RECIPROCATING ENGINE DRIVER

Fuel gas availability & quality Required / low quality

Speed control Included

Fuel gas vs electric cost varies

Maintenance vs initial cost Maintenance medium / Low Initial cost

Lead time short

2012 Valerus. Confidential and proprietary. All rights reserved.

2012 Valerus. Confidential and proprietary. All rights reserved.

RECIPROCATING ENGINE VS. GAS TURBINES DRIVERS

Weight / Footprint Low

2012 Valerus. Confidential and proprietary. All rights reserved.

Mature Technology Since 1940s

2012 Valerus. Confidential and proprietary. All rights reserved.

2012 Valerus. Confidential and proprietary. All rights reserved.

CENTRIFUGAL COMPRESSOR APPLICATION LIMITATIONS

2012 Valerus. Confidential and proprietary. All rights reserved.

CENTRIFUGAL COMPRESSOR APPLICATION LIMITATIONS