Reciprocating Compressor

Optimization

Definition Of Important Terms

Reciprocating Compressor. Sometimes
called a piston compressor, is a positive
displacement
compressor
that
uses
pistons driven by a crank shaft to deliver
gases at high pressure. The intake gas
enters the suction manifold, then flows into
the compression cylinder where it is
compressed by a piston driven in a
reciprocating motion via a crankshaft and
is then discharged.

Picture Of A Reciprocating Compressor

Picture Of A Reciprocating Compressor

Definition Of Terms
Optimization: Finding an alternative
with the most cost effective or highest
achievable performance under the
given constraints, by maximizing
desired factors and minimizing
undesired ones.

Introduction And Objective

Optimizing a reciprocating compressor can have
different meanings based on your operating goals
and/or conditions. We are interested in maximizing
the throughput, reducing the fuel usage, lowering
emissions and reliability and maintenance.
Being a positive displacement compressor,
reciprocating compressors are flexible and are said
to be one of the most efficient type of compressors.
They can be single or multi staged and can operate
under a wide range of discharge pressure varying
from 100psig to 1000psig. In natural gas industry
they can range from 50HP to over 3000Hp on some
applications and are typically driven by combustion
engines or electric motors.

Maximizing Throughput.
This means maximizing the capacity of the compressor.
To achieve this, there are two concepts in play. First, the
gas has to go through the first stage cylinder(S). The
capacity can be impacted by clearance devices such as
variable volume clearance pockets(vvcp) or fixed volume
clearance pockets(FVCP) that add clearance to the head
end of a cylinder. The running speed of the compressor
and single acting the crank end or head end of a cylinder
will also influence the capacity of the machine. The
second concept is to increase the capacity of a
compressor by increasing the suction pressure; which
means that the suction pressure is dictated by the flow
of the compressor or vice versa.

Optimized Performance Of A Three Stage Unit

Discharge Pressure Of 1000Psig

The cylinder capacity portion of

the curve implies a cylinder
capacity utilization of 100%,
which means no clearance is
added to the first stage
cylinder(S) and the driver is
running at maximum speed.
The horsepower section of the
curve indicates a horsepower
utilization of 100%. In this
portion of the curve, clearance
devices are generally used to
unload the driver and this is
translated as an increased
capacity while maintaining the
horsepower usage at maximum.
The knee of the curve is the only
point on an optimized loading
curve where the cylinder
capacity utilization and
horsepower used is at 100%.

Case Study- Maximizing Throughput

On A Field Gathering Compressor
A gas producer has a 3
stage, 4 throw back
package with a
capacity of 4 mmscfd,
a suction pressure of
50 psig and a
discharge pressure of
1000 psig. Table 1
shows the current
operating conditions of
this unit.

As shown in Table 1, the

pockets are opened 0.5 inch on
both first stage cylinders and
the running speed is 900rpm
out of 1200rpm. According to
the producer the suction
pressure can be lowered and
the field is sensitive to suction
pressure.

Maximizing Throughput On A Field

Gathering Compressor.
The curve beside shows the
potential potential
production gains of the
current running conditions.
Depending on the well
response, by closing the
pockets and speeding the
driver up to 1200 rpm the
compressor will either see a
decrease in suction
pressure, an increase in flow
or most likely a combination
of both as shown in figure 2.

Maximizing Throughput On A Field

Gathering Compressor.

As indicated on figure 2 and 3, this

optimization resulted in a decrease of 7 psig
on suction pressure and increased flow of
0.9 mmscfd.

Fuel Efficiency
Optimizing a reciprocating compressor for fuel efficiency can be
translated to reducing the fuel consumption of the driver for same
conditions of operation. This generally occurs when the unit is
underutilized with the bypass valve opened. In a gas gathering
application a unit is identified as underutilized when its potential
capacity is above the amount of gas the field can deliver.
In North America, there are good number of natural gas fields that
are depleted; this situation is resulting in multiple compressors
being utilized. This fact highlights the importance of optimizing the
compressors for fuel efficiency and ensuring that the bypass valves
are closed. There is almost always a better solution than bypassing.
To optimize a compressor for fuel efficiency, the capacity of the
compressor needs to be adjusted to the amount of gas the well can
deliver. On a reciprocating compressor the capacity can be typically
controlled by varying running speed, clearance and cylinder action.

Conclusion
Regardless of natural gas price it is
imperative that compressors remain
operating in their optimized state. This
paper explored different meanings of
optimization for reciprocating
compressors from maximum
throughput, to fuel gas savings, to
maintenance optimization and
condition monitoring.