Compression

Split - Technical Seminar

y
IUVATlD STANDARDS. DEEPER INSIGHT . VALERUS
 COMPRESSION : COMPARISON OF HIGH / MEDIUM SPEED VS.
SLOW SPEED

02012 VaIerus. ConIdenhal ancI floopnelaly. AlI,oghIJ "' .... ed_

 PREAMBLE - RECIPROCATING COMPRESSOR BASICS

• Understand how a compressor functions NEWESIPBESENTATIQN

~u.uA""""""M"M"M.M.MMMAM.AYdtoYllJa.lllC!\l

• Overview 01 major components in the system

• Video - Compressor Package in Operation

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 COMPLETED PACKAGE y YAWl\JS

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 SKID

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 COMPRESSOR FRAME y YA1U\JS

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 DRIVER & COUPlING y YA1U\JS

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 COOLER & SHEAVES y YA1U\JS

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 FU EL & UTILlTY SYSTEM y YAWl\JS

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 PULSATION BOTTLES y YAWl\JS

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 SCRUBBERS y YAWl\JS

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 PROCESS PIPING y YAWl\JS

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 CONTROL PANEL y YAWl\JS

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 EXHAUST SYSTEM & COOLER PLATFORM y YAWl\JS

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 FINISHED! y YAWl\JS

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 PREAMBLE - RECIPROCATING COMPRESSOR BASICS

• Video - Compressor Package in Operation

• Arrow.wmv

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 API-11 P (180-13631) V8 API-618 y YAWl\JS

API-11P (180-13631): High/Medium 8peed Compressors

vs

API-618: Low 8peed Compressors

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 API -6 18 GENERAL OBJECTIVE y YAWl\JS

1SI & 2 nd Edition (1964) Current 5th Edition

• Reeiproeating eompressors • Reeiproeating eompressor in
in refinery business petrochemical, chemical
and process gas industry
• Drivers
ser vices for handling
Integral & separable process alr or gas
englnes
• Applies to modera te to low
- Eleetrie motors speed in 'critical service'
(Note: 'critical service' is
- Steam turbines
not defined.)
- Direet aeting steam
• Drivers not eovered
turbines
- Gasengine
- Steam engines (direct)

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 API-618 GENERAL OBJECTIVE

• Design lor a minimum 20 year service lile

• Three (3) years 01 uninterrupted service (System design criteria)
• API-618 provides basic
• Compressor design standards
• Application limits

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 HISTORY - API 11P / ISO-13631 VS API618 y YAWl\JS

• API-618 1st ed . published in 1964. to define standards for

reciprocating compressors for use in refinery service .
• In the early 1970s, packaged separable compressors became
prevalent in oil and gas production and API realized that API-618
was not applicable to this market. Hence, a standard that covers the
complete package was necessary.

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 HISTORY - API 11P / ISO-1363 1 VS API618

• API-11 P - 1975 specilically covers packaged high-speed

separable reciprocating compressors lor oil and gas
production applications.
• The 3rd edition 01 API-618, paragraph 1.1 was rewritten
to exclude "packaged high-speed separable engine-
driven reciprocating gas compressors. "
• The specification lurther defined "compressors covered
by this standard are moderate to low speed and in
critical services." This addressed the growing use 01
higher speed separable compressors lor non-critical
services in relineries.

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 HISTORY - API 11P / ISO-13631 VS API618

• The 4th edition 01 AP 1-618, states; "requirements for

packaged high-speed reciprocating compressors lor oil
and gas production services are covered in API
Specilication 11 Po"
• The second edition 01 API-11 P - November 1989
includes the lollowing statement 01 applicability:
"This standard covers the minimum requirements lor a
packager supplied, designed and labricated, skid-
mounted reciprocating, separable or integral
compressor with lubricated cylinders and its prime
movers used in oil and gas production serviceso oo"

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 HISTORY - API 11P / ISO-13631 VS API618

• 618 Scope specilicaliy states that 618 "does not cover gas engine
drivers".

• In summary, applying API-618 to a packaged separable compressor

is contrary to the purpose and intent 01 API standards and could
result in lack 01 delinition lor critical requirements.

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 DIFFERENCE5 - API 11 P / 150-13631 V5 API 618

• Comments to API-618 5th ed. are available lrom most

manulacturers 01 separable compressors.

• Packagers can also provide complete packaging comments to API-

618.

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 DIFFERENCES - API 11 P / ISO-13631 VS API 618

• In general it should be remembered that API 618 is

written lar longer stroke, slower speed units that are
normally block mounted and driven by electric motors.
The logic lor so me 01 the requirements does not apply to
packaged shorter stroke compressors driven by either
gas engines or electric motors. It is also important to
note that it may take some time belore standards
recognize technological improvements.

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 DIFFERENCES . API 11 P / ISO· 13631 VS API 6 18

• Examples:
• paragraph 2.1.1 requires a design suitable for "expected
uninterrupted operation of at least 3 years."
• A gas engine must be maintained on a monthly basis
and therefore it does not make sense to invest in backup
au xiliary systems such as dual oil filters. Maintenance
on oil filters can be performed concurrently with engine
monthly

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 DIFFERENCES - API 11 P / ISO-13631 VS API 618

• Examples:
• Paragraph 2_6_2_3 states that "unless otherwise
specilied , each cylinder shall have a replaceable, dry-
type liner, not contacted by coolant."
• The main reason lor liners on the longer stroke units is to
provide an economical means lor repair.
On average, lor smaller bore cylinders a replacement
barrel is less costly than a liner. Additionally, a metal
spray processes can be used to rebuild cylinders to
original dimensions. Metal spray processes are an even
more economical repair technique.

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DIFFERENCES - API 11 P / ISO-13631 VS API 618

• Examples:
• Paragraph 2.6.2.3 conlinued
• Adding a liner lo a 15" slroke adds very little clearance bul il is a
significanl increase on Ihe shorter slroke separable unils.
• This can reduces volumelric efficiency and Ihe flexibilily of Ihe
Variable Volume Clearance Pocket.

anall base Clearance

DIFFERENCES- APlllP / ISO-13631 VSAPI618

• Cylinder Water Jackets:

• Water jackets required to address thermal bore distortion in

long-stroke cylinders
• Originally API-618 asked that water jackets not be included
• Water jackets added in 2nd edition due a unit that ran without
gas flow
• Never meant as a method to 'coal' gas
• Desire for water jackets 'institutionalized ' by API-618
lir.'m,'ntfor of 'air cooled' cylinders

I
 DIFFERENCES - API 11 P / ISO- 13631 VS API 6 18

• Examples:
• Paragraph 2_6_3_2 states "air-cooled cylinders shall not
be lurnished without the expressed written approval 01
the purchaser. "
• Air-cooled cylinders have been in use lor over 30 years
with thousands 01 cylinders in operation and millions 01
successlul running hours. The impact 01 lorced liquid
cooling on higher speed units is not nearly as signilicant
as it is on the slower speed units.

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 DIFFERENCES - API 11 P / ISO-13631 VS API 618

• Examples:
• Paragraph 2_7_2 requires the purchaser to specify if
valve unloading is required.
• The norm for process machines is to use automatic
valve unloaders for both start up unloading and capacity
control.
• The norm for separable compressors is to unload for
starting with a by pass and to use speed and recycle for
capacity control.

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 DIFFERENCES . API 11 P / ISO·13631 VS API 618

• Paragraph 2.10.1.1 states "type A distance pieces are

used only lor non·llammable or non·hazardous gases."
• Packaged units are typically designed lor ease 01
shipment and width is an important design criterion. There
are thousand 01 units compressing sweet natural gas and
operating salely with API11 P / ISO-13631 type 1 distance
•
pleces
• With the smaller diameter piston rods used in separable
compressors, shorter rods are prelerred to provide proper
stiffness.

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 DISTANCE PIECE y YAWl\JS

Intennediate packing Window size allows removal

with optional purge o. complete packing case

High efficiency
oil wiper Pressure i with
Slinger
water cooling and purge

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 DIFFERENCES-API11P / ISO-13631 VSAPI618

• Paragraph 2.14.2 table 1

impases arbitrary
pressure limits lar cast
cylinders.
• These limits have nat
changed in aver 25 years.
Despite OC, linite
element analysis and
manulacturing
improvements.

02012V8Ierus Conhdenllal and propnetary AlI nghes reservod

 CYLlNDER DESIGN HISTORY y YAWl\JS

Year 1964 2000

Casting Historical Computer
Design Algorithms Modeled
Casting
Good Better
Quality
Dimensional Movement No Movement
Stability Caused Problems Problems
Piston Ring Metallic or Soft
Material Hard Non-Metallic Non-Metallic
Hardened
No Ves
Cylinder Bore?

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 CYLlNDERS y YAWl\JS

Moderate-Speed Low-Speed

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 API11P / ISQ-13631 VSAPI618

In conclusion:

Specilying API 618 lar high speed packaged compressors can add
considerable casI, lar limiled benelils and may leave impcrlanl
packaging issues unspecilied. II is better lo lollow Ihe inlenl 01 API and
useAPlllP / ISO-13631. Illhere arespecilic issues lromAPI618
Ihal are imporlanl lo Ihe purchaser Ihey should be addressed
individually.

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 y YAWl\JS

CAN MODERATE SPEED COMPRESSORS BE APPLlED IN

TRADITIONAL API 618 APPLlCATIONS?
 SPEED

°Low and Moderate Speed Definitions

Low-Speed Moderate-Speed

RPM 200 - 700 700 -1200

Stroke 229 - 508 76 - 203

mm (Ineh) (9 - 20) (3 - 8)

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 ALLOWABLE SPEEDS
y YAWl\JS

Wear is effecled by:

• Pistan Speed
• Piston rings
• Wear bands
F
• Packings
• •
• Rotating Speed
• Valve cyclic (fatigue) life
• Forces and moments
created

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 PISTON SPEED lIMITS

• Current Iimits lor 3 year operation

• Lubrieated : 4.3 mis (850 ftlmin )
• Non-Iubrieated: 3.8 mIs (750 ftlmin )
• Aeeeptable speeds vary with user
• Lower pisto n speed provide longer operation
• Other laetors alleet wear part lile
- Lubrieation
- Surfaee linish 01 eounter-Iaee
- Pressure loading on wear part
- Non-metallie material seleetion
- Gas eomposition and any partieulate
- Operating temperature

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 EFFECTS OF OPERATING TEMPERATURE y YAWl\JS

Piston ring, ridef ring and pac:king ring life trend

fV'Ig material: catbon, gIass and moIybdeoum-filled TFE ring

135 0 e
(275 0 F)

1X 2X 3X 4X 5X 6X 7X BX
Ring lite, lite lM'lits

Fig. 5. Trend for ring life liS . cylinder gas discharge temperatura for
lubricated cylinders on hydrogen serviee.

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 PISTON SPEED VS. DRIVER SPEED

llXX1 ,
Currentlubelimit ___ u_ho . .. ] Tradlllooallube &Curren! Non-lube lImtl -- -- -- -- _. ·- 1 5.0

850 ~ ..............•. " ....... , 4.3

3.8 ~
E
3.5 :;-
••
3.0 '"e
f/)

o ~

1.5 ¡¡:•

1.0
Moderate Speed (shart strokel
SllOkelengthmlnches(mm) 1.5
IGOuI 1100
ISQuI
Synchronous Speeds (RPM )

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 SPEED COMPARISON y YAWl\JS

Traditlonal
Hlgh Speed Moderate Speed
Slow Speed

Orive Speed
1000 · 1800 700 - 1200 300 - 700
(RPM)

Piston Speed 2.8 -4.8

4.6-6.1 2.8 - 4.4
lubricated (900 -1200) (560 - 870) (560 - 910)
mIs (ft /min)

Piston Speed
2.3 - 3.8 2.3 - 3.8
Non-Lube Nol Available
(450 - 750) (450 - 750)
mIs (ft /min)

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 ROTATING SPEED

• Effects of rotating speed

• Valve cyclic (fatigue) life
• Compressor forces and moments

• Driver RPM capability has increased

• Materials
• Technology

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 ROTATING SPEED

• Valve cyclic (fatigue) life

• Improved technology and materials
• Non-metallic materials
• Prediction and control of impact velocity
• Impact velocity stress rather than bending stress determines life
• Current non-metallic valve experience
• 3 year time between maintenance
• 1200 rpm
• 7 mis impact velocity

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 EFFECTS OF VALVE LlFT / IMPACT VELOCITY

Compressor vaIve life for gas mole weights ranging from 2 to 9

VaIve types: Various manufactures 01 portad plate and COIlCentric ring

I
~- - i l--+
,- . ...9.-"1
11--+-------+-=
i t----t---t-- + _ ____+_'

1X 2X 3X 4X 5X 6X
Compressor vaIve life, lite units
Fig. 4. Trend tar compressor valve life vs. comprassor valve lift tar
lubricated cylinders on hydrogen service.

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 EFFECTS OF VALVE LlFT / IMPACT VELOCITY

VALVE COMPARISON :

.
.......
- ...-..-.-'
,.-
HiSpeed Low Speed

• Valve Type
Non-Metallic
Plate, Ring or
Non-Metallic
Plate, Ring or
Poppet Poppet
Valve Lift 1.5-2.6 1 .5 - 2.5
Mm (Inch) (0.06-0.1) (0.06-0.1)

Expected
24 Months 36 Months
Valve Life

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 ROTATING SPEED VALVE LlFE

• Other factors effecting valve life

• Valve Type
• Unknown operating points
• Oil sticktion

• Liquids
• Dirt

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 ROTATING SPEED HORIZONTALLY OPPOSED y YAWl\JS

Inertial torces act in opposite directions

"
- IIJ ~ ¡~~±l~ ~;j$ - Fl I • I
BY SELECTIVE ASSEMBL Y FL = FR

Equal masses result in equal but opposite torces

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 ROTATING SPEED COMPRESSOR BALANCE (1 MW)

• Low-speed horizontally opposed

• 25 to 50 lbs. (11 to 23 kg)

• Moderate-speed horizontally opposed

• 2.5 lbs. (1.15 kg)
• Components weighed and balance components selected during
assembly

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 MODERATE-SPEED COMPRESSOR BALANCE y YAWl\JS

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 PISTON y YAWl\JS

Moderate Speed lowSpeed

Piston Material Ductile Iron Ductile Iron or Aluminum

Piston Ring and Piston Ring +

Piston Ring + Separate
Wear Band Separate Wear
Wear Band
Configuration Band
Piston Ring and
Non-Metallic Non-Metallie
Wear Band
As Required As Required
Material
Wear Band

.. 0.035 0.069 (10)

Loading
(5) or 0.035 (5)
N/mm2 (psi)

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 COMPRESSOR COMPARISON y YAWl\JS

Natural Gas Process

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 CYLlNDER y YAWl\JS

Moderate Speed Slow Speed

Ductile Iron
Ductile Iron
Material Cast Steel
Forged Steel
Forged Steel

NACE Option Ves Ves

As Required or
Water Jacket Not Required
As an Option

As Required or
Cylinder Liner No
As an Qption

61 Re 25 Re
Surface Hardness
(Nominal) Typieal

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 CAN MODERATE SPEED COMPRESSORS BE APPLlED IN TRADITIONAL
API 618 APPLlCATIONS?

With correct application engineering

VES

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