Valerus Compression

September 26, 2013
Compression
Split Technical Seminar
Tom Birney,
Director of Business Development
2012 Valerus. Confidential and proprietary. All rights reserved.
COMPRESSION: COMPARISON OF HIGH / MEDIUM SPEED VS.

SLOW SPEED
2012
2012 Valerus.
Valerus. Confidential
Confidential and
and proprietary.
proprietary. All
All rights
rights reserved.
reserved.
PREAMBLE RECIPROCATING COMPRESSOR BASICS
Understand how a compressor functions NEWEST PRESENTATION

AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA\Video Library.mov
Overview of major components in the system

Video Compressor Package in Operation
COMPLETED PACKAGE
4
SKID
5
COMPRESSOR FRAME
6
DRIVER & COUPLING
7
COOLER & SHEAVES
8
FUEL & UTILITY SYSTEM
9
PULSATION BOTTLES
10
SCRUBBERS
11
PROCESS PIPING
12
CONTROL PANEL
13
EXHAUST SYSTEM & COOLER PLATFORM
14
FINISHED!
15
PREAMBLE RECIPROCATING COMPRESSOR BASICS
Video Compressor Package in Operation

Arrow.wmv
API-11P (ISO-13631) VS API-618
API-11P (ISO-13631): High/Medium Speed Compressors

vs
API-618: Low Speed Compressors
API-618 GENERAL OBJECTIVE
1st & 2nd Edition (1964)

Reciprocating compressors
in refinery business
Drivers
Integral & separable

engines
Electric motors
Steam turbines
Direct acting steam
turbines
Current 5th Edition

Reciprocating compressor in
petrochemical, chemical
and process gas industry
services for handling
process air or gas
Applies to moderate to low
speed in critical service
(Note: critical service is
not defined.)
Drivers not covered
Gas engine
Steam engines (direct)
API-618 GENERAL OBJECTIVE
Design for a minimum 20 year service life

Three (3) years of uninterrupted service (System design criteria)
API-618 provides basic
Compressor design standards

Application limits
HISTORY - API 11P / ISO-13631 VS API 618
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.
API-11P - 1975 specifically covers packaged high-speed

separable reciprocating compressors for oil and gas
production applications.
The 3rd edition of API-618, paragraph 1.1 was rewritten
to exclude packaged high-speed separable enginedriven reciprocating gas compressors.
The specification further defined compressors covered
by this standard are moderate to low speed and in
critical services. This addressed the growing use of
higher speed separable compressors for non-critical
services in refineries.
The 4th edition of API-618, states; requirements for

packaged high-speed reciprocating compressors for oil
and gas production services are covered in API
Specification 11P.
The second edition of API-11P - November 1989

includes the following statement of applicability:
This standard covers the minimum requirements for a

packager supplied, designed and fabricated, skidmounted reciprocating, separable or integral
compressor with lubricated cylinders and its prime
movers used in oil and gas production services
618 Scope specifically 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 of API standards and could
result in lack of definition for critical requirements.
DIFFERENCES - API 11P / ISO-13631 VS API 618
Comments to API-618 5th ed. are available from most

manufacturers of separable compressors.
Packagers can also provide complete packaging comments to API618.
In general it should be remembered that API 618 is

written for longer stroke, slower speed units that are
normally block mounted and driven by electric motors.
The logic for some of 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 before standards
recognize technological improvements.
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
auxiliary systems such as dual oil filters. Maintenance
on oil filters can be performed concurrently with engine
monthly
Examples:
Paragraph 2.6.2.3 states that unless otherwise
specified, each cylinder shall have a replaceable, drytype liner, not contacted by coolant.
The main reason for liners on the longer stroke units is to
provide an economical means for repair.
On average, for 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.
Examples:
Paragraph 2.6.2.3 continued
Adding a liner to a 15 stroke adds very little clearance but it is a
significant increase on the shorter stroke separable units.
This can reduces volumetric efficiency and the flexibility of the

Variable Volume Clearance Pocket.
Additional base Clearance
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 cool gas
Desire for water jackets institutionalized by API-618
requirement for specific approval of air cooled cylinders
Examples:
Paragraph 2.6.3.2 states air-cooled cylinders shall not
be furnished without the expressed written approval of
the purchaser.
Air-cooled cylinders have been in use for over 30 years

with thousands of cylinders in operation and millions of
successful running hours. The impact of forced liquid
cooling on higher speed units is not nearly as significant
as it is on the slower speed units.
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 bypass and to use speed and recycle for
capacity control.
Paragraph 2.10.1.1 states type A distance pieces are

used only for non-flammable or non-hazardous gases.
Packaged units are typically designed for ease of
shipment and width is an important design criterion. There
are thousand of units compressing sweet natural gas and
operating safely with API 11P / ISO-13631 type 1 distance
pieces
With the smaller diameter piston rods used in separable

compressors, shorter rods are preferred to provide proper
stiffness.
DISTANCE PIECE
Intermediate packing
with optional purge
High efficiency
oil wiper
Slinger
Window size allows removal

of complete packing case
Pressure packing with

water cooling and purge
Paragraph 2.14.2 table 1

imposes arbitrary
pressure limits for cast
cylinders.
These limits have not
changed in over 25 years.
Despite QC, finite
element analysis and
manufacturing
improvements.
Ion-Nitrider
CYLINDER DESIGN HISTORY
Year
1964
2000
Casting
Design
Historical
Algorithms
Computer
Modeled
Casting
Quality
Good
Better
Dimensional
Stability
Movement
Caused Problems
No Movement
Problems
Piston Ring
Material
Metallic or
Hard Non-Metallic
Soft
Non-Metallic
Hardened
Cylinder Bore?
No
Yes
CYLINDERS
Moderate-Speed
Low-Speed
API 11P / ISO-13631 VS API 618
In conclusion:
Specifying API 618 for high speed packaged compressors can add
considerable cost, for limited benefits and may leave important
packaging issues unspecified. It is better to follow the intent of API and
use API 11P / ISO-13631 . If there are specific issues from API 618
that are important to the purchaser they should be addressed
individually.
CAN MODERATE SPEED COMPRESSORS BE APPLIED IN

TRADITIONAL API 618 APPLICATIONS?
SPEED
Low and Moderate Speed Definitions
Low-Speed
Moderate-Speed
RPM
200 - 700
700 1200
Stroke
mm (Inch)
229 508
(9 20)
76 - 203
(3 8)
ALLOWABLE SPEEDS
Wear is effected by:
Piston Speed
Piston rings
Wear bands
Packings
Rotating Speed
Valve cyclic (fatigue) life
Forces and moments
created
PISTON SPEED LIMITS
Current limits for 3 year operation

Lubricated: 4.3 m/s (850 ft/min )
Non-lubricated: 3.8 m/s (750 ft/min )
Acceptable speeds vary with user

Lower piston speed provide longer operation
Other factors affect wear part life
Lubrication
Surface finish of counter-face
Pressure loading on wear part
Non-metallic material selection
Gas composition and any particulate
Operating temperature
EFFECTS OF OPERATING TEMPERATURE
135 C
(275 F)
PISTON SPEED VS. DRIVER SPEED
SPEED COMPARISON
High Speed
Moderate Speed
Traditional
Slow Speed
Drive Speed
(RPM)
1000 - 1800
700 - 1200
300 - 700
Piston Speed
Lubricated
m/s (ft/min)
4.6 6.1
(900 1200)
2.8 4.4
(560 870)
2.8 4.8
(560 910)
Piston Speed
Non-Lube
m/s (ft/min)
Not Available
2.3 3.8
(450 750)
2.3 3.8
(450 750)
ROTATING SPEED
Effects of rotating speed

Compressor forces and moments
Driver RPM capability has increased
Materials
Technology
ROTATING SPEED

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 m/s impact velocity
EFFECTS OF VALVE LIFT / IMPACT VELOCITY
EFFECTS OF VALVE LIFT / IMPACT VELOCITY

VALVE COMPARISON:
Hi Speed
Low Speed
Valve Type
Non-Metallic
Plate, Ring or
Poppet
Non-Metallic
Plate, Ring or
Poppet
Valve Lift
Mm (Inch)
1.5 2.6
(0.06 0.1)
1.5 2.5
(0.06 0.1)
Expected
Valve Life
24 Months
36 Months
ROTATING SPEED VALVE LIFE
Other factors effecting valve life

Valve Type
Unknown operating points
Oil sticktion
Liquids
Dirt
ROTATING SPEED HORIZONTALLY OPPOSED
Inertial forces act in opposite directions
Equal masses result in equal but opposite forces
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
MODERATE-SPEED COMPRESSOR BALANCE
PISTON
Moderate Speed
Low Speed
Piston Material
Ductile Iron
Ductile Iron or Aluminum
Piston Ring and

Wear Band
Configuration
Piston Ring +
Separate Wear
Band
Piston Ring + Separate

Wear Band
Piston Ring and

Wear Band
Material
Non-Metallic
As Required
Non-Metallic
As Required
Wear Band
Loading
N/mm2 (psi)
0.035
(5)
0.069 (10)
or 0.035 (5)
COMPRESSOR COMPARISON
Natural Gas
Process
CYLINDER
Moderate Speed
Slow Speed
Material
Ductile Iron
Forged Steel
Ductile Iron
Cast Steel
Forged Steel
NACE Option
Yes
Yes
Water Jacket
Not Required
As Required or
As an Option
Cylinder Liner
No
As Required or
As an Option
Surface Hardness
61 Rc
(Nominal)
25 Rc
Typical
CAN MODERATE SPEED COMPRESSORS BE APPLIED IN TRADITIONAL

API 618 APPLICATIONS?
With correct application engineering
YES

Valerus Compression

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September 26, 2013

2012 Valerus. Confidential and proprietary. All rights reserved.

COMPRESSION: COMPARISON OF HIGH / MEDIUM SPEED VS.

PREAMBLE RECIPROCATING COMPRESSOR BASICS

Understand how a compressor functions NEWEST PRESENTATION

Overview of major components in the system

2012 Valerus. Confidential and proprietary. All rights reserved.

DRIVER & COUPLING

COOLER & SHEAVES

FUEL & UTILITY SYSTEM

EXHAUST SYSTEM & COOLER PLATFORM

PREAMBLE RECIPROCATING COMPRESSOR BASICS

Video Compressor Package in Operation

2012 Valerus. Confidential and proprietary. All rights reserved.

API-11P (ISO-13631) VS API-618

API-11P (ISO-13631): High/Medium Speed Compressors

2012 Valerus. Confidential and proprietary. All rights reserved.

API-618 GENERAL OBJECTIVE

1st & 2nd Edition (1964)

Integral & separable

Current 5th Edition

Steam engines (direct)

2012 Valerus. Confidential and proprietary. All rights reserved.

API-618 GENERAL OBJECTIVE

Design for a minimum 20 year service life

Compressor design standards

2012 Valerus. Confidential and proprietary. All rights reserved.

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

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

2012 Valerus. Confidential and proprietary. All rights reserved.

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

API-11P - 1975 specifically covers packaged high-speed

2012 Valerus. Confidential and proprietary. All rights reserved.

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

The 4th edition of API-618, states; requirements for

The second edition of API-11P - November 1989

This standard covers the minimum requirements for a

2012 Valerus. Confidential and proprietary. All rights reserved.

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

2012 Valerus. Confidential and proprietary. All rights reserved.

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

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

2012 Valerus. Confidential and proprietary. All rights reserved.

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

In general it should be remembered that API 618 is

2012 Valerus. Confidential and proprietary. All rights reserved.

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

A gas engine must be maintained on a monthly basis

2012 Valerus. Confidential and proprietary. All rights reserved.

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

On average, for smaller bore cylinders a replacement

2012 Valerus. Confidential and proprietary. All rights reserved.

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

This can reduces volumetric efficiency and the flexibility of the

2012 Valerus. Confidential and proprietary. All rights reserved.

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

Cylinder Water Jackets:

Originally API-618 asked that water jackets not be included

2012 Valerus. Confidential and proprietary. All rights reserved.

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

Air-cooled cylinders have been in use for over 30 years

2012 Valerus. Confidential and proprietary. All rights reserved.

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

2012 Valerus. Confidential and proprietary. All rights reserved.