• Gathering Systems

Willbros Total Project Services Delivering Natural Gas Solutions • Compressor Stations

• Gas Processing Plants • Measurement Facilities

Facility Development and Operations Single Source EPC Services
• Pipelines Onshore & Offshore • Dehydration Facilities

WILLBROS International, Inc. | WILLBROS USA, Inc. | Willbros RPI, Inc. | Constructora CAMSA, C.A. | The Oman Construction Co. | WILLBROS (Overseas) Ltd. | WILLBROS West Africa, Inc | WILLBROS Middle East, Inc. WILLBROS (Nigeria) Ltd. | WILLBROS Engineers, Inc. | WILLBROS Engineering & Construction Limited | WILLBROS Far East, Inc. | WILLBROS Energy Services Co. | Willbros Mt.West, Inc.

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OIL & GAS JOURNAL
1700 West Loop South, Suite 1000
Houston, TX 77027 USA
www.ogjonline.com

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Onshore Gas Pipeline
Compressor Station 12 3
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Editorial direction and coordination from
Warren R. True, Chief Technology Editor–LNG/Gas Processing
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Oil & Gas Journal

MUSTANG ENGINEERING 11
16001 PARK TEN PLACE 12
HOUSTON, TX 77084 USA
www.mustangeng.com

People Oriented…Project Driven™

Content by the Mustang Engineering technical team: 19 11

Troy Waldron, PE, Project Manager 18 18
Ben Sprueill, Frank Mazzola, Dudley Benoist, 3D Piping Design and Graphics
Artwork & rendering: Beau Brown, Industrial3d
Graphic coordination: Chris Jones, xenongroup 10
Back copies of this poster may be obtained from PennWell.
To order: call 713/963-6210; fax 713/963-6228; e-mail bettyk@pennwell.com;
or submit request to 1700 West Loop South, Suite 1000, Houston, TX. 77027.
Reproduction of the contents of this poster, in any manner, is prohibited without the consent of PennWell Corp. ©2005

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Onshore Gas Compression 15
This gas compressor station is typical of new
worldclass facilities being built to transport major gas
supplies from production to market and storage. 22
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Pressure moves natural gas through the pipelines. As the gas moves centrifugal compressors
through the pipe, the pressure decreases and the gas must be 5 are used as the base units
4
recompressed to maintain the flow. This station would be on a major to compress the majority of the flow.
pipeline system and downstream of a gas separation plant that removes These are compressor drivers that are turbine engines using
the primary solids and liquids from the producing field. Gas compressor natural gas for fuel. Smaller reciprocating piston-type compressors
stations are located along the pipeline at intervals sufficient to boost driven by gas reciprocating-piston engines 6 or electric motors 7 22
the gas pressure and maintain flow through the pipeline. are used to compress smaller flow increments for more accurate and the positions of
adjustment of the overall pipeline throughput. the valves controlling the
Inlet receiving. The gas compressor station’s inlet receiving facilities gas flow through that compressor.
consist of “pig” receivers 1 and a slug- catcher 2 to remove large Compressor selection is primarily influenced by flow and the amount of 2
solid and liquid contaminants followed by filter coalescers 3 to pressure boost. Driver selection is influenced by energy consumption, This example station uses redundant communication using 8 2
remove fine solids and hydrocarbon mist. A pig refers to a device that speed, and environmental (emissions/noise) considerations. In microwave, satellite 10 , or conventional leased telephone systems.
is pushed by the gas through the pipe either this example, two 19,000-hp and one 1 6
to clean the pipe of obstructive material 1 15,000-hp gas turbine-driven centrifugal This station is designed for the option of completely unmanned operation of human response to noise
or inspect the pipe for defects. A slug compressors are the base units. Four by Gas Control. The PLC compressor on/off operation, performance set at the nearest noise sensitive area.
refers to volumes of hydrocarbon liquids 2,000-hp gas-engine-driven reciprocating points, and all station-critical valves may be remotely controlled. Gas This complies with current US Federal Energy
and water that accumulate in a pipeline compressors are the adjustment units Control may monitor all station alarms and shutdowns. Regulatory Commission regulations. Noise levels within a
as entrained liquids in natural gas and are connected by station piping to be 3-ft distance from equipment for the employee’s average time
condense. Slugs also occur from cleaning operated in parallel or series. Acoustical treatment. Silencing equipment incorporated into the of exposure is less than 85 dBA. This complies with current US 3
solutions injected into the pipeline for engine air intake ducting and filters, 11 engine exhaust systems 12 , Occupational Safety and Health Administration requirements.
integrity maintenance pigging. Normal Total station capacity is certificated at 2.2 vent and blowdown exits 13 , equipment enclosures, and piping insu- 7
gas flow bypasses the slug catcher to bscfd throughput. Gas leaves the station lation accomplish noise control for the surrounding community and Aesthetics. Facility aesthetics are important for being compatible from a fire or equipment failure disabling an
reduce pressure losses. Flow is switched at the increased pressure to maintain station employees. with the surrounding community. Aesthetics are a factor in the facility entire station.
through the slug catcher for as-needed use. the pipeline flow rate. Pig launchers 8 layout, building designs, coating colors, and landscaping. This example • Using redundant and parallel filter coalescers prevents
Equipment and piping pressure losses are are installed in the station exit piping to Liners and baffles of noise-reduction material are used inside the station is in a US farming community. unexpected large amounts of contaminants from impeding the gas
avoided in the station as much as possible. facilitate pipeline integrity maintenance engine air intake ducting and filters, engine exhaust, and vent and flow and allows filtration-cartridge replacement without interrupting
pigging downstream. blowdown exits. Acoustical lining on the internal walls and silenced Emissions. The reciprocating and turbine engine’s emission levels are compressor operation. 4
In this example, final protection of equipment by the filter coalescers ventilation systems reduce noise from primary considerations in equipment selection. Also important are the • Monitoring and trending of vibration, bearing temperatures, and Legend
occurs near the compressor or group of compressors being protected. Station control. The overall control of a 3 the compressor buildings. As much exhaust system’s exit height and location determined by emission- other critical operational parameters by the compressor PLC identify 1. Pig receivers 13. Gas vent; blowdown exit 5
A filter coalescer also cleans the gas in each fuel supply to the turbines major gas pipeline transportation system station gas piping as possible is installed dispersion modeling studies. All station-emission sources, such service needs to prevent catastrophic equipment failures. 2. Slug catcher 14. Water-mist fire suppression
and gas engines. typically originates from a central “Gas below grade to provide additional as vents from piping, valve operators, tanks, and so forth, must be • Fire detection and automated fire-suppression systems using water 3. Filter coalescer 15. Water storage tank
Control” office that is remote from all noise reduction. Abovegrade station controlled to reduce any air, water, or ground contamination. mist 14 or chemical cleaning agents are in the control, compressor, 4. Hydrocarbon storage tank 16. Firewater pump
The liquids, removed from the gas, flow to a hydrocarbon storage tank of the compressor stations. Gas Control gas piping is acoustically insulated. and other equipment areas to minimize fire damage and out-of- 5. Gas turbine-driven centrifugal compressor 17. Standby generator
4 to be separated by gravity and then be transported by truck as monitors flow measurement for the Internal noise-reduction modifications Reliability. Compressor-station reliability is paramount to overall service time. 6. Gas engine-driven reciprocating compressor 18. Glycol coolant
saleable hydrocarbon liquid or as disposed waste product. total station throughput as well as are required in flow control valves. Fan gas pipeline delivery dependability. Reliability considerations are • A water storage tank 15 plus a diesel-engine-driven and an electric- 7. Electric-motor-driven reciprocating compressor To tanker truck
each compressor’s throughput and fuel tip speed limitations and low-noise fan incorporated into many areas of the facility. motor-driven firewater pump 16 supplement or provide back-up for 19. Lubricant oil
8. Pig launchers
Compression. Multiple common-owner parallel cross-country pipelines consumption. drive designs are required for gas and • The total amount of installed compression must be more than the the station’s commercial water supply. 20. Plant air storage
9. Compressor control building; programmable logic
may be operated where each pipeline operates at a different pressure oil coolers 23 24 . normal design requirement to allow for equipment failures and • An automatic diesel-engine-driven standby generator 17 backs up controller (PLC) 21. Workshop, compressor-parts storage
or they may be interconnected where several or all operate at the same The programmable logic controller (PLC) maintenance downtime. the station’s commercial electric power supply. 10. Communication tower 22. Compressor-unit isolation valves Gas
pressure. The gas pressure in the pipelines is increased by a combination 9 in each compressor unit’s control Station noise control provides a day- • Spacing between compressor or compressor groups aims at • Supplies critical to operation such as frequent use and long-lead
of multiple compressors connected in parallel to the pipelines by panel, communicates to Gas Control the night average sound level (Ldn) of less preventing fire damage in one compressor from harming others. delivery time parts, tooling, glycol engine coolant 18 , lubricants 19 ,
11. Air intake ducting and filter 23. Gas coolers 1 Hydrocarbon liquids
12. Engine exhaust system 24. Oil cooler
the station piping. Typically for mainline stations, gas turbine-driven operating parameters for that compressor than 55 decibels per the “A” rating (dBA) • Multiple compressor-control buildings 9 are used as a precaution and lubricant testing equipment are stored on site.

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