Natural Gas Engineering

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Compressor

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 Compressor for Natural Gas

Compressor: is a machine for raising a gas - a compressible fluid - to a LPG domestic tank in India

higher level of pressure.

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Pipeline and compressor station
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potential energy to flow, a compressor station is
needed.

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Basic pipeline capacity design concept (EIA, 2008) 2
 Compression Station

 Field gas-gathering stations

 to gather gas from wells in which pressure is insufficient to produce at a desired rate of flow into a transmission or distribution
system. These stations generally handle suction pressures from below atmospheric pressure to 750 psig and volumes from a few

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thousand to many MMscf/d

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 Relay or main line stations
 to boost pressure in transmission lines. They compress generally large volumes of gas at a pressure range between 200 and 1,300

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psig.

 Repressing or recycling stations

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 to provide gas pressures as high as 6,000 psig for processing or secondary oil recovery projects.

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 Storage field stations O
 to compress trunk line gas for injection into storage wells at pressures up to 4,000 psig.
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 Distribution plant stations
 to pump gas from holder supply to medium- or high-pressure distribution lines at about 20 to 100 psig, or pump into bottle storag
up to 2,500 psig.
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 Types of Compressors

• Positive displacement and Dynamic  Selection of compressors requires considerations of

volumetric gas deliverability, pressure,
compression ratio, and horsepower.

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• Reciprocating compressor and Rotatory compressor

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rotary blower: one or more impellers rotate in opposite directions.
• Centrifugal compressor and Rotary blower the pressure differential between suction and discharge is <15 psi.

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Unlike reciprocating compressors, compression is done without
Reciprocating compressors are most commonly used in the natural gas industry confinement and physical squeezing.
volumetric gas flow rate up to 30,000 cfm at a discharge pressure up to 10,000 psig 100,000 cfm and discharge pressure is up to 100 psig.
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 Compression Process
Compressors are needed to ensure that the natural gas gets to the destination with sufficient pressure along the path
and outlet.
 Isothermal 𝑝𝑉 = 𝑎 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡

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 Overall compression ratio  Polytropic 𝑝𝑉 𝑛 = 𝑎 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡
 Capacity

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 Adiabatic 𝑝𝑉 𝑘 = 𝑎 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡

 The ratio of the discharge pressure to the inlet

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pressure is called compression ratio

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 Adiabatic: Reciprocating compressor

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 Polytropic: Centrifugal compressor
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Volumetric Efficiency and required horsepower
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Analytical expression
Enthalpy-Entropy: Mollier diagram
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 Compression Process

 perfectly reversible adiabatic: an isentropic process

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𝑝𝑉 𝑘 = 𝑎 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡

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𝐶𝑝

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𝑘=
𝐶𝑣 k is an isentropic exponent given by the specific heat ratio

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2.738 − 𝑙𝑜𝑔𝛾𝑔
𝑘150°𝐹 ≈ 0.55 <γg< 1

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2.328
O 𝑛−1 𝑘−1 1
n is related to k through polytropic efficiency Ep = ×
𝑛 𝑘 𝐸𝑝
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The isentropic exponent k applies to the ideal frictionless adiabatic process, while the polytropic exponent n applies to
the actual process with heat transfer and friction.
Rollins (1973): 𝐸𝑝 = 0.61 + 0.031log(𝑞1 ) q1 = gas capacity at the inlet condition, cfm
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Compression Process

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 Compression Process
Volumetric Efficiency
 volumetric efficiency represents the efficiency of a compressor cylinder to compress gas

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 ratio of the volume of gas actually delivered to the piston displacement

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corrected to suction temperature and pressure

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The theoretical formula 𝐸𝑣 = volumetric efficiency, fraction
r = cylinder compressor ratio
𝐸𝑣 = 1 − 𝑟1/𝑘 − 1 𝐶𝑙 𝐶𝑙 = clearance, fraction

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In practice, adjustments are made to the theoretical

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formula in computing compressor performance

𝐸𝑣 = 0.97 −
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𝑟 𝑘 − 1 𝐶𝑙 − 𝑒𝑣
𝑧𝑠 = gas deviation factor at suction of cylinder
𝑧𝑑 = gas deviation factor at discharge of cylinder
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𝑧𝑑 𝑒𝑣 = correction factor

• the constant 0.97 is a reduction of 1 to correct for minor inefficiencies such as incomplete filling of the cylinder during the intake stroke.
• correction factor ev is to correct for the conditions in a particular application that affect the volumetric efficiency and for which the theoretical formula is inadequate.

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 Stage Compression
 As pressure ratio increases: the volumetric efficiency becomes less, and mechanical stress limitation becomes
more pronounced Natural gas is usually compressed in stages with the pressure ratio per stage being less than 6.
 In field practice, the pressure ratio seldom exceeds 4. When the total compression ratio is greater than this, more

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stages of compression are used to reach high pressures.

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 The total power requirement is a minimum when the pressure ratio in each stage is the same.

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1/𝑁𝑠
𝑝𝑑
𝑟=

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𝑝𝑠

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Large compression ratios result in gas being
heated to undesirably high temperatures O
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Two-stage compression arrangement
with intercoolers and aftercoolers
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 Stage Compression

Isentropic Horsepower
 The computation is based on the assumption that the process is

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 ideal isentropic or perfectly reversible adiabatic.

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 The total ideal horsepower for a given compression is the
 the sum of the ideal work computed for each stage of compression.

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 The ideal isentropic work can be determined for each stage of compression in a number of ways.

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 One simple and rapid way to solve a compression problem is by using the Mollier diagram
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 tracing the increase in enthalpy from the cylinder suction pressure and temperature to its discharge pressure along the
path of constant entropy
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 This involves some care in handling and converting the various units such as cubic feet per minute, pounds of
vapor, British thermal units, and horsepower, but it is a simple and straightforward method.
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 Enthalpy-Entropy: Mollier Diagram
Mollier diagram provides a simple, direct, and rigorous procedure for determining the
horsepower theoretically necessary to compress the gas.

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Enthalpy-entropy diagram for 0.6 gravity natural gas Adiabatic work of compression from the enthalpy-entropy

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 Compression Process

• Another approach commonly used is to calculate the horsepower for each stage from the isentropic work formula:

w= theoretical shaft work required to compress the gas, ft-lbf/lbm

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(𝑘−1)/𝑘
𝑘 53.241𝑇1 𝑝2 Tl = suction temperature of the gas, °R
𝑤= −1

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𝛾𝑔 = gas-specific gravity, air = 1
𝑘−1 𝛾𝑔 𝑝1
𝑝𝑙 = suction pressure of gas, psia
𝑝2 = pressure of the gas at discharge point, psia

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When the deviation from ideal-gas behavior is appreciable,

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𝑍1 (𝑘−1)/𝑘 𝐻𝑝𝑀𝑀 = required theoretical compression power, hp/MMcfd
𝑘 53.241𝑇1 𝑝2

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𝑝𝑏 = base pressure for specifying 1 MMcfd of gas, psia
𝑤= −1
𝑘−1 𝛾𝑔 𝑝1 O 𝑇𝑏 = base temperature for specifying 1MMcfd of gas, °R
Z1= compressibility factor at suction conditions
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𝑍1 (𝑘−1)/𝑘
𝑘 3.027𝑝𝑏 𝑝2
In terms of power: 𝐻𝑝𝑀𝑀 = 𝑇1 −1
𝑘 − 1 𝑇𝑏 𝑝1
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 Compressor Efficiency
• The theoretical adiabatic horsepower can be converted to brake horsepower (Hpb) required at the end of
prime mover of the compressor using an overall efficiency factor, E0.

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• The brake horsepower is the horsepower input into the compressor.
The overall efficiency of a compressor depends

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𝑞𝐻𝑝𝑀𝑀 on a number of factors:
𝐻𝑝𝑏 = where q is the gas flow rate in MMscfd.

𝐸𝑜 design details of the compressor,

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 suction pressure,
The efficiency factor E0 consists of two components:  speed of the compressor,
 compression ratio,
 compression efficiency (compressor-valve losses) and

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 loading
 the mechanical efficiency of the compressor. 

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general mechanical condition of the unit.

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 In most modern compressors, the compression efficiency ranges from 83 to 93%.
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 The mechanical efficiency of most modern compressors ranges from 88 to 95%.
 Overall efficiency ranges from 75 to 85%, based on the ideal isentropic compression process as a standard.

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 Compressor Efficiency

 The actual efficiency curves can be obtained from the manufacturer.

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 The discharge temperature for real gases can be calculated by:

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𝑧1 (𝑘−1)/𝑘
𝑝2
𝑇2 = 𝑇1
𝑝1

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 the heat removed by intercoolers and after coolers can be accomplished using constant pressure specific

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heat data

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𝑛𝐺 =number of lb-mole of gas
∆𝐻 = 𝑛𝐺 𝐶𝑝 ∆𝑇 O 𝐶𝑝 = specific heat under constant pressure evaluated
at cooler operating pressure and the average temperature, Btu/lb-mol-°F
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Example
𝑍1 (𝑘−1)/𝑘
𝑘 3.027𝑝𝑏 𝑝2
𝐻𝑝𝑀𝑀 = 𝑇1 −1

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𝑘 − 1 𝑇𝑏 𝑝1

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 Selection of Centrifugal Compressors

• The procedure of preliminary calculations for selection of centrifugal compressors is summarized as follows:
𝑝2

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1. Calculate compression ratio based on the inlet and discharge pressures: 𝑟=
𝑝1

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𝑝𝑏 𝑇1
2. Based on the required gas flow rate under standard conditions (q), 𝑞1 = 𝑞
𝑝1 𝑇𝑏

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estimate the gas capacity at inlet condition (q1) by ideal gas law:

3. Find a value for the polytropic efficiency Ep from the manufacturer's manual based on q1.

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4. Calculate polytropic ratio (n-l)/n using 𝑛−1 𝑘−1 1
𝑅𝑝 = = ×
𝑛 𝑘 𝐸𝑝

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5. Calculate discharge temperature by: 𝑇2 = 𝑇1 𝑟 𝑅𝑝
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 Selection of Centrifugal Compressors
6. Estimate gas compressibility factor values at inlet and discharge conditions.

7. Calculate gas capacity at the inlet condition (q1) by real gas law: 𝑧1 𝑝𝑏 𝑇1
𝑞1 = 𝑞
𝑧2 𝑝1 𝑇𝑏

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8. Repeat steps 2 through 7 until the value of q1 converges within an acceptable deviation.

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9. Calculate gas horsepower by: 𝑞1 𝑝1 𝑧1 + 𝑧2 𝑟 𝑅𝑝 − 1
𝐻𝑝𝑔 =

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229𝐸𝑝 2𝑧1 𝑅𝑝
Some manufacturers present compressor specifications using polytropic head in lbf-ft/lbm defined as:

𝑟 𝑅𝑝 − 1

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𝑧1 + 𝑧2
𝐻𝑔 = 𝑅𝑇1
where R is the gas constant given by 1,544/MWa in psia-ft3/lbm-oR. 2 𝑅𝑝

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The polytropic head relates to the gas horsepower by 𝑚𝐻𝑔
𝐻𝑝𝑔 =
33000𝐸𝑝
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where is mass flow rate in lbm/min.
10. Calculate gas horsepower by: 𝐻𝑝𝑏 = 𝐻𝑝𝑔 + ∆𝐻𝑝𝑚

where ΔHpm is mechanical power losses, which is usually taken as 20 horsepower for bearing, and 30
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 Natural Gas Processing

Compressor Design Calculation

 Perfectly reversible adiabatic (an isentropic process. ) 𝑝𝑉 𝑘 = 𝑎 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡

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𝑧𝑠 1
 Volumetric efficiency 𝐸𝑣 = 1 − 𝑟1/𝑘 − 1 𝐶𝑙 𝐸𝑣 = 0.97 − 𝑟 𝑘 − 1 𝐶𝑙 − 𝑒𝑣

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𝑧𝑑
1/𝑁𝑠
𝑝𝑑
 Stage compression 𝑟=
𝑝𝑠

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𝑍1 (𝑘−1)/𝑘
𝑘 53.241𝑇1 𝑝2
 Work 𝑤= −1
𝑘−1 𝛾𝑔 𝑝1

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𝑍1 (𝑘−1)/𝑘
𝑘 3.027𝑝𝑏 𝑝2

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 Horsepower 𝐻𝑝𝑀𝑀 = 𝑇1 −1
𝑘 − 1 𝑇𝑏 𝑝1

𝐻𝑝𝑏 =
𝑞𝐻𝑝𝑀𝑀
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 The brake horsepower 𝐸𝑜
𝑧1 (𝑘−1)/𝑘
𝑝2
 The discharge temperature for real gases 𝑇2 = 𝑇1
𝑝1
 Heat removed by intercoolers and after coolers ∆𝐻 = 𝑛𝐺 𝐶𝑝 ∆𝑇
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