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Understanding Centrifugal
Compressor Performance in a
Connected Process System
Scott Golden, Scott A. Fulton and Daryl W. Hanson
Process Consulting Services Inc., Houston, Texas

W
et gas compressor capacity lim- Suction pressure changes have a much process flow scheme, tower internals, heat
its feed rate or unit conversion larger influence on compressor capacity exchangers, piping/nozzles, control valves,
in many FCC and delayed due to their effect on overhead receiver and orifice plate modifications. These com-
coker units. Understanding compressor condensation, gas density, and compressor ponents all generate pressure drop. Process
performance and its interaction with the head. flow scheme changes may include adding a
connected process systems is critical when pumparound to the main column or
revamping FCC and delayed coker units. Connected Process System bypassing absorber bottoms liquid around
Many times unnecessary changes are Process system operating pressure and sys- the high pressure condenser to reduce pres-
made to the compressor and driver. tem pressure drop strongly influence wet sure drop.
Alternatively, lower cost process system gas compressor capacity. Compressor dis- System pressure drop between the main
modifications can be used to debottleneck charge and suction pressure are variables column inlet nozzle and the compressor
a compressor limit. Figure 1 shows a block and should be manipulated whenever pos- inlet will vary from a low of 5 to over 25 psi.
diagram of a compressor and the connect- sible to raise compressor capacity. High pressure drop components need to be
ed process system components. Increasing compressor suction pressure identified and cost-effective and reliable
The connected process system and com- and reducing discharge pressure will changes made. In some instances, replac-
pressor performance must be thoroughly increase compressor capacity. Finding ing main column trayed internals with
evaluated as a single system to determine cost-effective solutions always starts with structured packing will be the low-cost
the most cost-effective way to increase field measurements of the current opera- solution. Other times, condenser system
compressor capacity, but conventional pro- tion to identify high pressure drop compo- pressure drop will control compressor suc-
cess design approaches use several equip- nents. Distillation column internals, pro- tion pressure. Therefore, piping, fin-fan,
ment disciplines to evaluate piping, heat cess piping, heat exchangers, control shell and tube exchanger, control valve, or
exchange, and distillation systems inde- valves, and flow metering in the connected flow metering modifications will need to be
pendently. Thus the opportunity to debot- process system must be modeled together considered.
tleneck the compressor with lower cost pro- with the compressor to quantify compres- Absorber operating pressure and system
cess system changes may go unnoticed. sor capacity increases resulting from equip- pressure drop set the compressor discharge
Reducing system pressure drop (Table 1) ment modifications. pressure (Figure 1). Lower discharge pres-
to increase suction pressure or decrease In an FCCU, feed rate, reactor/regenera- sure reduces compressor head and driver
discharge pressure allows more gas to be tor differential pressure, and system pres- power, which increases compressor capaci-
compressed through the compressor with- sure drop set com-
out modifications. However, the impact of pressor suction
FUEL
suction and discharge system changes on pressure. In a GAS
compressor capacity is not the same. coker, coke drum
constraints and the
Process Equipment system pressure
Pressure Drop OVERHEAD COMPRESSOR
drop set suction CONDENSERS
CONDENSERS SYSTEM
Main Column Internals pressure. Discharge
Piping/Nozzles pressure is con-
ABSORBER/
Control Valves trolled by the gas MAIN DEETHANIZER
COLUMN
Fin-fans plant operating
FEED
pressure and sys- OPERATING
Shell and Tube Exchangers
tem pressure drop. PRESSURE
Flow Metering
Practical changes
Table 1. to consider include Figure 1. Compressor and Connected Process System

Reprinted from Petroleum Technology Quarterly® Spring 2002 Issue


REVAMPS

TO TO 29,000
INTERSTAGE HIGH PRESSURE 7,700 RPM
CONDENSER CONDENSER
28,000

POLYTROPIC HEAD, FEET


27,000
FROM FROM
OVERHEAD INTERSTAGE
RECEIVER RECEIVER 26,000

25,000

24,000
DRIVER
LOW STAGE HIGH STAGE (MOTOR OR 23,000
STEAM TURBINE)
11,500 12,000 12,500 13,000 13,500 14,000 14,500
COMPRESSOR VOLUMETRIC FLOW, ICFM

Figure 2. Compressor Block Diagram Figure 3. Compressor Performance Curve, Low-Stage

ty. Discharge pressure should be mini- improves compressor efficiency and compressor curve flow term is always
mized without reducing gas plant perfor- reduces the gas temperature rise through based on inlet conditions; consequently
mance. Absorber pressure controls C3 the stages of compression. Inter-cooled inlet gas density influences volumetric
recovery assuming other process variables compressors will have a low-stage curve flow. Flow is shown on the X-axis and
have been optimized. In a few instances, defining performance upstream of the head on the Y-axis. For a fixed speed, the
reducing absorber operating pressure will inter-cooler and a high-stage curve for the curve shows that for a known inlet flow
not materially change C3 recovery. In most downstream portion (Figure 2). In reality, rate a fixed head is developed. Centrifugal
cases, however, propylene recovery drops the low (Figure 3) and high-stages (Figure compressor inlet flow rate increases as the
as pressure is reduced and it is not a cost- 4) will have 3-4 actual wheels having their head decreases. Gas plant operating pres-
effective way to increase compressor own individual performance curves. These sure, connected system pressure drop, and
capacity. If the existing compressor dis- low and high-stage performance curves gas composition sets the developed head.
charge system has high pressure drop, are a composite of the individual stage Increasing suction pressure, decreasing
then equipment changes may be an effec- (Figure 5) curves. Usually these low and gas plant operating pressure and/or
tive means to debottleneck the compres- high-stage curves are sufficient to evaluate decreasing process system pressure drop
sor. Typically, compressor discharge pres- compressor performance and the connect- will increase inlet flow rate as long as the
sure will need to be reduced by at least 20 ed process system’s influence on compres- compressor is not operating at choke flow.
psi to have a meaningful effect on com- sor capacity. A compressor curve starts at the surge
pressor capacity and driver power. Centrifugal compressors have perfor- point and ends at stonewall, or choke flow.
mance curves similar to pumps. The major The surge point is the head at which inlet
Compressor Fundamentals difference is that a compressor moves gas flow is at its minimum. At this point, the
Most FCC and delayed coker wet gas com- which is compressible, while the pump compressor suffers from flow reversal,
pressors have an inter-cooler system that moves liquid that is not compressible. The which is a very unstable operation that is

7,700 RPM
28,000
LOW STAGE HIGH STAGE
26,000
POLYTROPIC HEAD, FEET

24,000

22,000

20,000

18,000
SUCTION INTERCONDENSER DISCHARGE
16,000 SYSTEM
2,800 3,000 3,200 3,400 3,600 3,800 4,000 4,200
VOLUMETRIC FLOW, ICFM

Figure 4. Compressor Performance Curve, High-Stage Figure 5. Compressor Stages

Reprinted from Petroleum Technology Quarterly® Spring 2002 Issue


REVAMPS

accompanied by vibration and possible and coke drum


damage. On the other end of the curve is effluent composi- 7,700 RPM
28,000
the choke (or stonewall) point. At the tion controls gas

POLYTROPIC HEAD, FEET


choke point, the inlet flow through the molecular weight.
27,000 REDUCED
compressor cannot increase no matter FCC dry gas typi- HEAD
what operating changes are made. cally has a molecu-
26,000
Therefore, the range of compressor perfor- lar weight in the 1,500 FT HEAD
mance is defined between these two flow- range of 21-23.
25,000
head limitations. Typically, the curve is flat Typical propy-
near the surge point and becomes steeper lene/propane mix- 6%
24,000
as flow is increased. Hence, small head tures have a
changes near the surge point cause a large molecular weight 23,000
increase in compressor capacity. As com- of 43.5. As the FCC 11,500 12,000 12,500 13,000 13,500 14,000 14,500
pressor operation moves toward reactor reduces the VOLUMETRIC FLOW, ICFM
stonewall, decreasing head has less influ- dry gas yield and
ence on inlet flow rate because the curve increases heavier Figure 6. Compressor Performance Curve, Head Reduction
slope increases. As the stonewall point is C3 and C4’s yield,
approached, changes in head will have the wet gas molecular weight and wet gas magnitude of the inlet flow rate increase
negligible effect on inlet flow rate. density increase, thus reducing inlet vol- resulting from a given polytropic head
ume. A 5% increase in gas molecular reduction. Process changes that move the
Compressor Inlet Flow weight decreases inlet volume flow rate by operating point to the right include higher
The performance curve flow rate is based 5% for a fixed temperature and pressure. gas molecular weight, raising suction pres-
on suction conditions and expressed as sure, or lowering discharge pressure. Gas
inlet cubic feet per minute (ICFM). It is not Compressor Head temperature changes have little influence
standard gas flow metering units. Wet gas Centrifugal compressors do not develop a on head. Compressor molecular weight is
is a compressible fluid, therefore changes constant differential pressure; they devel- set by the coke drum or FCC reactor gas
in compressor suction conditions that op a constant differential polytropic head composition. Suction pressure changes of
increase gas density will reduce wet gas at a given inlet flow rate. Often, the com- 5 psi or higher can also influence gas com-
volumetric flow rate and free up compres- pressor curves provided by the E&C com- position and molecular weight through the
sor capacity. pany or the compressor vendor will report impact of condensation.
Gas density is a function of temperature, the performance curve as differential pres- Compressor suction and discharge pres-
pressure, and gas molecular weight. Gas sure versus inlet flow rate. These differen- sure both influence the polytropic head.
density is calculated from the ideal gas law tial pressure curves represent one set of Compressor discharge pressure is set by
shown in equation 1. For a fixed mass flow inlet operating conditions only. They are the gas plant operating pressure and the
not sufficient to evaluate the compressor pressure drop from the compressor dis-
Equation 1. and connected system performance. charge to the absorber pressure control
Understanding the components of this valve. For instance, compressor discharge
Gas Density = P(MW)/RT head term is essential when considering and suction pressures of 220 psig and 10
P = Gas pressure (absolute) the influence of the process operating psig, respectively, are common. Therefore,
T = Gas temperature (absolute)
MW = Gas molecular weight pressure and the system pressure drops the pressure ratio term is 234.7 psia/24.7
R = Gas constant effect on compressor capacity. Equation 2 psia or 9.5. Reducing head requires a
shows the polytropic head term. decrease in the pressure ratio term. This
rate and gas composition, temperature has Reducing polytropic head will increase simplified evaluation ignores the influence
a small effect on gas density because the of the inter-stage system.
temperature term is very large. Conversely, Equation 2. Understanding how discharge and suc-
increasing compressor suction pressure tion pressure influence the polytropic
P2  n 
n–1
will significantly increase gas density and head term and compressor capacity is the
  
1,545 n
reduce the gas volume. The lower the suc- Hp =
MW
ZAVGT1
 n–1  P1
–1
key to evaluating potential connected pro-
tion pressure the larger the effect of pres- cess system modifications. Figure 6 repre-
Where:
sure changes on compressor capacity. For Hp Polytropic head, ft
sents the influence of a 1500-foot head
example, increasing pressure from 18.7 MW Molecular weight reduction on compressor inlet flow rate for
psia to 20.7 psia decreases the inlet gas ZAVG Average compressibility one compressor. Increasing suction pres-
T1 Suction temperature, °R
flow rate by 10.6% for the same mass flow n Compression coefficient
sure P1 or decreasing discharge pressure
rate. When the suction pressure is 44.7 P1 Suction pressure, psia P2 will reduce head. Quantifying the suc-
psia the same 2 psi change reduces gas P2 Discharge pressure, psia tion and discharge pressure changes that
volume by only 4%. result in the same polytropic head reduc-
Increasing gas molecular weight will compressor capacity by moving the oper- tion is useful. Either increasing suction or
also increase gas density and reduce vol- ating point to the right except at stonewall. decreasing discharge pressure can be used
ume for a fixed mass flow rate. Reactor The slope of the curve will determine the to reduce polytropic by 1500-feet and

Reprinted from Petroleum Technology Quarterly® Spring 2002 Issue


REVAMPS

MAIN

PRODUCTION, ICFM
FRACTIONATOR STRIPPER VAPOR 15,000
VAPOR

WET GAS
WET GAS
COMP. PRIMARY 12,000
ABSORBER
BOTTOMS
9,000
COMP.
DRIVER 9 10 11 12 13
OVERHEAD RECEIVER PRESSURE, PSIG
PRIMARY RECEIVER TEMPERATURE=100°F
ABSORBER
FEED
Figure 8. Suction Pressure vs. Wet Gas Production

OVERHEAD INTERSTAGE HIGH PRESS.


RECEIVER RECEIVER RECEIVER STRIPPER/

PRODUCTION, ICFM
DEETHANIZER
FEED 18,000

WET GAS
15,000

PRIMARY
ABSORBER 12,000
LIQUID FEED 100 110 120 130 140
OVERHEAD RECEIVER TEMPERATURE, °F
RECEIVER PRESSURE=8.5 PSIG

Figure 7. Compressor and Connected System Figure 9. Suction Temperature vs. Wet gas Production

increase the compressor inlet flow capaci- flow rate. When the drivers are limited the amount of condensation that occurs.
ty by 6%. turbine steam rate and speed or the motor Compressor suction pressures and temper-
Suction pressure changes have a much amps are at maximum. Compressor driver atures vary from 1.5 to 30 psig and 80°F to
larger influence on compressor capacity power consumption is a function of the 135°F, respectively.
than discharge pressure changes. Raising mass flow, compressor polytropic head, Main fractionator pressure and temper-
suction pressure by 2.0 psi decreases the compressor efficiency, and gear efficiency. ature can be optimized through equipment
head by 1500-feet as a result of reducing Compressor shaft horsepower (SHP) is changes. Figures 8 and 9 show the effect of
the pressure ratio term from 9.5 shown in Equation 3. Reducing polytropic pressure and temperature on wet gas rate
(234.7/24.7) to 8.8 (234.7 psia/26.7 psia). head lowers the compressor shaft horse- for one unit. A low-capital revamp may
The compressor discharge pressure would power. involve replacing the 4-tube row fin-fan
have to be lowered from 220 psig to 202 bundles with 6-row bundles. The 6-tube
psig (P2/P1=216.7 psia/24.7 psia =8.8) to Unit Operations row bundles will have less than half the
produce the same head reduction. Wet gas compressors increase the system pressure loss of the 4-tube rows and add
Reducing gas plant operating pressure operating pressure so that C3-C12 hydro- surface area that can lower receiver tem-
reduces propylene recovery and an 18 psi carbon components can be recovered as perature. In one instance, this raised com-
operating pressure reduction is generally liquid product. Compressor system operat- pressor capacity by over 20% by increas-
not feasible. On the other hand, it may be ing suction and discharge pressure will ing receiver pressure by 2 psi and reducing
possible to reduce system pressure drop vary depending on reactor/regenerator, temperature by 10°F.
by 18 psi. Suction pressure changes of 2 coke drum, gas plant, compressor, and/or Three revamp examples will highlight
psi, however, are practical on many units. upstream equipment design and opera- the relationship between the connected
tion. The compressor takes suction from process system pressure drop, compressor
Compressor Capacity: the main column overhead receiver or performance curves, and wet gas compres-
Driver Power downstream knockout drum, which oper- sor capacity.
Compressor driver power requirements ates at 1.5-30 psig and discharges to a gas
can also limit the compressor maximum plant absorber/deethanizer system operat- EXAMPLE 1: Increasing
ing at 160-240 psig. (Figure 7) Compressor Suction
Equation 3. Main column overhead receiver temper- Pressure Using Structured
ature and pressure determine the amount Packing
Compressor SHP = (m) Hp/[(np) 3300] 1.02
of wet gas production for a fixed reactor A 50,000-bpd unit was revamped to
SHP Shaft horsepower
HP Polytropic head
effluent or coke drum composition. increase capacity to 65,000 bpd. Wet gas
m Mass flow rate of gas Increasing compressor inlet pressure compressor capacity was one of the major
np Polytropic efficiency
1.02 2% gear losses
and/or decreasing temperature reduces the unit limits. Revamping the compressor,
wet gas mass flow rate by changing the installing a new parallel compressor, or

Reprinted from Petroleum Technology Quarterly® Spring 2002 Issue


REVAMPS

MAIN MAIN
COLUMN COLUMN
14.0 18.0

ATMOSPHERE ATMOSPHERE
20.0 22.0 10.0
20.0 22.0 14.0
10.5 14.5

WET GAS WET GAS


COMPRESSOR COMPRESSOR
19.0 19.0
AIR AIR
TRAY P=5.0 PSI PACKING P=1.0 PSI
32.0 32.0
OIL FEED = PSIG OIL FEED
AIR BLOWER = PSIG

Figure 10. Main Column with Trays Pressure Profile Figure 11. Main Column with Packing Pressure Profile

reducing connected system pressure drop psig. The revamp replaced the trays with sor capacity was one of the revamp limits.
were all evaluated and cost estimates gen- structured packing (Figure 11). This A consequence of the heavy naphtha draw
erated for each option. Compressor perfor- reduced column pressure drop to 1.0 PSI. is that wet gas production increases as
mance curves, driver horsepower, and con- Compressor inlet pressure was increased overhead gasoline rate decreases. Prior to
nected system pressure drop were all thor- from 10.5 to 14.5 psig. This increased con- the revamp, the compressor was operating
oughly studied. Compressor modification densation, increased gas density, at maximum capacity. Unlike example 1,
required changes to the compressor inter- decreased compressor polytropic head, where the main column had high pressure
nals, motor replacement, new motor con- and decreased the inlet volume to the com- drop, here the column pressure drop was
trol center gear, and substation modifica- pressor. This increased compressor mass only 2.5 psi. Piping and condenser system
tions. A new parallel compressor was very flow capacity by over 30% without changes represented almost 85% of the total system
expensive and increased operating com- to the compressor or the driver. pressure loss. This emphasizes that accu-
plexity. Reducing system pressure drop rate field measured pressure drop must be
was the least-cost option. EXAMPLE 2: Increasing done as part of preparing for any revamp.
Compressor suction pressure drop Compressor Suction The overhead system pressure profile
includes the main column, condenser sys- Pressure, Reduced Piping shown in Figure 12 had a measured pres-
tem, and piping. Condenser and overhead Pressure Drop sure drop of 13 psi. Pressure drop from the
system pressure drop were only 3.5 psi. A 40,000-bpd unit was revamped to add a fin-fan outlet to the compressor was 10 psi.
Main column pressure drop was 5 psi, heavy naphtha draw and increase unit The revamp replaced the piping down-
which represented over 60% of the suction capacity by 20%. Heavy naphtha contains stream of the fin-fans, shell and tube
system pressure loss. The unit pressure a large portion of the gasoline sulfur, and exchanger shell, piping to the overhead
profile is shown in Figure 10. The main col- the gas plant liquid handling bottlenecks receiver, and orifice plate. Compressor
umn overhead receiver operated at 10.5 limited unit conversion. Wet gas compres- inlet pressure was increased from 2 to 7.5

15.0 15.0

NEW
PIPING PIPING
12.0 12.0

9.0 INLET 11.0 INLET


NOZZLE WET GAS NOZZLE WET GAS
NEW
COMPRESSOR EXCHANGER COMPRESSOR
SHELL
COMPRESSOR
FI 2.0 7.5
OULET 6.0 OULET 9.0 FI SUCTION PRESSURE
NOZZLE NOZZLE INCREASED BY 5.5 PSI
4.0 8.5
PIPING NEW
OPERATING PIPING NEW OPERATING
PRESSURE VENTURI PRESSURE

Figure 12. FCC Measured Pressure Drop Figure 13. FCC Revamp Pressure Drop

Reprinted from Petroleum Technology Quarterly® Spring 2002 Issue


REVAMPS

psi (Figure 13). This increased condensa- field test run to gather all the necessary without changes to the compressor or aux-
tion, increased gas density, decreased data to calibrate process and equipment iliaries.
compressor polytropic head, and models. This was the critical first-step in Increased condensation, increased gas
decreased the inlet volume to the com- establishing all significant unit bottlenecks. density, decreased compressor polytropic
pressor. This raised compressor mass flow As part of the test run, the column and head, and decreased inlet volume to the
capacity by over 30%. overhead system pressure profile was mea- compressor would be the outcome. This
sured with two digital pressure gauges. would permit a 25% increase in feed rate
EXAMPLE 3: Increasing Pressure readings between any two points without any compressor modifications.
Compressor Suction were taken simultaneously with gauges The cost would be a fraction of a new com-
Pressure, Reduced Fin-fan accurate to within +/- .01 psi. The unit pressor. ■
Pressure Drop pressure profile is shown in Figure 14.
A delayed coker unit revamp objective was Measured overhead system pressure drop
to increase capacity by 25%. The unit was was 16 psi with 13 psi measured across the THE AUTHORS
operating at the maximum compressor fin-fans alone. The pressure drop from the
capacity. If compressor suction pressure overhead receiver to the compressor was Scott W. Golden is a chemical engineer with
and temperature were maintained at cur- 2.5 psi with more than 50% across the ori- Process Consulting Services in Houston,
TX. The company specializes in refinery
rent conditions, increasing the gas flow fice meter. Hence measured pressure pro- unit revamps. His previous experience
rate by 25% would require major compres- files clearly pinpointed the high pressure includes refinery process engineering and
distillation troubleshooting and design.
sor and driver modifications at a cost of drop components. Golden has authored more than 80 tech-
more than $2 MM. Hence, more cost As noted, modifying the compressor nical papers on revamping, troubleshooting, and dis-
tillation. He holds a BS degree in Chemical
effective process system changes were would be very costly. Reducing fin-fan and Engineering from the University of Maine and is a
evaluated. orifice plate pressure loss would be a more registered professional engineer in Texas.

The study began with a comprehensive cost-effective alternative. Compressor inlet Scott A. Fulton is a chemical engineer with
pressure could be Process Consulting Services in Houston,
TX. He has worked on 10 FCC unit
increased from 13 to 23 revamps in his current position, where he
psi (Figure 15) with its is responsible for process flow sheet mod-
FI eling, conceptual design, and detail
29.0 resultant benefits. equipment modeling and design. Fulton
Process system changes previously worked as a process engineer for Coastal
Corporation performing revamp and troubleshooting
from the main column work for its refineries in the US and Caribbean. He
16.0 overhead to the com- has authored several papers on revamping. He holds
13.0
30.0 a BS degree in Chemical Engineering from Texas
pressor would include a A&M University.
15.5
new fin-fan bay in par-
Daryl W. Hanson is a chemical engineer with
allel to the existing Process Consulting Services in Houston,
bays, new fin-fan bun- TX. His responsibilities include process
and equipment design and field trou-
dles with additional bleshooting. He specializes in all phases
tube row design to of refinery distillation from process simu-
COKER lation through field inspection. Previously
FRACTIONATOR lower pressure drop he was lead process specialist for Koch-Glitsch Inc.
OPERATING and increase surface where he was involved with more than 100 column
PRESSURE revamps including heavy oils and light-ends recov-
area, and larger fan ery towers. Hanson has authored more than 20 tech-
motors to raise the air nical papers on revamping, troubleshooting, and dis-
tillation. He holds a BS degree in Chemical
Figure 14. Delayed Coker Measured Pressure Drop rate. Thus, overhead Engineering from Texas A&M University.
receiver temperature
could be maintained at
pre-revamp conditions
29.0 with a 10 psi increase in
FI compressor suction
NEW FIN
FANS pressure. In addition,
25.0
compressor discharge
23.0
30.0 system condenser pres-
24.5
sure loss (Figure 1)
would be very high at
increased gas flow.
Discharge system con-
denser modifications
COKER would permit lower
FRACTIONATOR
OPERATING compressor pressure.
PRESSURE
These changes would
debottleneck the wet
Figure 15. Delayed Coker Revamp Pressure Drop gas compressor limit

Reprinted from Petroleum Technology Quarterly® Spring 2002 Issue

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