CONSTRAINTS COMPLICATE CENTRIFUGAL COMPRESSOR D...

http://www.ogj.com/articles/print/volume-91/issue-19/in-this-issue/pro...

Stay Connected

Login or Register using SUBSCRIBE: MAGAZINE | NEWSLETTERS

HOME

GENERAL INTEREST

EXPLORATION & DEVELOPMENT

DRILLING & PRODUCTION

PROCESSING

TRANSPORTATION

Home CONSTRAINTS COMPLICATE CENTRIFUGAL COMPRESSOR DEPRESSURIZATION

CONSTRAINTS COMPLICATE CENTRIFUGAL COMPRESSOR DEPRESSURIZATION

05/10/1993 Bill Key Hoover & Keith Inc. Houston Frank L. Colbert Paragon Engineering Services Inc. Houston

Looking for past issues? Click here.

During an emergency shutdown, safe depressurization of a centrifugal compressor requires a design that considers all of the process and mechanical limitations. Process schemes can limit the depressurization rate while mechanical constraints might require a faster rate. In complex facilities, centrifugal compressors operate at high revolutions per minute and discharge pressures. Because large amounts of energy are stored in a confined space, depressurization is a major design consideration. During an emergency shutdown (ESD), the compressor's speed decrease from the operating speed to 0 rpm, while the gas in the compressor system is depressurized. Knowing the time required for these actions is important for verifying a safe operation. The mechanical constraints of the compressor and attached piping define the required time frame. The methodology discussed in this article was used to analyze a Dresser-Rand offshore gas lift compressor package, but the method can serve as an important checklist for any centrifugal compressor in all applications, i.e., refineries, gas plants, gas injection/gas lift compressor plants, and pipeline compressor stations.

OPERATING POINT
A centrifugal compressor can operate continuously anywhere on the curve between the surge-control line and stonewall (Fig. 1). With a variable-speed driver, the compressor has a family of curves (Fig. 2). The most important consideration for depressurization calculations is to find the operating point on the compressor performance curve that will take the longest time to depressurize. The operating point having the highest discharge pressure represents the condition of maximum mass in the attached piping. With more mass, the time to depressurize the compressor will increase. During emergency situations such as a fire, it is imperative to release the gas before a mechanical failure. Therefore, the compressor operating point used in depressurization time calculations is at the surge-control line. This operating point is noted in Figs. 1 and 2 as Point A and represents the condition when the compressor system is at its highest pressure. For multicase compressors along a common drive train, this principle can be applied simultaneously to each case. Although all cases will not be at the surge point in the same instant, this approach will lead to a conservative design.

PREVENTING SURGE
At the start of an emergency shutdown, the power driving the compressor rotation is removed. When this happens, the

1 of 5

12/5/2013 4:35 PM

CONSTRAINTS COMPLICATE CENTRIFUGAL COMPRESSOR D...

http://www.ogj.com/articles/print/volume-91/issue-19/in-this-issue/pro...

revolutions per minute decays and the compressor immediately stops compressing the gas to the discharge piping pressure. Because the compressor's discharge pressure is less than the pressure in the piping, an immediate no-flow condition exists. This means that the unit will be in surge as its revolutions per minute decays (Fig. 3). To prevent surge, depressurization should start in the discharge piping simultaneously with the initiation of the shutdown signal to the driver. The compressor-system valve configuration required to prevent a surge is shown in Fig. 4. The sequence of events upon initiation of an ESD is as follows:

Driver power is terminated. Blowdown valve opens. Surge-control valve opens. Isolation valves close. This valve arrangement and sequencing allows the engineer to size a blowdown valve with flow characteristics such that the depressurization rate matches the coast-down rate, thus preventing surge. It should be emphasized that this constraint is set by the compressor's manufacturer. Many compressors, such as pipeline centrifugal compressors, are operated such that a momentary surge during a shutdown is not harmful.

OIL & GAS JOBS

COAST-DOWN TIME
All engineers are familiar with Newton's second law, F = ma. This equation can be used to calculate the time required to accelerate or decelerate a known mass to a given velocity. For rotating systems such as the compressor driver shaft, however, the equation can be written as Equation 1 (see equation and nomenclature boxes). This equation governs the time frame that the compressor driver shaft will take to decelerate from one speed to the next. The polar mass, J, of the compressor driver system is provided by the compressor manufacturer. Gas load is the torque, T, causing the system to slow down. This number is obtained by successive readings from the compressor performance curves for variable-speed compressors. For single-speed machines, performance curves at reduced revolutions per minute (obtained from the compressor vendor) are available until the curve decays to a point of insignificant length. The time for the compressor/drive-shaft system to coast down to a lower speed can be calculated from Equation 2, a numerical integration of Equation 1. The log of "tau" is introduced to account for the fact that the gas load, decelerating the torque, varies with the revolutions per minute. Equation 2 can determine the time for the compressor to decelerate to its minimum speed. Fig. 5 is an example calculation using the compressor's horsepower performance curves. Thus, to prevent surge during coastdown, the pressure in the discharge system must decay to a level that matches the pressure discharge capability of the compressor at the minimum continuous revolutions per minute. As illustrated by Fig. 6, the time frame for this pressure decay must be the same as the compressor driveshaft system to coast down to its minimum revolutions per minute.

Electric Meter Technician City of Santa Clara Country: United States The City of Santa Clara CaliforniaEMPLOYMENTOPPORTUNITYELECTRIC METER TECHNICIAN #64-13-42 MONTHLY SALARY RANGE: $7,773- $9,437 (Longevity Pay up to $9,928) DISTINGUISHING CHARACTERISTICS: Incumbents in this classification are responsible for the testing, maintenance, repair and installation...

Independent Sales Representative Hytorc Country: United States INDUSTRIAL SALES REPRESENTATIVE The worlds largest hydraulic torque wrench manufacturer with over 40 years of experience in the heavy industry seeks successful individuals to be part of a fast growing business. This is a recession proof business due to the various Industries we serve, which inc...

Offshore & International Banking

This will occur by selecting a blowdown orifice with an area, A, obtained from Equation 3. The time, t, in Equation 3 is obtained from Equation 2.

Entrepreneurs
View more Job Listings >> Global Placements International

GAS LEAKS
One design constraint is to keep the gas in the compressor case. The oil-film sealing system is designed to do this for all operation modes. During normal operation, the shaft seal on each end of the compressor case seals against a pressure differential of compressor-case suction pressure to atmospheric pressure. As illustrated in Fig. 7, at this pressure differential, the flow rate across the atmospheric side is at its design condition. As stated previously, the surge valve opens upon initiation of an ESD signal. After opening, the compressor's high and low-pressure sides are connected. The action causes the suction pressure to increase until reaching an equilibrium pressure, known as the settle-out pressure. At settle-out pressure, the pressure differential across the atmospheric side of the compressor shaft seal is much higher than the design condition. This significantly increases the flow. For example, if the design atmospheric sealing differential pressure is 114.7 psia suction pressure and the settle-out pressure is 214.7 psia, then the flow rate out of the atmospheric seal increases by approximately 40%. If the ESD occurred because of a seal-oil pump failure, the volume in the overhead seal-oil tank must equal the amount that flows across the atmospheric seal while the suction pressure decays from the settle-out pressure to atmospheric

2 of 5

12/5/2013 4:35 PM

CONSTRAINTS COMPLICATE CENTRIFUGAL COMPRESSOR D...

http://www.ogj.com/articles/print/volume-91/issue-19/in-this-issue/pro...

pressure. API's Standard 614 recommends that for this condition, the volume of oil in the seal-oil tank lasts for a minimum of 3 min. 1 In this 3 min, the compressor will coast down, depressure, and be isolated. Because flow out of the atmospheric seal is a function of settle-out pressure, this amount does not ensure gas containment. Settle-out pressure cannot be accurately determined until the piping design is complete and all piping and equipment volumes are known. For scheduling reasons, the overhead seal-oil tanks are generally specified and purchased in advance of piping design completion. To ensure correct volume in the seal-oil tank, the purchaser must calculate the pressure decay (pressure-vs.-time) in the suction system after reaching settle-out pressure. A typical curve, from Equation 3, is shown as Fig. 8. This curve must be provided to the compressor vendor. The flow rate across the atmospheric seal is a function of settle-out pressure and compressor revolutions per minute. With this information, the compressor vendor should verify that the seal-oil tank volume is adequate. The settle-out pressure calculation is complicated by the fact that the blowdown valve opens simultaneously with the surge-control valve. This will decrease the discharge pressure immediately. For a conservative design, however, the effect of this discharge system depressurization is generally ignored. Settle-out pressure can be calculated from Equation 4. The settle-out temperature is obtained from a heat balance using a weighted average of existing temperatures in each portion of the system.

THRUST-BEARING OVERLOAD
Thrust-bearing overload criteria are applicable to centrifugal compressors that have two stages of compression in one case. Such compressors are generically known as "back-to-back" or "compound" machines. A typical configuration is shown in Fig. 9. The thrust bearing in these compressors is designed for a specific range of pressure ratio across each stage. If during depressurization this range is exceeded, the thrust-bearing load will be outside its design limits. To prevent this, the range of pressure ratios must be obtained from the compressor vendor. A typical curve that provides this information is shown in Fig. 10. Thrust-bearing overload can then be prevented with Equation 3. Starting at settle-out pressure and proceeding to the pressure at the minimum revolutions per minute, the pressurevs.-time curve can be developed for each stage during compressor blowdown. The pressure loading on the thrust bearing can then be checked at various time increments.

SYSTEM CONSTRAINTS
During an emergency shutdown, the process gas piping and vent piping are active and impose constraints on the blowdown rate and time frame. The process gas piping is protected by safety devices that serve all anticipated operation. modes. Therefore, this system in most cases does not impose any additional constraints. In some cases, however, the vent piping is connected to a flare. This flare will limit blowdown rates and, thereby, impose a potential constraint on the depressurization time frame. On large offshore compressor platforms, the high-pressure gas is sometimes vented into a system that only contains a vertical pipe exhausting to the atmosphere, i.e., vent. This system will impose constraints on the vent rates and thereby affect the time frame.

FLARE EXTINGUISHING
Preventing the extinguishing of the flare is a constraint of depressurizing systems that discharge to a flare. API Recommended Practice RP-521 2 states that the maximum flow rate through the flare tip should not exceed 50% of the value of the speed of sound existing at the flare tip. Some flares, however, are capable of exit velocities at or near the speed of sound. Flare tip manufacturers should be consulted for the information. Equation 5 can calculate the speed of sound at the flare tip. The gas temperature, T, at the flare tip can be approximated by assuming isoenthalpic expansion from the temperature and pressure upstream of the blowdown valve/orifice to atmospheric pressure. Data contained in Reference 3 can approximate the downstream temperature. While this technique ignores heating effects of the piping on the expanded gas in the piping system, the gas is only in the vent piping for a very short period, thus minimizing this effect. For practical purposes the flow can be assumed to be isothermal. The mass flow rate associated with the 0.5 Mach number at the flare tip is the constraint on maximum blowdown rate. Mathematically this is written as Equation 6. The initial flow rate through the blowdown valve/restriction orifice can be calculated from Equation 7.

3 of 5

12/5/2013 4:35 PM

CONSTRAINTS COMPLICATE CENTRIFUGAL COMPRESSOR D...

http://www.ogj.com/articles/print/volume-91/issue-19/in-this-issue/pro...

For a conservative design, the rate from Equation 6 should be equal to the rate from Equation 7.

HEAT LEVELS
Acceptable heat radiation levels also constrain depressurizing systems that discharge to a flare. When a compressor is depressurized, large instantaneous flow rates occur. These high flow rates burn at the flare tip radiating large amounts of heat (BTU/[hr-sq ft]). This radiated heat constrains the depressurization rate. API Recommended Practice RP-521 Table 3 of Paragraph 4.4.1.3 contains recommended design flare radiation levels. 2 These radiation levels are a function of what receives the heat, i.e., structure, process vessel, operating personnel, and the time frame that the radiation level will persist. The radiated heat level exiting at any particular location is a function of the compressor system depressurizing flow rate and the distance to the flare tip. Reference 4, Paragraph 4.4-1.3, contains an exact expression for computing the radiated heat level as a function of these variables. The depressurizing flow rate can be calculated from Equation 7. The distance to the flare tip is computed on a case-by-case basis.

PRESSURE DROP
The pressure drop through the flare/vent piping system is a constraint in the design pressure rating of the flare or vent system piping, ANSI 150 psi in most applications. Thus, the pressure drop from the flare tip or vent stack exit back to the furthest point upstream in this system generally cannot exceed 285 psig. The calculation for this dynamic pressure profile is indirect. The maximum flow rate into this piping system occurs when the blowdown valve is initially opened. Because the vent system is everywhere at Atmospheric pressure, however, no flow out of the system occurs during this very brief instant. As the pressure builds up, gas will flow out from the tip. This action happens very quickly. There are several calculation techniques for simulating this dynamic pressure buildup. One technique is to assume no flow leaves the vent system for the initial second after initiation of the ESD signal. Because of the flow into the vent system, the volume of the vent system and the temperature and mole weight of the gas flowing in are all known. The pressure existing in the vent system after 1 sec can then be calculated from Equation 8. The total mass in the vent system after 1 sec can be computed by multiplying the flow rate computed by Equation 7 by 1 sec. After 1 sec the flow rate of the gas discharging from the flare/vent system can be calculated from Equation 9. The effect of pressure buildup in the flare/vent system on the density of the gas at the tip must be accounted for. Although the calculation for gas velocity is complex it can be determined by techniques presented in either Reference 2 or 5 for isothermal gas flow through pipe and fittings. Thus, the dynamic pressure buildup of the vent/flare system, in very short time increments, can be calculated from the flow rate in (Equation 7) and flow rate out (Equation 9). If the pressure buildup is assumed at the flare tip, one can conservatively use isothermal flow equations to obtain a pressure drop starting at the flare tip and calculating upstream.

REFERENCES

1. "Lubrication, Shaft Sealing, and Control-Oil System for Special-Purpose Applications," API Standard 614. 2. "Guide for Pressure-Relieving and Depressurizing Systems," API Recommended Practice 521, Second Edition, September 1982. 3. Grote, S.H., "Calculating Pressure Release Times," Chemical Engineering, July 17, 1967, pp. 203-06. 4. Dodge, R.A., and Thompson, M., Fluid Mechanics, McGraw-Hill, 1937, pp. 279-82. 5. "Flow of Fluids Through Valves, Fittings, and Pipe," Crane Technical Paper 410, 1982.

Copyright 1993 Oil & Gas Journal. All Rights Reserved.

More Oil & Gas Journal Current Issue Articles More Oil & Gas Journal Archives Issue Articles

RELATED ARTICLES

4 of 5

12/5/2013 4:35 PM

CONSTRAINTS COMPLICATE CENTRIFUGAL COMPRESSOR D...

http://www.ogj.com/articles/print/volume-91/issue-19/in-this-issue/pro...

12/04/2013 Noble Energy Inc. has made a natural gas discovery with its Tamar Southwest (SW) exploration well offshore Israel. This find marks the companys ei...

Noble discovers oil in deepwater Gulf of Mexico

12/04/2013 Noble Energy Inc. has made an oil discovery at the Dantzler exploration well in deepwater Gulf of Mexico. Dantzlers discovered gross resources are...

Oil & Gas UK slams report on subsidies

12/04/2013 An oil and gas trade group has rejected a UK House of Commons committee recommendation to cut fossil-energy tax allowances that the committee descr...

MARKET WATCH: Oil prices jump ahead of OPECs call to hold production quota steady
12/04/2013 Oil prices jumped Dec. 3 on the heels of news that members of the Organization of Petroleum Exporting Countries, who met Dec. 4 in Vienna at the ca...

1455 West Loop South Houston, Texas 77027 (713) 621-9720 Copyright 2013: PennWell Corporation All Rights Reserved. Home General Interest Exploration & Development Drilling & Production Processing Transportation Unconventional Events Market Connection White Papers Webcasts RSS PennEnergy Jobs Equipment Research Magazine Subscription Newsletter Subscription Book Store Privacy Policy Terms & Conditions Contact Us Advertise Mobile About Us PennWell View All Pennwell Websites View All Pennwell Events Site Map Webmaster

5 of 5

12/5/2013 4:35 PM