COMPRESSOR STATION OPERATIONS

Transcription

1 CONTENTS FIGURES AND TABLES... viii PREFACE... xi ACKNOWLEDGEMENTS... xiii CHAPTER 1. INTRODUCTION... 1 Scope and Outline... 1 Types of Stations... 2 Production Stations... 2 Storage Stations... 3 Transmission Stations... 5 CHAPTER 2. ENGINEERING AND DESIGN CONSIDERATIONS... 7 Siting and Location... 7 Site Selection... 7 Layout and Arrangement Buildings Building Utilization Requirements Building Design Requirements Heating and Ventilation Yard Structures Roads and Sidewalks Fencing Culverts and Drainage iii

2 iv COMPRESSOR STATION OPERATIONS Prime Movers Reciprocating Engines Rotary Engines Gas Turbines Steam Turbines Electric Motors Gas Compressors Types of Compressors Compressor Applications Compressor Calculations Compressor Characteristics and Load/Capacity Control Engine and Compressor Auxiliary Equipment Air Inlet System Exhaust System Lube Oil System Jacket Water System Starting System Fuel Gas System Vents and Drains Engine and Compressor Foundations Foundation Design Considerations Alignment and Grouting Gas Piping Gas Piping Design Criteria Piping Valves Pressure Control Devices Gas Pulsation and Control Overpressure Protection Gas Cleaning Types of Gas Cleaners Application Factors for Gas Cleaners Dump Systems Gas Cooling Heat Exchangers Temperature Control Fan Devices Compressed Air Facilities Air Volume Requirements

3 CONTENTS v Air Compressors Conditioning of Compressed Air Air Receivers Electric Power and Lighting Purchased Power Power Distribution On-Site Generation Hazardous Locations Lighting Motors and Generators Grounding System Electrical Codes and Standards Instrumentation and Controls Control Philosophy Control Requirements Instrumentation Liquid Storage Liquid Storage Tanks Spill Prevention Water and Waste Systems Water Supply Sanitary System Plant Waste CHAPTER 3. OPERATIONS Personnel Requirements Attended Manual Attended Automatic Unattended Automatic Remote Automatic Duties of Personnel Station Superintendent s Responsibilities in Station Operations Housekeeping Records and Reports Personnel Training Training Procedures Standard and Emergency Operating Procedures

4 vi COMPRESSOR STATION OPERATIONS CHAPTER 4. MAINTENANCE Scheduling Fixed Interval Scheduling Predictive Failures Scheduling Emergency Maintenance and Scheduling Personnel Requirements Maintenance Requirements Maintaining Prime Movers Maintaining Compressors Maintaining Auxiliary Systems Maintaining Piping and Vessels Maintaining Electrical Systems Maintaining Instruments and Controls Maintaining Structures and Hoisting Equipment Maintenance Equipment Testing, Inspection, and Monitoring Test Equipment Testing and Analysis Inspection Operational Monitoring Spare Parts Use Factor for Compressor Engines Staging Areas for Spare Parts Computer-Monitored Inventories CHAPTER 5. SAFETY AND SECURITY Emergency Shutdown Systems Emergency Shutdown System Components Design Considerations for Emergency Shutdown Systems Types of Emergency Shutdown Systems Testing, Inspection, and Maintenance of ESD Systems Records and Reports for Emergency Shutdown Systems Equipment Protection Systems Engine/Compressor Protection Systems Other Equipment Protection Systems Testing and Maintenance of Protection Systems

5 CONTENTS vii Environmental Monitoring Systems Combustible Gas Detection Equipment Fire Detection and Extinguishing Systems Security Systems Accident Prevention Emergency Procedures CHAPTER 6. ECONOMIC EVALUATION Capital Investment Versus Annual Cost Capital Investment Method Annual Cost Method Leasing Compression Equipment Evaluation of Equipment Examples of Economic Analysis Summary of Economic Evaluation APPENDIX A. CODES AND STANDARDS APPENDIX B. SYMBOLS AND ABBREVIATIONS GLOSSARY BIBLIOGRAPHY INDEX

6 FIGURES AND TABLES FIGURES 1. Small gas gathering compressor station with two belt-driven compressors Modern semiautomatic gas gathering compressor station with three skid-mounted reciprocating compressors Typical transmission compressor station Maximum frost penetration in the United States Cross-section of a typical compressor building Fuel efficiency for various prime mover arrangements Cross-section of a 2-stroke natural gas engine with integral compressors Cross-section of a 4-stroke natural gas engine Top cross-section of a small reciprocating integral engine/compressor Typical heat balance diagram for 2-stroke reciprocating engine Cutaway view of two-shaft gas turbine engine Turbine-driven centrifugal compressor package Reciprocating, integral engine/compressor unit Skid-mounted, reciprocating, separable engine/compressor package Cross-section of a reciprocating separable compressor Positive displacement rotary compressor Centrifugal compressor unit Exploded view of a high-speed compressor plate valve P-V diagram illustrating ideal reciprocating compressor cycle viii

7 FIGURES AND TABLES IX 20. Compression ratio versus volumetric efficiency Compressibility factor for compressor capacity calculations Compression ratio versus brake horsepower per MM cf/d Cross-section of a modern pipeline cylinder Cutaway of centrifugal compressor Cutaway view of centrifugal compressor Compressor cylinder head end clearance pocket configuration Typical reciprocating compressor cylinder loading diagram Typical horsepower-capacity diagram for reciprocating compressor Typical centrifugal compressor flow nomograph Dry type air filter Flow diagram of glycol regeneration from engine waste heat Engine exhaust silencer and combustion air filter Cross-section of typical engine exhaust silencer Flow diagram of engine/compressor lube oil system Shell-and-tube lube oil heat exchanger showing bypass temperature control valve Compressor cylinder lubricator pump Divider block for cylinder lubricator system Forced draft, fin fan heat exchangers Reciprocating engine cooling water pump Flow diagram of engine/compressor jacket water system Expander starter motors for reciprocating engine Engine fuel gas filter/separator Typical concrete pad compressor foundations Concrete block and mat compressor foundation Direct full-bed grouting method for baseplate engine/compressor unit Method of grouting engine/compressor units using individual chocks and soleplates Existing compressor unit re-grouted with steel chocks and soleplates Typical reciprocating compressor station piping schematic illustrating valve applications Compressor unit gas flow diagram for storage injection and withdrawal service Typical compressor station pipe yard

8 X COMPRESSOR STATION OPERATIONS 51. Adjustable pipe support with leveling block Cutaway of typical pulsation damper Cross-section of a pilot-operated relief valve Cross-section of horizontal, impingement type separator Cutaway of vertical, centrifugal gas separator Typical gas scrubbers Cross-section of a motor-driven, rotating vane scrubber Horizontal gas filter showing cylindrical type filter elements Horizontal filter-separator to remove liquids as well as solids Types of aerial heat exchangers Examples of cooler fan drive arrangements Vertical air storage tanks Electrical transformer substation Compressor station electrical switchgear Motor control center Standby electrical generator Modern control panel for reciprocating engine/compressor unit Typical compressor station operational personnel Compressor daily operating log Turbine daily log Gas generator daily log Base line performance calibration Turbine performance calculations Condition monitoring performance trends Gas turbine performance calculations Turbine performance record Typical lube oil analysis report Typical engine coolant analysis report Crankweb deflection report TABLES 1. Typical presumptive soil-bearing pressures for the preliminary design of foundations Lighting illumination levels at compressor stations Compressor station monitor and control parameters Suggested employee complement for station with 8 to 10 units Proposed compressor station economic evaluation