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... 10 Buildings... 12 Building Utilization Requirements... 13 Building Design Requirements... 13 Heating and Ventilation... 19 Yard Structures... 20 Roads and Sidewalks... 20 Fencing... 21 Culverts and Drainage... 21 iii
iv COMPRESSOR STATION OPERATIONS Prime Movers... 22 Reciprocating Engines... 22 Rotary Engines... 30 Gas Turbines... 30 Steam Turbines... 34 Electric Motors... 36 Gas Compressors... 39 Types of Compressors... 39 Compressor Applications... 42 Compressor Calculations... 46 Compressor Characteristics and Load/Capacity Control... 66 Engine and Compressor Auxiliary Equipment... 73 Air Inlet System... 73 Exhaust System... 77 Lube Oil System... 83 Jacket Water System... 87 Starting System... 93 Fuel Gas System... 93 Vents and Drains... 96 Engine and Compressor Foundations... 97 Foundation Design Considerations... 97 Alignment and Grouting... 103 Gas Piping... 107 Gas Piping Design Criteria.... 108 Piping Valves... 113 Pressure Control Devices... 115 Gas Pulsation and Control... 116 Overpressure Protection... 118 Gas Cleaning... 120 Types of Gas Cleaners... 121 Application Factors for Gas Cleaners... 126 Dump Systems... 130 Gas Cooling... 130 Heat Exchangers... 130 Temperature Control... 134 Fan Devices... 135 Compressed Air Facilities... 137 Air Volume Requirements... 137
CONTENTS v Air Compressors... 138 Conditioning of Compressed Air.... 140 Air Receivers... 140 Electric Power and Lighting.... 141 Purchased Power... 142 Power Distribution... 145 On-Site Generation... 148 Hazardous Locations... 150 Lighting... 156 Motors and Generators... 158 Grounding System... 162 Electrical Codes and Standards... 163 Instrumentation and Controls... 163 Control Philosophy... 164 Control Requirements... 165 Instrumentation... 170 Liquid Storage... 172 Liquid Storage Tanks... 172 Spill Prevention... 174 Water and Waste Systems... 175 Water Supply... 175 Sanitary System... 177 Plant Waste... 177 CHAPTER 3. OPERATIONS... 179 Personnel Requirements... 179 Attended Manual... 180 Attended Automatic... 182 Unattended Automatic... 182 Remote Automatic... 182 Duties of Personnel... 182 Station Superintendent s Responsibilities in Station Operations... 183 Housekeeping... 183 Records and Reports... 183 Personnel Training... 184 Training Procedures... 184 Standard and Emergency Operating Procedures... 185
vi COMPRESSOR STATION OPERATIONS CHAPTER 4. MAINTENANCE... 187 Scheduling... 187 Fixed Interval Scheduling.... 187 Predictive Failures Scheduling... 187 Emergency Maintenance and Scheduling... 188 Personnel Requirements... 188 Maintenance Requirements... 188 Maintaining Prime Movers... 189 Maintaining Compressors... 199 Maintaining Auxiliary Systems... 202 Maintaining Piping and Vessels... 203 Maintaining Electrical Systems... 203 Maintaining Instruments and Controls... 204 Maintaining Structures and Hoisting Equipment... 205 Maintenance Equipment Testing, Inspection, and Monitoring... 206 Test Equipment... 206 Testing and Analysis... 208 Inspection... 212 Operational Monitoring... 213 Spare Parts... 215 Use Factor for Compressor Engines... 215 Staging Areas for Spare Parts... 216 Computer-Monitored Inventories... 216 CHAPTER 5. SAFETY AND SECURITY... 217 Emergency Shutdown Systems... 217 Emergency Shutdown System Components... 218 Design Considerations for Emergency Shutdown Systems... 218 Types of Emergency Shutdown Systems... 219 Testing, Inspection, and Maintenance of ESD Systems... 220 Records and Reports for Emergency Shutdown Systems... 220 Equipment Protection Systems... 220 Engine/Compressor Protection Systems... 221 Other Equipment Protection Systems... 223 Testing and Maintenance of Protection Systems... 223
CONTENTS vii Environmental Monitoring Systems... 224 Combustible Gas Detection Equipment... 225 Fire Detection and Extinguishing Systems... 226 Security Systems... 227 Accident Prevention... 227 Emergency Procedures... 228 CHAPTER 6. ECONOMIC EVALUATION... 229 Capital Investment Versus Annual Cost... 230 Capital Investment Method... 231 Annual Cost Method... 231 Leasing Compression Equipment... 232 Evaluation of Equipment... 232 Examples of Economic Analysis... 234 Summary of Economic Evaluation... 236 APPENDIX A. CODES AND STANDARDS... 239 APPENDIX B. SYMBOLS AND ABBREVIATIONS... 255 GLOSSARY... 259 BIBLIOGRAPHY... 267 INDEX... 271
FIGURES AND TABLES FIGURES 1. Small gas gathering compressor station with two belt-driven compressors... 4 2. Modern semiautomatic gas gathering compressor station with three skid-mounted reciprocating compressors.... 4 3. Typical transmission compressor station... 5 4. Maximum frost penetration in the United States... 15 5. Cross-section of a typical compressor building... 18 6. Fuel efficiency for various prime mover arrangements... 23 7. Cross-section of a 2-stroke natural gas engine with integral compressors... 25 8. Cross-section of a 4-stroke natural gas engine... 26 9. Top cross-section of a small reciprocating integral engine/compressor... 28 10. Typical heat balance diagram for 2-stroke reciprocating engine... 29 11. Cutaway view of two-shaft gas turbine engine... 31 12. Turbine-driven centrifugal compressor package... 33 13. Reciprocating, integral engine/compressor unit... 40 14. Skid-mounted, reciprocating, separable engine/compressor package... 40 15. Cross-section of a reciprocating separable compressor... 41 16. Positive displacement rotary compressor... 43 17. Centrifugal compressor unit... 44 18. Exploded view of a high-speed compressor plate valve... 48 19. P-V diagram illustrating ideal reciprocating compressor cycle... 49 viii
FIGURES AND TABLES IX 20. Compression ratio versus volumetric efficiency... 52 21. Compressibility factor for compressor capacity calculations... 54 22. Compression ratio versus brake horsepower per MM cf/d.. 56 23. Cross-section of a modern pipeline cylinder... 58 24. Cutaway of centrifugal compressor... 61 25. Cutaway view of centrifugal compressor... 61 26. Compressor cylinder head end clearance pocket configuration... 69 27. Typical reciprocating compressor cylinder loading diagram... 70 28. Typical horsepower-capacity diagram for reciprocating compressor... 71 29. Typical centrifugal compressor flow nomograph... 74 30. Dry type air filter... 75 31. Flow diagram of glycol regeneration from engine waste heat... 78 32. Engine exhaust silencer and combustion air filter... 80 33. Cross-section of typical engine exhaust silencer... 81 34. Flow diagram of engine/compressor lube oil system... 85 35. Shell-and-tube lube oil heat exchanger showing bypass temperature control valve.... 86 36. Compressor cylinder lubricator pump... 88 37. Divider block for cylinder lubricator system... 88 38. Forced draft, fin fan heat exchangers... 89 39. Reciprocating engine cooling water pump... 90 40. Flow diagram of engine/compressor jacket water system... 92 41. Expander starter motors for reciprocating engine... 94 42. Engine fuel gas filter/separator... 95 43. Typical concrete pad compressor foundations... 98 44. Concrete block and mat compressor foundation... 99 45. Direct full-bed grouting method for baseplate engine/compressor unit... 103 46. Method of grouting engine/compressor units using individual chocks and soleplates... 104 47. Existing compressor unit re-grouted with steel chocks and soleplates... 108 48. Typical reciprocating compressor station piping schematic illustrating valve applications... 109 49. Compressor unit gas flow diagram for storage injection and withdrawal service... 110 50. Typical compressor station pipe yard... 111
X COMPRESSOR STATION OPERATIONS 51. Adjustable pipe support with leveling block... 114 52. Cutaway of typical pulsation damper... 117 53. Cross-section of a pilot-operated relief valve... 119 54. Cross-section of horizontal, impingement type separator.... 122 55. Cutaway of vertical, centrifugal gas separator... 123 56. Typical gas scrubbers... 124 57. Cross-section of a motor-driven, rotating vane scrubber... 125 58. Horizontal gas filter showing cylindrical type filter elements... 126 59. Horizontal filter-separator to remove liquids as well as solids.... 126 60. Types of aerial heat exchangers... 132 61. Examples of cooler fan drive arrangements... 136 62. Vertical air storage tanks.... 141 63. Electrical transformer substation... 143 64. Compressor station electrical switchgear... 146 65. Motor control center.... 147 66. Standby electrical generator... 149 67. Modern control panel for reciprocating engine/compressor unit.... 173 68. Typical compressor station operational personnel... 180 69. Compressor daily operating log... 190 70. Turbine daily log... 191 71. Gas generator daily log.... 192 72. Base line performance calibration... 194 73. Turbine performance calculations... 195 74. Condition monitoring performance trends... 197 75. Gas turbine performance calculations... 198 76. Turbine performance record... 200 77. Typical lube oil analysis report... 210 78. Typical engine coolant analysis report... 211 79. Crankweb deflection report... 214 TABLES 1. Typical presumptive soil-bearing pressures for the preliminary design of foundations... 101 2. Lighting illumination levels at compressor stations... 159 3. Compressor station monitor and control parameters... 167 4. Suggested employee complement for station with 8 to 10 units.... 181 5. Proposed compressor station economic evaluation... 235