199.

High speed high pressure compressors

Joe Nitzsche Posted on 12 Apr 04 22:44

Joe Nitzsche -
SIEP EPT-PD -
New Orleans
Total Accesses: 180 View names of users who have accessed this entry...
Does anybody out there have any actual operating experience with high speed (700-1000 rpm) high
pressure (200+ bar) reciprocating compressors (driver size about 600 kW)? We're looking at an
offshore gas lift application and low speed units are pretty heavy.... Would appreciate your feedback
on do's and dont's - whose compressors did you use, what speed/pressure/kW?

Keywords: high pressure, high speed, reciprocating compressor

Replies:
3199.1. SPDC's bitter experience and contact Vincent Osifeso 14 Apr 04 04:46
Joe,
SPDC has operated four units of high speed (~750rpm) high pressure (up to 300bar) Dresser
Rand (now called IR?) reciprocating compressors (driven by 3,000 kw Solar Centaur turbines) at
Oguta gas injection plant since 1980s. It was almost a constant migraine for every operations crew
(including myself!). Suggest you contact spdc's George GIFFARD, (PSE-MTC), my ex-boss &
mechanical specialist , who has very vast wealth of experience on these compressors.

3199.2. HSHP Recips Lorimer Watson 14 Apr 04 09:01

Joe,
Shell Expro had 2 Ariel JGs one of which was on gas reinjection duty on Brent C (and as far as I'm
aware still is). This unit to my knowledge tended to be quite reliable for a recip. Suggest you
contact Ken Innes for the technical details or Eulogia Heredia for the maintenance history.

3199.2.1. Brent C Recip Compressor Simon Ritom 5 May 04 10:22

Under Penguins Phase 2 development we are looking at converting the injection compressor on
Brent C to supply gaslift to Penguins. The compressor is an Aerial JGD-6 with six 4-5/8" D-FS
double-acting cylinders driven by an electric motor. The motor is rated at 2875 kW at 890 rpm. The
compressor itself is rated at 4633 kW @ 1200 rpm. The compressor is an API 11D
machine originally designed for 84 mmscf/d @ 285 bara discharge (max. rating is 310 bara). The
revised operating duty for Penguins gaslift service is 20 mmscf/d at max discharge of 285 bara. To
operate in this new service (minimise recycle) the compressor will be de-staged by disabling 2 out
of the 6 cylinders and installing HEVUs to the remaining cylinders.

3199.4. High Speed Recips Darrell Wood 23 Apr 04 07:23

How many times have high-speed recips been a discussion topic on SGN ? Quite a number is the
answer. I would hazard a guess that 95% of the compressors built in the world today are high-
speed units to API 11D yet the DEP is based on the other 5% (API 618). Previous statements that
API 618 units are more reliable resulted in a number of claims to the contrary so it is clear that we
are buying high-speed units in spite of the DEP and seem to be generally happy with them.
Cheaper, lighter, faster delivery, arguably equal reliability - and not recommended. Can we have
a DEP please ? I thought one of the mantras of the new EP Organisations was stop reinventing
the wheel.

3199.4.1. high-speed recips David Saile 26 Apr 04 08:06

Darrel, You seem to be referring to the wrong API spec.
There is no such standard as API 11D.
I guess you intended to refer to API 11P (Packaged Reciprocating Compressors for Oil and Gas
Production Services), but please note that the last edition of this standard was 1989 and has since
been withdrawn and is out of print.
Nevertheless, suggest you ask Wim Hardeveld for his opinion regarding high-speed recips.

3199.4.1.1. High speed recip standard - withdrwan Darrell Wood 17 Jun 04 02:38
David
I missed your comment on the SGN about the recip standard I had quoted. It should have read
API 11P not 11D. Maybe the d and the p on this keyboarp have got mixep ud. However, looking
on the API website it appears that 11P has been withdrawn in the past few years. I don't know
why but I suspect that because there are only a few manufacturers of high speed machines - Ariel,
Superior, Dresser Rand and Gemini are the ones that come to mind - it's not worth maintaining a
standard and each company is starting do its own thing based on their original 11P design. Just a
guess mind.
I still believe we should have some form of DEP guidance on high speed machines. On the last
three projects I have been involved with, one purchased high speed recips (due to significant cost
and schedule benefits), one was offered high speed as an alternative to API 618 and therefore
had to assess the pros and cons of different standards in order to baseline the bids and the
current one will probably end up buying high speed because the 618 boys on the (imposed) bid list
probably won't quote because they know they can't compete on cost and delivery. Fortunately I
can call on previous experience to help me but this doesn't help other people and my peers may
disagree with my approach.
Although there are only a few manufacturers, they make the majority of the recips produced each
year and much of the technology they develop is being adopted by conventional API 618
manufacturers who recognise that it can give them an edge over competitors who stick rigidly to
what can be an unduly conservative base standard. A number of compressor companies quote
hybrids claiming to take the best of each standard.
As we would be a relatively small purchaser of machines which are meant to be standards, the
opportunities to modify would be limited and/or costly. Starting with a knowledge of the (few)
manufacturers is perhaps the best way rather than trying to work with a defunct standard.
However, the manufacturers do provide a range of options and these machines are usually
packaged by licenced companies and the ancillaries and the way they are handled make all the
difference. There are also options to derate machines by going for reduced speeds or increasing
margins on frame power.
Just a brain dump. Do with it what you wish.
Regards

3199.5. Tried to select a high speed recip - but did not Rob Jansen 27 Apr 04 09:16
Joe,

Agree with Darell that the question has come up quite a lot. I posted a query back in 8/2003 on the
same subject - but can't seem to find it anymore.
In the end I did not specify a high speed recip as the power requirement was to large for high
speed recips to handle - I needed ~ 1.8 MW, where the largest high speed recip was in the order
of magnitude of 0.9 - 1.0 MW. Apart from this slight problem, I did receive a couple of warnings on
installation (what to ensure) and on higher maintenance cost/downtime. The latter I could however
not get substaniated, as some of the examples given with high downtime had several problems
that were not directly related to the fact that a high speed was chosen.
My advise would be - check the database for history and try and locate the query that I posted for
starters. No doubt the administrators can help you.
Do post your findings & results at the end of your search as I am very interested in your final way
forward.
Regards,

Rob

3199.6. High speed reciprocating comressors Peter Fowler 4 May 04 17:07

I agree with Darrell on this. General equipment selection objectives include identifying
the lowest lifecycle cost equipment that is proven to have the desired reliability and
availability. For the majority of reciprocating compressor duties in the EP business the
‘high-speed’ compressor should be the standard selection, and can be demonstrated as
proven. Many downstream operators are also moving towards using higher speed
compressors for duties in refineries and other plant, typically for debottlenecking,
however it is likely that new plant will begin to incorporate the latest developments.
In the US compressor selections are divided into low (<700rpm) medium (700 to
1200rpm) and high speed (>1200rpm), although any such divisions are meaningless
and mainly used by suppliers for marketing purposes. The Group has used compressors
at 700 to 1000rpm for many years, and as pointed out by others, the reliabilities and
availabilities are typically comparable or better than low speed machines. Reliabilities
are improving as valve and packing designs/ materials improve, and availabilities are
inherently better than low speed compressors as the short strokes involved mean that
cylinders do not need to be water cooled to prevent thermal distortion and cross-head
guides are single-piece components that do not need adjustment.

The majority of unavailability’s of remote oil-field type applications are due to prime
movers such as gas engines and gas turbines (a horrendous, happily unusual,
application at Oguta described by the colleague from SPDC). There is a general
development in the Group for distributed power, so more and more applications will be
directly-driven by motors at 700 to 1000rpm, and 1500rpm for smaller/ lower-pressure
duties.

I suspect that Joe Nitzsche’s initial query was about higher-pressure machines, ie
200bar plus. In fact this is well within demonstrable proven experience by many short
stroke/ high speed compressor manufacturers, and the 600kW is well within available
frame sizes, that typically go up to around 4MW. I suggest that if approached
manufacturers will be able to demonstrate proven experience and reliability; including
Dresser Rand, Cooper Energy Services, Ariel and Nuovo Pignone (Gemini). The first
three of these manufacturer’s (and possibly NP) use licensed packagers who can
design, construct and test complete compressor packages.

This was originally thought to be a drawback as there was a risk of reduced focus on the
compressor itself. There are older examples of packages that have suffered low
reliability due to the extended scope process and peripheral supporting equipment and
systems, however the manufacturers have inexorably moved towards the use of
licensed packagers, who, over time, have become much more competent in designing
processes and systems around the core compressor. Although the reason for using
packagers was a cost optimisation for the manufacturers, the change in the industry as a
whole has meant that all manufacturers have to ensure the packagers are competent so
as to remain in business over the long-term. We are developing a database of
experienced packagers who are acceptable as prime compressor package suppliers;
using them in no way prevents direct dialogue with the compressor manufacturers or
diminishes the importance placed on the core compressor.

The original specification for ‘high-speed’ compressors was API11P, however that was
intended to cover standardised packaged gas engine driven compressors complete with
interstage scrubbers and coolers. As pointed out by David Saile this seems to have been
withdrawn. In fact the API11P could be used as the basis of any ‘high-speed’
compressor package, with extended scope, and with any driver, by supplementing and
modifying as necessary. The API was intended as the basis for standardised packages
that could be transported between sites, either owned or as part of a rental fleet. There
were a number of aspects not included in API11P that we would want to include in a
compressor package in a permanent, fixed location; for example a pulsation study to
API618 design approach 3.

As suggested by Darrell perhaps there is a need for a DEP to cover packaged

reciprocating compressors with extended (process) scope, for reciprocating gas engine
and electric motor drive.

3199.7. DEP for high speed compressors Wim Hardeveld 14 Jul 04 08:33
There are indeed a number of different views and experiences relating to the application of high
speed recips. We have inventorised over the last year some experiences and limitations of use. I
agree that we should provide guidance on this matter in the DEP for recipson the use of such
equipment in relation to its application.
I will action and dioscuss with Peter Fowler how we can introduce this in EP projects and sollicit
your input in the DEP scripting.
Based on a number of inputs received last year we have formulated following provisional
suggestions in use:

1. The machine shall be in non-critical service

As non-critical service is understood a service which is spared or does not cause safety risk or
financial risk from lost production when the machine is out of service.
2. Use fixed speed el. motor as driver
An engine driver is the highest maintenance cost factor. Variable speed drive poses serious
vibrational challenges on the foundation and piping design because it is very difficult to avoid
natural frequency of some kind. El. motors are reliable and cheap to maintain.
3. Limit the speed to 900 Rpm
Vibration, fatigue and wear problems grow proportionally to speed squared.
4. Place a coalescing filter between the scrubber and pulsation bottle (each stage)
Solid and liquid particles of any size accelerate to compressor wear. This tendency grows in
proportion with speed.
Moisture causes valve sticking and valve slamming which has detrimental effect on capacity
and is number one valve killer.
5. Use Hoerbiger valves with nylon or nylon "mt" plates - have the manufacturer's valve selection
confirmed by Hoerbiger
Well designed valves with soft plates maximize durability.
6. Specify API 618 approach III for pulsation damper sizing
Adequately sized dampers minimize possibility of pulsation related vibrations.
7. No drain valves or any other small bore connections on the pulsation dampers.
Valves on pulsation bottles have the nasty habit of fatigue cracking at the weld connection to
the damper.
8. Specify pulsation bottles with no internal pipe protrusion or other design features inclined to
collect liquids
Internal pipe protrusion are responsible for liquid collection leading to liquid slugs. Liquid slug
amounting to a small cup is the death of any compressor, the more of a fast one. The drain
holes drilled in the compressor suction connection protruding into the damper are inadequate
as they plug up with sludge.
9. Review imbalance force calculations
Compressor vibration is one of the most common problems on recips. The problems grow
proportionally to speed squared.
10. Specify 40 degrees piston rod force reversal as minimum at any load step. Most 11P
manufacturers go down to 20 which may cost you a rod bearing or wrist pin bearing when you
get a massive valve failure.
The duration (measured in degrees of crank rotation) of piston rod force reversal is crucial for
proper lubrication. A valve failure may cause sufficient bias in the rod force to restrict the
lubrication of vital components beyond tolerable limit. Long lubrication period is a safety
margin for emergencies.
11. Pay close attention to suction piping design.
Low-slung piping is easier to fasten, but tends to collect liquids which you absolutely do not
want in the compressor. High slung piping is more difficult to fasten and requires solid support
and good clamping but is safer.
12. Mechanical natural frequency analysis with verification (including piping) should be specified.
This is just another provision for safeguarding against vibration problems after start-up.
13. Pay attention to attachment and support of instruments (transmitters, level bridals etc.).
Heavy objects attached to piping, vessels or machines via relatively small piping tend to have
low natural frequency in the harmonic range of the running speed. They are prime candidates
for vibration induced fatigue failures.
14. Check piping and instruments for vibration during start-up. pay particular attention to small
bore piping.
See above for reasoning.
15. Review the package design for operability and maintainability
It will not be maintained if it is difficult to maintain. API 11P machines do require more
maintenance and tend to be less carefully packaged if the owner does not push for clean
design.
16. Specify flywheel also on el. motor driven units
Another means for vibration reduction.
I realise that the above will trigger quite a number of comments, but that is what is needed .
Wim Hardeveld
Principal Engineer Rotating Equipment
Focal Point E & P and T&OE FE
Shell Global Solutions Int'l - OGER