RIPI: RIPI: 26 26 February February 20132013
Some new insights to efficient design Some new insights to efficient design of gas processing and transmission of gas processing and transmission
plantsplants
NigcNigc R&D symposiumR&D symposium
Some new insights to efficient design of gas processing and transmission plants
Overview
New design of compressor stations
Power generation in GPRS of compressor stations
Energy integration in existing compressor stations
Active control of surge in gas compressors
Some new insights to efficient design of gas processing and transmission plants
Industrial Gas Turbine
Fuel Gas
Centrifugal Compressor
Station Inlet
Station Outlet
Recycle sy
stem
1- NEW DESIGN OF COMPRESSOR STATIONS
J-T valve
Heater
Some new insights to efficient design of gas processing and transmission plants
GT3 GC3
GT2 GC2
GT1 GC1
Heat Recovery Steam Generator
GC4ST
condenser
Stand byStand by
1- NEW DESIGN OF COMPRESSOR STATIONS
Some new insights to efficient design of gas processing and transmission plants
1- NEW DESIGN OF COMPRESSOR STATIONS
Some new insights to efficient design of gas processing and transmission plants
ParameterNG saving per
annumBudget price
CO2
reduction
Unit MMSCM MUS$ Ton/year
KHONJ 47.73 45 94135
JAHROM 45.6 43 89058
ARSANJAN 44.71 43 87355
ARDESTAN 36.36 36 68906
DEHSHIR 36.34 37 71271
NODOOSHAN 40.67 43 78840
KASHAN 40.59 44 78525
Total 292 291 568090
Note: Net investment for IGEDC is about 136 MUS$Note: Net investment for IGEDC is about 136 MUS$
1- NEW DESIGN OF COMPRESSOR STATIONS
Some new insights to efficient design of gas processing and transmission plants
Note: Net investment for IGEDC is about Note: Net investment for IGEDC is about 136 136 MUS$MUS$
ParameterIGEDC net
Investment costSaved NG worth Reduced CO2 worth
Total
income
Unit MUS$ MUS$ /Year MUS$/Year MUS$/Year
KHONJ 20 14.319 0.94135 15.26035
JAHROM 18 13.68 0.89058 14.57058
ARSANJAN 18 13.413 0.87355 14.28655
DEHSHIR 17 10.902 0.71271 11.61471
NODOOSHAN 23 12.201 0.7884 12.9894
ARDESTAN 16 8.7264 0.551248 9.277648
KASHAN 24 9.7416 0.6282 10.3698
The most optimistic economic outlook-full load operation
1- NEW DESIGN OF COMPRESSOR STATIONS
Some new insights to efficient design of gas processing and transmission plants
2- POWER GENERATION IN GPRS OF COMPRESSOR STATIONS
Some new insights to efficient design of gas processing and transmission plants
Gas Composition Based on IGS-CH-033(0):2004
Gas Turbines
• Nuovo Pignone M5238C
• Siemens SGT600
• Zorya UGT25000
•Zorya UGT16000
Compressor Stations
• Gathered Data
Capacity – Inlet & Exit Pressure – Height – Gas Turbine
• Data from Simulation
Gas Turbine Power, Load, Efficiency and Fuel consumption
Gas Turbine Type
Fuel
Pressure
(bar)
Fuel
Temperature
(°C)
Nuovo Pignone M5238C 19 25
Siemens SGT600 24.5 10
Zorya UGT25000 35 20
Zorya UGT 16000 24.5 20
2- POWER GENERATION IN GPRS OF COMPRESSOR STATIONS
Some new insights to efficient design of gas processing and transmission plants
Compressor Stations Data; A Sample Case: FARASHBAND-2
Nominal
Capacity
(MSCMD)
Inlet
Pressure
(bar)
Exit
Pressure
(bar)
Height
(m)
Gas
Turbine
Type
Arrange
-ment
Gas
Turbine
Fuel Gas
Pressure
(bar)
Gas Turbine
Fuel Gas
Temperature
(°C)
79 48 84 762.3 M5238C 4+1 19 25
A
B
Gas Compressor
Gas compressor
Gas Compressor
Gas Compressor
AFTER COOLER
Ambient pressure 0.9251 barAmbient temperature 15 CAmbient RH 40 %Gross power 0 kWGross electric efficiency(LHV) 0 %
2
17°
18°
19°
20°
21°
22
235
6
7
24
26
25
8GE M5382C
9GE M5382C
10GE M5382C
27GE M5382C
11
12
13
28
29
14
15
16
30
31
1
33
34
3536
37
38
3
13
14
15
16
174
5
6
18
20
19
7
8
9
21
10
11
12
22
231
2
26
27
28
29
30
31
32
33
34
Each Gas
Turbine Power
Generation
(kW)
Each
Gas
Turbine
Load
(%)
Each Gas
Turbine
Efficiency
(%)
Each Gas
Turbine Fuel
Consumption
(kg/s)
Total Fuel
Consumption /
Turboexpander Flow
(kg/s)
20516 81.23 28.39 1.607 6.428
2- POWER GENERATION IN GPRS OF COMPRESSOR STATIONS
Some new insights to efficient design of gas processing and transmission plants
Electrical Network Data
Compressor Stations Existing Substations
20 kV to 400 V
Turboexpander Power Generation Level
LV → 400 V
Connection to Grid
• 400 V (through the existing substation)
• Automatic
- Export to Grid
- Import from Grid
Some new insights to efficient design of gas processing and transmission plants
Assume η = 0.8
Calculate SHP;
SHP = 1.41ṁΔhη
Determine N
(From Diagram I)
Calculate NS;
Look up New η
(From Diagram II)
Diagram I
Diagram II
2- POWER GENERATION IN GPRS OF COMPRESSOR STATIONS
Some new insights to efficient design of gas processing and transmission plants
A Sample Case: FARASHBAND-2
Parameter Symbol Unit Value
Station / Turboexpander Inlet Pressure P1 bar 48
Station / Pre-heater Inlet Temperature T0 °C 24
Pre-heater Exit / Turboexpander Inlet Temperature T1 °C 75
Gas Turbines Fuel / Turboexpander Flow mf kg/s 6.428
Gas Turbines Fuel / Turboexpander Discharge Pressure P2 bar 19
Gas Turbines Fuel / Turboexpander Discharge Temperature T2 °C 25
Required Input Heat to Gas Q0 kW 839.9
Input Heat Considering Pre-heater Efficiency Q kW 1199.9
Turboexpander Speed N rpm 31125
Turboexpander Specific Speed NS - 40.78
Turboexpander Efficiency ηTE % 78.87
Electrical Power Generation W kW 631.3
First-Law Thermal Efficiency ηth % 52.61
2- POWER GENERATION IN GPRS OF COMPRESSOR STATIONS
Some new insights to efficient design of gas processing and transmission plants
Power Generation Calculations
Rank Station Name Power HeatThermal
Efficiency
W
(kW)
Q
(kW)
ηth
(%)
1 FARASHBAND-2 631.3 1199.9 52.61
2 NOORABAD-3 567.7 1091.3 52.02
3 PATAVEH-2 528.6 1008.6 52.41
4 DORAHAN-2 474.7 915.1 51.87
5 DAHAQ-2,3 398.8 554.3 71.95
6 SAFASHAHR 389.3 582.0 66.89
7 KHONJ 382.8 592.9 64.56
8 FARASHBAND-3 352.9 512.4 68.87
9 ESFAHAN-2 333.8 578.3 57.72
10 SHAHREZA 320.7 487.9 65.73
11 NOORABAD-2 303.0 533.3 56.82
12 QOM-3 295.8 387.9 76.26
13 KHAVARAN 267.5 507.6 52.70
14 QOM-2 265.0 504.6 52.52
15 PATAVEH-3 256.3 353.4 72.52
16 ESFAHAN-3 255.6 346.1 73.85
17 DORAHAN-3 252.5 348.4 72.47
2- POWER GENERATION IN GPRS OF COMPRESSOR STATIONS
Some new insights to efficient design of gas processing and transmission plants
Why Using Gearbox?
Case Study; FARASHBAND-2
Heater Turboexpander Gearbox Generator
Heat (kW)Speed
(rpm)
Specific
Speed
(-)
TypeEfficiency
(%)
Mechanical
Power
(kW)
Efficiency
(%)
Efficiency
(%)
Electrical
Power
(kW)
Thermal
Efficiency
(%)
1119.9 31125 40.78 Radial 78.87 671.0 97 97 631.3 52.61
715.4 3000 3.93 Axial 42 331.6 - 97 321.7 44.97
2- POWER GENERATION IN GPRS OF COMPRESSOR STATIONS
Some new insights to efficient design of gas processing and transmission plants
Total Fuel Saving PotentialSummary of Power Generation and Heat Consumption
Turboexpander
(New Design)
Expansion Valve
(Current Situation)
Station NamePower
(kW)
Heat
(kW)
Power
(kW)
Heat
(kW)
FARASHBAND-2 631.3 839.9 0 321.9
NOORABAD-3 567.7 763.9 0 310.7
PATAVEH-2 528.6 706 0 294.8
DORAHAN-2 474.7 640.6 0 263.0
DAHAQ-2,3 398.8 388.0 0 86.16
SAFASHAHR 389.3 407.4 0 98.15
KHONJ 382.8 415.0 0 105.6
FARASHBAND-3 352.9 358.1 0 84.30
ESFAHAN-2 333.8 404.8 0 172.5
SHAHREZA 320.7 341.5 0 86.74
NOORABAD-2 303.0 373.3 0 155.4
QOM-3 295.8 271.5 0 57.75
KHAVARAN 267.5 355.3 0 145.4
QOM-2 265.0 353.2 0 142.9
PATAVEH-3 256.3 247.4 0 54.30
ESFAHAN-3 255.6 242.3 0 52.84
DORAHAN-3 252.5 243.9 0 53.53
2- POWER GENERATION IN GPRS OF COMPRESSOR STATIONS
Some new insights to efficient design of gas processing and transmission plants
Economic OUTLOOK
Investmen
t cost
(MUS$)
Water Bath Heater for
Expansion Valve Case
Electrical Heater for
Expansion Valve Case
Station NameNG Saving
(MSCM/year)
Saved NG price
(MUS$/year)
NG Saving
(MSCM/year)
Saved NG price
(MUS$/year)
FARASHBAND-2 1.471902 1.053390 0.316017 1.617315 0.485195
NOORABAD-3 1.334991 0.961775 0.288533 1.505990 0.451797
PATAVEH-2 1.251125 0.908120 0.272436 1.424595 0.427379
DORAHAN-2 1.135330 0.805920 0.241776 1.266550 0.379965
DAHAQ-2,3 0.972248 0.694960 0.208488 0.845705 0.253712
SAFASHAHR 0.952039 0.661380 0.198414 0.833295 0.249989
KHONJ 0.938095 0.644225 0.193268 0.829280 0.248784
FARASHBAND-3 0.873832 0.606995 0.182099 0.754820 0.226446
ESFAHAN-2 0.832607 0.605170 0.181551 0.907390 0.272217
SHAHREZA 0.804517 0.544945 0.163484 0.696785 0.209036
NOORABAD-2 0.766727 0.541295 0.162389 0.813585 0.244076
QOM-3 0.750964 0.527060 0.158118 0.628530 0.188559
KHAVARAN 0.690339 0.457345 0.137204 0.712115 0.213635
QOM-2 0.684971 0.450410 0.135123 0.700800 0.210240
PATAVEH-3 0.666291 0.447490 0.134247 0.542755 0.162827
ESFAHAN-3 0.664674 0.450045 0.135014 0.542755 0.162827
DORAHAN-3 0.658207 0.440920 0.132276 0.534725 0.160418
Total 15.44886 10.80145 3.240437 15.15699 4.547102
2- POWER GENERATION IN GPRS OF COMPRESSOR STATIONS
Some new insights to efficient design of gas processing and transmission plants
3- Energy integration in existing compressor stations
Industrial Gas Turbine
Fuel Gas
Centrifugal Compressor
Station Inlet
Station Outlet
Kick
Back
Sy
stem
0.85$
1$
0.15$
More than More than 62 62 units older than units older than 35 35 years years (already retired) with such a performance:(already retired) with such a performance:
Some new insights to efficient design of gas processing and transmission plants
3- Energy integration in existing compressor stations
Some new insights to efficient design of gas processing and transmission plants
4- surge active control in gas compressors
Gas compressor has to follow the downstreamGas compressor has to follow the downstream
Some new insights to efficient design of gas processing and transmission plants
4- surge active control in gas compressors
-50 0 50 100 150 200 250 300 350 4001
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
Mass flow (kg/s)
Pre
ssu
re r
atio
Generatedspeed lines
Surge Line
Existing speed lines
-100 0 100 200 300 400 5001.6
1.65
1.7
1.75
1.8
1.85
1.9
Mass flow (kg/s)
Pre
ssu
re R
ise
operating condition
Surge Line
40 50 60 700
1
2
3
4x 10
4
t (s)
To
rqu
e (
N.m
)
0 20 40 60 80 100700
800
900
1000
t (s)
spe
ed
(ra
d/s
)
0 50 100
1.55
1.6
t (s)
Pre
ssu
re R
ise
0 20 40 60 80-200
0
200
400
600
t (s)
Ma
ss
Flo
w (
kg/s
)
Some new insights to efficient design of gas processing and transmission plants
4- surge active control in gas compressors
50 100 150 200 250 300 350 4001.3
1.35
1.4
1.45
1.5
1.55
1.6
1.65
1.7
1.75
1.8
Mass flow (kg/s)
Pre
ssure
Ris
e
Design Speed
Max. Speed
Maximum turn down ratio: Customized for refrigeration circuits (LNG) and injection to wells
Some new insights to efficient design of gas processing and transmission plants
Thanks for your attention