ADVANCED RECIPROCATING COMPRESSION TECHNOLOGY (ARCT)

The U.S. natural gas pipeline industry is facing the twin challenges of increased flexibility and capacity expansion. To meet these challenges, the industry requires improved choices in gas compression to address new construction and enhancement of the currently installed infrastructure. The current fleet of installed reciprocating compression is primarily slow-speed integral machines. Most new reciprocating compression is and will be large, high-speed separable units. The major challenges with the fleet of slow-speed integral machines are: limited flexibility and a large range in performance. In an attempt to increase flexibility, many operators are choosing to single-act cylinders, which are causing reduced reliability and integrity. While the best performing units in the fleet exhibit thermal efficiencies between 90% and 92%, the low performers are running down to 50% with the mean at about 80%. The major cause for this large disparity is due to installation losses in the pulsation control system. In the better performers, the losses are about evenly split between installation losses and valve losses. The major challenges for high-speed machines are: cylinder nozzle pulsations, mechanical vibrations due to cylinder stretch, short valve life, and low thermal performance. To shift nozzle pulsation to higher orders, nozzles are shortened, and to dampen the amplitudes, orifices are added. The shortened nozzles result in mechanical coupling with the cylinder, thereby, causing increased vibration due to the cylinder stretch mode. Valve life is even shorter than for slow speeds and can be on the order of a few months. The thermal efficiency is 10% to 15% lower than slow-speed equipment with the best performance in the 75% to 80% range. The goal of this advanced reciprocating compression program is to develop the technology for both high speed and low speed compression that will expand unit flexibility, increase thermal efficiency, and increase reliability and integrity. Retrofit technologies that address the challenges of slow-speed integral compression are: (1) optimum turndown using a combination of speed and clearance with single-acting operation as a last resort; (2) if single-acting is required, implement infinite length nozzles to address nozzle pulsation and tunable side branch absorbers for 1x lateral pulsations; and (3) advanced valves, either the semi-active plate valve or the passive rotary valve, to extend valve life to three years with half the pressure drop. This next generation of slow-speed compression should attain 95% efficiency, a three-year valve life, and expanded turndown. New equipment technologies that address the challenges of large-horsepower, high-speed compression are: (1) optimum turndown with unit speed; (2) tapered nozzles to effectively reduce nozzle pulsation with half the pressure drop and minimization of mechanical cylinder stretch induced vibrations; (3) tunable side branch absorber or higher-order filter bottle to address lateral piping pulsations over the entire extended speed range with minimal pressure drop; and (4) semi-active plate valves or passive rotary valves to extend valve life with half the pressure drop. This next generation of large-horsepower, high-speed compression should attain 90% efficiency, a two-year valve life, 50% turndown, and less than 0.75 IPS vibration. This program has generated proof-of-concept technologies with the potential to meet these ambitious goals. Full development of these identified technologies is underway. The GMRC has committed to pursue the most promising enabling technologies for their industry

INCREASED FLEXIBILITY OF TURBO-COMPRESSORS IN NATURAL GAS TRANSMISSION THROUGH DIRECT SURGE CONTROL

The objective of this Direct Surge Control project was to develop a new internal method to avoid surge of pipeline compressors. This method will safely expand the range and flexibility of compressor operations, while minimizing wasteful recycle flow at the lower end of the operating envelope. The approach is to sense the onset of surge with a probe that directly measures re-circulation at the impeller inlet. The signals from the probe are used by a controller to allow operation at low flow conditions without resorting to a predictive method requiring excessive margin to activate a recycle valve. The sensor developed and demonstrated during this project was a simple, rugged, and sensitive drag probe. Experiments conducted in a laboratory compressor clearly showed the effectiveness of the technique. Subsequent field demonstrations indicated that the increase in range without the need to recycle flow was on the order of 19% to 25%. The cost benefit of applying the direct surge control technology appears to be as much as $120 per hour per compressor for operation without the current level of recycle flow. This could amount to approximately$85 million per year for the U.S. Natural Gas Transmission industry, if direct surge control systems are applied to most pipeline centrifugal compressors