Hi igh Pressure Fuel Gas Boosting Compressors Takao Koga, Kobelco EDT! Compressors IR. fact gas boosting compresor is the “blood pump” for gas turbine power plans because iF the fuel gas compresor fils, the gas tur bine powerplant stops entirely As a result, compressors are critically important for reliable gas turbine power plat operation. At the same time, the demands on compresors have been increasing because gas turbines require higher fuel gas pressures to achieve increased performance effcieney and because pipeline pressures fluctuate dae to increased overall peak requirements “Therefore, selecting the coreet type of fel gas compressor is one of the most important factors in achieving, saccessfal plant operation Gas turbines require a certain pressure of fuel gas to combine the fuel gas and pressurized air before combustion Historically, when main pipelines were | built the gas pressure was and demand adequate. Normally, the gas pressure was | reduced from this & pipeline pressure and delivered at the gas turbine’s required pressure, In the North American market, fsel gas compressors were not offen required. However, as higher efficiency gas turbines were developed, the required gas pressure kept increasing, The required gas pressare for conventional types of industrial gas turbines is around 250 to 300 pounds per square inch gauge (psig), oF 17.5 to 21 barG on average. However, the latest generation of industrial gas turbine requires relatively high pressure gas, such as 500 to 600 psig Mg SCREW COMPRESSOR (35 to 42 barG), In addition, aeroderivative type gas turbines ‘how require gas pressure as high as 700 t0 1,000 psig (49 to 70 barG), Ar the same time, natural gas demand has been increasing so that the new development and supply of natural gas is aot sufficient forthe growth of demand in many parts of the world, ‘As a result, the gas pressure in the pipeline cannot be maintained as high as before. This is pariculasy true during peak demand such as summertime or daytime. It means that the gas pressure in the pipeline would gradually decrease and even facta, A fuel gas compressor War) should properly handle such uctuating gis pressure from the pipeline while Meni a simultancously meeting the gas turbine’s required gas flow ite, Two changeable conditions are most relevant to fisel gas Compressors: suction gis pressure Quctuation mae and the turbine’s load St changes 4 In addition, reduced cil carryover ‘and. lew end i pulsation/vibration are also important, because they can lead t0 mechanical problems, Palsation in particular is a big concer to gas turbines with dry low NO, combustors since the combustor is ‘more sensitive to pulsation. In addition, natural gas can include impurities or dirt and its precise composition can even be subject to change ‘Three Designs “There are three basi gas compressor designs exist: centrifugal, reciprocating and screw. Each design has mechanically www power-eng comRCRA Contin crate soe es comes from the wells changes, which leads to molecular weight changes. The molecular weight change possibly could cause performance problems, especially for a centrfagal compressor due to the principle of the compression Furthermore, although gas turbine load ‘normally changes, centrifugal compressor tumdown ranges are limited from 100 percent to about 70 percent, even with an inlet guide vane Therefore, on occasion, centrifugal compressors have been used for fuel gas compressors for large industrial gs turbines and low compression ratio cases; however they are not so beneficial and reliable under changeable operating Conditions as those which are present in fuel gas boosting services. Also, if the required compression ratio is high, the centrifagal compressor requires multiple stages, making it a less economical investment. The same applies t0 reciprocating compressors, 3000 Suction Pressure (Ps) Fluctuation 2500 Discharge Pressure: 45barA = 1500 Power Consumgtion (kW) 1000 500 The reciprocating compressor is suitable for high pressure and middle o gs flow services such as hydrogen make © to000 20000 © s0000 40000 50000 60000 tp service in oil refining processes capacity vinim/) The advantage of the reciprocating compressor is its high efficiency due t0 simple displacement compression, This cans the reciprocating compressor has been historically the most traditional type. Fealso has been wsed for various gas compression services in the world the disadvantages of reciprocating compressors include reduced reliability and more frequent ‘maintenance, which can mean that a different features. To date, centrifugal gas boosting in pipelines. However, types have been used centrifugal compressors are equally well as boosting services in suited for changeable operatingcondlitions the United States and Europe, Serew-type because ofits surging nature, This means fuel gas boosting compresors have been that the compression ratio must remain used mainly in Japan and Asian markets. constant and, if higher suction pressure A.cutaway diagram of typical screw-type than design pressure (minimum pressure) ‘compressor is shown in Figure 1 ‘occur, it must be reduced to the design ‘After development of high pressure pressure (minimum pressure) and then screw gas compressors in late 1990's, this boosted tthe and reciprocatin ‘mainly for fuel However, type of fel gas boosting compressor has required — discharge Figure 3 BASIC PRINCIPLE OF THE begun tobe sed forthe mosteffcient gas pressure to maintain Ea turbines (fr example the GE LM6000 the designed and F7EA/EB, the MHI 501G, the compression ratio oT Siemens/Westinghouse501G,theAlstom However, because | ae GT26 and 50 on), Now, high pressure pipeline pressures | &| a 8 screw gts compresors can achive up todo fucuate, | J ‘|g g 1,500 psig (equal to 100 barG), which the centrifugal | 2 v | é covers any required fuel gas presures of compressor ist at the most effet and the most recently furnish a suction developed gas turbines. throttle valve to : Centrifugal compresors are suitable regulate the suction | |Sueton for large gas flow, nv compression ratio presaire down | to and stable operational conditions; that design pressure is, basically for operations that present (minimum pressure). rnd change in pressure, gas flow and gis The drop of suction Rotor Rotor composition. As a result, this type of pressure isa waste of 7 Discharge Discharge compressor has been used mainly for energy Side Valve to process gas services in petrochemical In addition, in oat) tnd oil refining fields and for natural some countries gas www pomer-eng.com MAY 2007 POWER ENGINEERING + 49spare compressor is normally required in the case of continuous operation services. Ie also requires frequent maintenance within a short interval. (approximately once a year) because of the many sliding and wearing parts inside. This makes the reciprocating compressor less suitable for continuous and long-term operation, Incase ofthe gas turbine’s load change, reciprocating compressor ean save more ower consumption than a centrifagal compressor, but it requires non linear step controls (for example 100 percent, 5 percent, 50 percent and 25 percent), In addition, environmental issues can arise, such a5 noise, emissions, pulsation, vibration and s0 on. To date, reciprocating compressors hhave been ‘sed in ftel gis boosting compressor applications for middle sized gas turbines or high pressure scroderivative gas turbines; however, they are growing less popular due to the disadvantages such as reduced reliability, and reduced increased cavironmental fiendliness, Especially for dry low NO, combustors, the pulsation caused by the piston movement of the reciprocating compressor is now a serious problem, meaning that their use for fuel igs compressors is declining, Screw compressors were originally suitable for middle pressure and middle gis flow rate services. Their advantages include high reliability, reduced maintenance and power savings because of the builtin slide valve. However, the original applicable range was not wide because of pressure limitations Pee a te Fuel Gas Compressor Specifications as Turbine Output (simple cyte) 250M Fuel Gas Natural Gas as Capacity (Nm3/hn) 60,000; (97,331 SCFM) Suction Pressure bar A) 15 ~ 40; (214 ~ 571 PSIA) Discharge Pressure (bar A) 45; 643 PSIA) Power Consumption at 100% Load 2850KW Effect of Power Saving-Cost Saving ‘Avg. power ference between screw and centrifugal 1,250 kW Cost per kWh estimate) Scents Operating Hours per Year 8.000 hours Cost Savings per Year $500,000 Estimated CO, Reduction ‘Avg. power ference between screw and centrifugal 1,250 kW as Turbine Efficiency 50% Operating Hows per Year 8.000 hours eduction of CO, per Hour 4359 peak load operation. Normally, no spare ‘compressor is required, Centrifugal and reciprocati ‘compressors have limited ability to adjust, their performances to accommodate the changing operational conditions of (3) saryinggas supplypressures, (b)gasturbine load changes and (@) gs composition changes. Serew-type compressors can accommodate these variables, and by the ‘ery nature of their design can contribute Screw compressors can save power consumption by 1,250 kW/hr on average with an operational cost savings of over $10 million for 20 years of operation. Screw compressors have been used for small. oF middle-sized gas turbines, Following development of high pressure screw compressors in late 1990s, screw compressors are now being used for fuel igs boosting services for large industrial and high efficiency seroderivative gas turbines as well. Several reasons exist to demonstrate why screw compressors are chosen for fuel gs boosting services, First, screw compressor reliability is aque high so that it s suitable For lon term continuous operation and ex power savings to the owner/operstor, should situation (a) or (b) develop. This ‘means that serewtype fuel gas boosti ‘compressors can contribute toa gas turbine power plant's total efficiency To illustrate, consider a 250 MW large gas turbine that operates 8,000 hours a year, has operating costs equal to 5 cents ‘ KWh, a required gas turbine pressure of (648 psa (45 bar), gas pipeline pressure fluctuations that range from 214 psia to 571 psia (15 barA to 40 barA) and an average gas pipeline pressure of 430 psia (Bo bard) Screw compressors can save power consumption by 1,250 KW/hr on average, ‘with an operational cost savings of over $10 million for 20 years of operation (see Table 1), Should the gas turbine's Toad also change during this time frame, additional cost savings may be realized This power savings means reduced CO, ‘emissions as an additional benef In case the gas composition changes, screw compressors donot have any problem because the compression principle is a positive displacement type. Even if the composition of natural as would change, screw compressor performance is not affected. Also, the screw compressor has few internal parts, so less maintenance is required than with reciprocating compressors. Five to. six years of continuous operstion may be possible without any overhauling. The screw compressor is also an environmentally friendly machine, For example, the noise level is low and its frequency’ is high 30 that it is easy to reduce the level to 85 dbA at 3 ft (Im) with minimal sound attenuation. Also, there is no pulsation and vibration issue because it hasno piston movement, only a rotating movement ‘A caraway drawing of a typical oil injected type screw compressor is shown in Figure 3. There are two rotors inside the casing and they contact each other at lobe surface via an oil film, wana power-eng.comil is supplied not only to the bearing and seal, but also t0 the rotor chamber directly and oil will act as lnbricant, coolant and sealant in the rotor chamber. Typically, the male rotor is driven by a directly coupled 2-pole or 4-pole electric motor and it drives the female rotor. An external gear unit is typically not used since the tip speed of the oil injected serew compressor is within the proper design limits when driven at motor speed, Since oil is injected into the rotor chamber, the seal area between the rotor lobe and bearing is no longer necessary. There is a single mechanical seal located atthe drive shaft end. There are typically sleeve-type journal bearings on both ends of the rotor lobes. Thrust bearings are typically iting pad type and re located on the outside ofthe journal bearings. "The oil and gas mixture is discharged through the compressor dischargenozzleintoanoil eparationsystemlocated downstream fof the compressor. The oil that is separated inthe oil separation system is circulated in the compressor lube system, ‘An unloaded side valve is located in the compressor beneath the twin rotors and is used to adjust the inlet volume. The inlet volume of the compressed gas can be adjusted by moving the slide valve, which is actuated by a hydraulic cylinder. ‘Compressor lubricant cil is present in the process side, wich ‘means the Inbe oil selection is very different from other types ff machines. The bulk of the oil is separated in the primary oil separator, buta secondary coalescing ol separator may beused3san ‘ekdtional separator. Oil separation is one ofthe important fictors for oil injected screw compresors. Typically, a combination of sdemistr mesh pad and coalescing elements are used. For example, O.Appm wr level ean be achieved by combining a demister mesh pad and two stages of coalescing elements. In addition, since almost pure synthetic oil such as PAO (polyalphaoefin olor vacuum oil are used, there sno influence tothe gas turbine by the oil, Normally the latest generation gas turbines accept less than 0.5ppm vr oil earyover from the fuel gas compressorsso that screw ‘compresior has no problem as far as sich conservative design for oil separation system is done. Borocilicate micro fiber isa typical ‘material used in coalescing lements and sub-micronic particles of cil canbe separated from the compressed gas, Unlike reciprocating ‘compresiors, ol fiom the compressor experiences no deterioration by piston rubbing so oil can be re-created in the sytem 35, Iubicant for longer lif. The lube oil circulation system consis of ‘compressor lube line, oil cooler, oil filters and oil pump. The oil pump may be double or single configuration, Thedesign of single pump system may be used wien the pump is required only during startup. In some cases, affer the compresor starts and dischagge pressure is established, ol can ctculate in the system by utilizing {5 differential pressure between suction and discharge "The slide valve is used to load and unload the compressor to ‘maintain suction pressure or discharge pressure, There is a spool wake actuated by air with solenoid valves to switeh over the oil Iines to pressurize the side vale cylinders to load side or unload side. Typical control range by slide valve is ftom 100 percent ro 15 percent and is stples by inlet volume. ‘Screw compressors for fel gas boosting services in gas ‘turbine powerplants contribute to increase the total efficiency in the power industry. Screw compressors minimize any excessive initial and maintenance costs, resulting in real cost savings For the users and emissions are reduced as well. 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