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COMPRESSION

MASTER PLANNER
An Expert System for Evaluation of Gas Pipeline Compressor Station Equipment Options

GAS PIPELINE COMPRESSION EQUIPMENT COMBINATIONS


Planners consider options from top to bottom of this decision tree * COMPRESSORS

Reciprocating

Centrifugal

PRIME MOVERS
Induction Motors Induction Motors

Engines

Synchronous Motors

Synchronous Motors

Turbines

Microprocessor Controlled Compressor Cylinders

CONTROL
Motor & gear Hi speed motor

Mechanical Drives

Adjustable Speed Drives Hi Speed ASDs

Expert System is based


on this logic tree

Allows users to find reasonable equipment combinations from specification database of suppliers models Evaluates and compares performance and life cycle costs Speeds up and improves the decision making process Makes broad industry experience from many companies available to all staff members

What Does Compression Master Planner Do?


Planner inputs station design requirements & up to ten more operating points Program sorts through database of specifications of available equipment models to find reasonable combos of Compressors Turbines/engines/motors Drives & capacity control Compares gas vs. electric and centrifugal vs. reciprocating compression Provides performance data & charts on the fly!

20,000 1 8,000 1 6,000 1 4,000 1 2,000 1 0,000 8,000 6,000 4,000 2,000 2,000

4,000

6,000

8,000

10,000

12,000

1 4,000

I nl et V o l ume A C F M

Provides life cycle cost comparison of up to six equipment options.

200-500 combinations of equipment selections and operating conditions can be evaluated in one fast analysis. Provides results in minutes, not weeks.

COMPRESSION MASTER PLANNER is overseen by a


Compression Review Team made up of gas pipeline planners. Subscribing suppliers will be able to participate.

What are the Benefits?


For gas pipeline planners and engineers
Provides faster & more thorough evaluations for asset decisions Flushes out options & equipment combinations which may not be considered otherwise Equipment options can be scoped in minutes, not weeks Allows preliminary screens to be provided to business development, facilities planning, & engineering Makes broad industry experience available to newer staff members

For equipment, service, power suppliers


Integrates and links product/service offerings and their advantages into platform viewed by customers Enhances sales opportunities thru early exposure Makes marketing interactive via 24/7 links with customers Provides direct customer interaction via Compression Review Team meetings.

Sunrise Springs near Albuquerque, one of the sites for Compression Review Team meetings

CENTRIFUGAL COMPRESSOR PERFORMANCE

12000

Centrifugal Compressor Performance Map Surge Line in Blue


MAX ACFM, 12,700

10000

Surge line
8000

Design point Alternate operating points


Design Point 10 9 7 6 4 8 2 1 3

Head

6000

4000

Alternate Operating points

2000

Minimum rpm 0
0 2000 4000

ACFM
6000 8000 10000 12000

MAX ACFM, 12,700 14000

USER VIEWS PERFORMANCE CHARTS such as: 1. HEAD vs. ACTUAL CU FT/MIN with constant efficiency & speed lines with surge line and minimum speed line 2. SUCTION & DISCHARGE PRESSURES vs. FLOW

USER CLICKS DIALOG BOX TO SELECT BOTH THE CASE & THE OPERATING POINT ON THE FLY USER CAN EASILY SEE WHICH OPERATING POINTS MAY VIOLATE CONSTRAINTS such as: Speed too high or too low Actual cubic feet per minute or head too high Proximity to the surge line

USER SEES TABLE OF ALL CONSTRAINTS FOR ALL POINTS

A DECISION CAN BE MADE TO KEEP THE SELECTION, CHANGE COMPRESSOR OR PRIME MOVER, OR MODIFY OPERATIONAL PARAMETERS

RECIPROCATING COMPRESSOR PERFORMANCE

Flow vs Suction Pressure


at design or alternate discharge pressure

Flow, MMSCFD

MAXIMUM FLOW max speed cylinders double acting 90% of max rod load MINIMUM FLOW max turn down, min speed cylinders single acting Design or alternate operating point

800 600 400 200 0 1000


Max rpm, all double acting Min rpm, all single acting Design or Alternate Op Point Rod Load Limit

200

400

600

800

Suction Pressure, psig

Horsepower vs. Suction Pressure


at design or alternate discharge pressure
M ax rpm, all double acting M in rpm, all single acting Design or Alternate Op Point Prime M over HP

Horsepower

15000 10000 5000

M in Prime M over HP

0
Rod Load Limit

200

400

600

800

1000

Suction Pressure, psig

USER VIEWS PERFORMANCE CHARTS FLOW or HORSEPOWER vs. PRESSURE (suction or discharge) At maximum flow & minimum flow capability of system Limit of 90 % of maximum compressive rod load shown

USER CLICKS DIALOG BOX TO SELECT BOTH THE CASE & THE OPERATING POINT ON THE FLY USER CAN EASILY SEE WHICH OPERATING POINTS MAY VIOLATE CONSTRAINTS such as: Horsepower needed too high or too low Flow too high Rod load too high

USER SEES TABLE OF CONSTRAINTS FOR ALL POINTS BORE, CYLINDER MODEL, or NUMBER OF POCKETS CAN BE ADJUSTED on the fly & THE EFFECT VIEWED

A DECISION IS MADE TO KEEP THE SELECTION, CHANGE COMPRESSOR OR PRIME MOVER, OR MODIFY OPERATIONAL PARAMETERS

LIFE CYCLE COSTS

LIFE CYCLE COSTS for COMPRESSION PROJECTS Net Present Value, cents/hp-hr
(real $'s)

15 10 5 0 10 30 50 70 90 Utilization, %

Gas Case 1 Gas Case 2 Gas Case 3 Elec Case 1 Elec Case 2 Elec Case 3

PROGRAM COMPARES INSTALLED CAPITAL, MAINTENANCE, & FUEL COST for any and all combinations of equipment. NET PRESENT VALUE IS DISPLAYED vs. UTILIZATION (fraction of the time the equipment is in use) PROGRAM PROVIDES DEFAULTS FOR ALL ECONOMIC INPUTS, but the user can override them based on company info or actual bids ELECTRIC and GAS COMPRESSION OPTIONS are addressed employing user-selected power and gas price forecasts

HOW DOES THE LIFE CYCLE COST MODEL WORK?


USER CAN USE DEFAULTS provided or modify them for INSTALLED CAPITAL INITIAL MAINTENANCE COSTS & ESCALATION WITH TIME HEAT RATES & EFFICIENCIES AVAILABILITY TURN DOWN RATIOS RECIP COMPRESSOR BORE, CYLINDERS, POCKETS SUBSTATION & POWER LINE EXTENSION CAPITAL if applicable CAPITAL & MAINTENANCE DEFAULT ALGORITHMS are designed to reflect experience of several gas pipeline firms EFFICIENCIES & HEAT RATES ARE CALCULATED for each piece of equipment at each operating point based on load or point on performance chart --- then they are weighed according to the time of operation at the point in question RECIPROCATING COMPRESSOR ENERGY USE is found by calculating valve pressure losses & computing horsepower across the cylinders at the required speed. Pockets are activated or controlled as needed.

From El Paso Corporation presentation at 2001 Gas/Electric Partnership workshop.

The efficient way to compare the multitude of gas pipeline compressor station options. ------- COMPRESSION MASTER PLANNER

Compressor Master Planner allows gas pipelines to see all options, evaluate performance, and compare life cycle costs almost instantly. Equipment and energy suppliers can link relevant information and algorithms into the basic evaluation program. Capability to evaluate both equipment options and multiple operating points provides useful oversight at various stages from screening to operational planning Encourages more efficient interactions among business development, facilities planning, & engineering

The COMPRESSION MASTER PLANNER Team


Dr. W. Richard Schmeal, Gas/Electric Ventures, Houston, TX/Santa Fe, NM C. R. Tucker, Santa Fe, NM

ADVISORY BOARD
Anders T. Johnson, El Paso Corporation, Colorado Springs, CO Mohan S. Dosanjh, RPM Engineering Consultancy, Birmingham, UK John Pitlak, Computer Technology Consultant, Santa Fe, NM

COMPRESSION REVIEW TEAM


Jorge Torres, Kinder Morgan Virginia P. Granoff, Williams Gas Pipeline Luis Alberto Pineda, El Paso Corporation

For more information, please contact: Dr. W. Richard Schmeal at 713 529 3216 or rschmeal@ix.netcom.com