Design of Compressor Suction Scrubbers - Noijen - Clinton PDF

Design of Compressor Suction
Scrubbers
Or
Dont wreck the expensive compressor with cheap
scrubbers or with inadequate engineering
TEKNA-Conference
Norway, 26-27 September 2012
Hans Nooijen, GSNL-PTD/TRD

Principal Technologist Distillation
Copyright of Shell Global Solutions International B.V.
Paul Clinton, GSNL-PTU/EKUW

Principal Concept Engineer
DEFINITIONS AND CAUTIONARY NOTE

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States ("SEC") proved oil and gas reserves or SEC proven mining reserves. Resources are consistent with the Society of Petroleum Engineers 2P and 2C definitions.
The companies in which Royal Dutch Shell plc directly and indirectly owns investments are separate entities. In this announcement "Shell", "Shell Group" and "Royal Dutch
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are also used to refer to subsidiaries in general or to those who work for them. These expressions are also used where no useful purpose is served by identifying the
particular company or companies. "Subsidiaries", "Shell subsidiaries" and "Shell companies" as used in this announcement refer to companies in which Shell either directly
or indirectly has control, by having either a majority of the voting rights or the right to exercise a controlling influence. The companies in which Shell has significant influence
but not control are referred to as "associated companies" or "associates" and companies in which Shell has joint control are referred to as "jointly controlled entities". In this
announcement, associates and jointly controlled entities are also referred to as "equity-accounted investments". The term "Shell interest" is used for convenience to indicate
the direct and/or indirect (for example, through our 23 per cent. shareholding in Woodside Petroleum Ltd.) ownership interest held by Shell in a venture, partnership or
company, after exclusion of all third-party interest.
This announcement contains forward looking statements concerning the financial condition, results of operations and businesses of Shell and the Shell Group. All
statements other than statements of historical fact are, or may be deemed to be, forward-looking statements. Forward-looking statements are statements of future
expectations that are based on management's current expectations and assumptions and involve known and unknown risks and uncertainties that could cause actual
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number of factors that could affect the future operations of Shell and the Shell Group and could cause those results to differ materially from those expressed in the forward
looking statements included in this announcement, including (without limitation): (a) price fluctuations in crude oil and natural gas; (b) changes in demand for Shell's
products; (c) currency fluctuations; (d) drilling and production results; (e) reserves estimates; (f) loss of market share and industry competition; (g) environmental and
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including regulatory measures addressing climate change; (k) economic and financial market conditions in various countries and regions; (l) political risks, including the risks
of expropriation and renegotiation of the terms of contracts with governmental entities, delays or advancements in the approval of projects and delays in the reimbursement
for shared costs; and (m) changes in trading conditions. All forward looking statements contained in this announcement are expressly qualified in their entirety by the
cautionary statements contained or referred to in this section. Readers should not place undue reliance on forward looking statements. Additional factors that may affect
future results are contained in Shell's 20-F for the year ended 31 December 2011 (available at www.shell.com/investor and www.sec.gov ). These factors also should be
considered by the reader. Each forward looking statement speaks only as of the date of this announcement, 22 February 2012. Neither Shell nor any of its subsidiaries nor
the Shell Group undertake any obligation to publicly update or revise any forward looking statement as a result of new information, future events or other information. In
light of these risks, results could differ materially from those stated, implied or inferred from the forward looking statements contained in this announcement.
Shell may have used certain terms, such as resources, in this announcement that the SEC strictly prohibits Shell from including in its filings with the SEC. U.S. investors
are urged to consider closely the disclosure in Shell's Form 20-F, File No 1-32575, available on the SEC website www.sec.gov. You can also obtain these forms from the
SEC by calling 1-800-SEC-0330.
CONTENTS
1. What is the problem?

2. Its an old problem and its an ongoing problem
3. Why do we get it wrong?
4. Examples of getting it wrong.

5. How should we get it right?
10/2/2012
WHATS THE PROBLEM?
10/2/2012
WHAT IS THE PROBLEM?

Inadequate separation upstream of compressors results in:
Liquids entering the compressor
Dissolved and entrained solids entering the compressor
Effect on the compressor:

Erosion
Deposition of solids
Eventual consequences:
Reduction of compression efficiency = loss of performance
Rotor imbalance - more unscheduled maintenance
Possible catastrophic failure
10/2/2012
ITS:
An old problem
A current problem
An ongoing problem
10/2/2012
COMPRESSOR FOULING - ITS AN OLD PROBLEM
27 May 1984
Case 1 Lift Gas Compressors Performance Check K-614
The second stage discharge pressure is higher than

expected. The high pressure trip has been reached
and the machine keeps tripping.
The problem has been getting worse and it is
suspected that carry-over is fouling the machine up.
This would have its greatest effect in the third stage
where the clearances are smaller.
10/2/2012
CASE 1 IN 2006
The liquid being drained from the casing drain resembled heavy crude
rather than condensate.
GS.06.50099 Case 1 Visit Report : COMPRI & Smart Fields Scouting Study
10/2/2012
CASE 2
10/2/2012
CASE 3
Salt
deposits
10/2/2012
10
CASE 4 - FOULED DIFFUSER
10/2/2012
11
CASE 5 - 1ST STAGE COMPRESSOR INLET EYE
10/2/2012
12
CASE 6 COMPRESSOR - EROSION
10/2/2012
13
CASE 7 CATASTROPHIC FAILURE
When machine
was opened,
these pools of
liquid were found
in it.
10/2/2012
14
CASE 7 - PIECE BROKEN OFF IMPELLER
10/2/2012
15
CASE 7 - BROKEN SEAL
10/2/2012
16
WHY DO WE GET IT WRONG?
10/2/2012
17
WHY DO WE GET IT WRONG?

Ignorance - not thinking about our design and not understanding
what is happening in our own process

Not following established good practice
Delegating design responsibility
Lack of attention to detail
No close supervision of contractors
Package unit & vendor guarantee mentality
Concept of Industry standard
Attempt to save money
10/2/2012
18
HOW DOES A COMPRESSOR SUCTION SCRUBBER

WORK?
Vessel
Provides larger flow area to
reduce flow velocity

For gas dominated two phase
flow, vertical vessel makes best
use of available area
If high proportion of liquid, need
pre-separation
Control volume for separated
liquid
Outlet nozzle & pipe

Avoids channeling of flow in the
demister
Demisting internals
Remove liquids by various means
Merge small droplets into bigger
droplets
Catch the droplets (cyclones, flow
direction change, etc
Return removed liquid to bottom
of vessel
Inlet device
Inlet nozzle & pipe
Avoids severe maldistribution of
two phase flow across pipe area

Provides non slugging flow
regime
If mist flow be careful - if very
small
droplet
size,International
difficultB.V.to
Copyright
of Shell
Global Solutions
separate
Makes coarse gas/liquid
separation
Distributes gas flow across vessel
area
Avoids re-entrainment of droplets
10/2/2012
19
UNDERSTANDING BEGINS AT THE PFS

What is wrong
with thisare
PFS?
Production
separators
only
(whatseparators,
is missing?)
bulk
just like slug
catchers.
Suction
scrubber was
missing
wells Flowlines
manifold
(5 - 10 km long)
Production separator
A clue:
Now the second
stage is shown
compressor
10/2/2012
20
UNDERSTANDING CONTINUES TO PEFS

WhatInstructions
instruction to
is avoid
missing
slug
from
formation!
these
PEFSs?
Slope, do
not pocket
Slope, do
not pocket
To compressor
Slope, do
not pocket
From separator
To second
compression train,
see PEFS xyz
PEFS
Production
separator
Copyright of Shell Global Solutions International
B.V.
PEFS
Compression
10/2/2012
21
RUNNING PIPING TO COMPRESSORS - PLAN VIEW
Distance can be > 100 m
Compression train
Well flowlines
Piping dept dont know about slugs and the
capabilities of your separators.
If you dont instruct otherwise they will run the
pipes in the most convenient way:
At grade
Underground
Compression train
10/2/2012
22
Suction scrubbers are not

slugcatchers.
When a slug hits the suction scrubber,
a significant proportion will leave in the
gas and enter the compressor.
Production
separator
This gas pipe is now similar to a two phase

cross country pipeline. And it also has
slugs:
Terrain induced
Flow rate induced
A half full 100m long 30 inch pipe holds 7
m3 ofCopyright
liquid!
of Shell Global Solutions International B.V.
Suction
scrubber
RUNNING PIPING TO COMPRESSORS - ELEVATION

VIEW
Worst case is starting another

compressor. The equilibrium hold up
changes and a huge slug can be
generated.
High carryover to compressor
LZHH may be reached on running
machines - which will trip.10/2/2012
23
I CAN SOLVE THAT WITH A DRAIN POT!
LZHH
By the time you have

engineered the drain pot,
how high must the pipe be
elevated?
Definitely higher than it
used to be!
Range for
control
LZLL
Clearance for
access
10/2/2012
24
IF YOU CANNOT ELIMINATE SLUGS, ONLY PROPER

SOLUTION IS A SLUGCATCHER
To suction scrubber
Long pipe
slugcatcher
The slugcatcher will eliminate slugs.

Liquid removal by dip tube or
occasional blowdown are
desperate measures for
constructed plant. They should not
be engineered into a new design.
Underground slugcatchers are nice for the

hydraulics, but very difficult for
maintenance and safety. (dont do it)
Dont forget that the compressor will still
require a suction scrubber.
10/2/2012
25
SUCTION SCRUBBER INLET & OUTLET PIPING
Inlet nozzle
straight length
requirement.
Slope, do
not pocket
Outlet nozzle v2
requirement usually
needs larger pipe
size.
Note 2
Outlet nozzle
straight length
requirement.
Note 1
Inlet nozzle v2
requirement usually
needs larger pipe size.
Note 1. No bends in horizontal plane, valves or swages allowed within 10 pipe diameters of inlet nozzle
Note 2. No bends in horizontal plane, valves or swages allowed within 2 pipe diameters of outlet nozzle
10/2/2012
26
DEVIATION FROM SEPARATOR DEP

Vendor Special
DEP Separator
Exciting new technology
Established technology
Smaller vessel
Based on many actual
Cheaper!
CFD based design
field tests across Shell

Group
Great list of installed units
(but have you spoken to

them?)
Deviation Control
Not applying the DEP requires approval to deviate from Shell practice.
You are not authorized to make this decision.
Why Gamble?
Taking a gamble on a cheaper scrubber is just not worth the risk of compressor damage.
10/2/2012
27
EXAMPLES OF GETTING IT WRONG

Please remember that all these examples were engineered by engineers - it wasnt an accident.
10/2/2012
28
CASE 1 IN 2006
The root cause failure report for K 0611 highlighted (utilizing thermo-graphic photos)
that the liquid suction header for the inlet scrubber was half filled with liquids (low
section of the header). This is the suction header to inlet scrubber V-0610.
10/2/2012
29
CASE 8
Long underground lines from flow

station
10/2/2012
30
CASE 1 K-614 SCRUBBER - VESSEL DATA SHEET
What basis is there for believing that

this proprietary separator will work?
10/2/2012
31
CASE 1 K-614 SCRUBBER - IT GETS EVEN WORSE
Dresser stated that they were

unable to comply with 24
manway requirements.
Customer (x) agreed for
vessels with no internals.
10/2/2012
32
PROPRIETARY SEPARATOR CASE 9

Outlet 12
Flow evenly
distributed
across vane
pack?
Channelling
through vane
pack?
Vessel ID
= 750 mm
Re-entrainment
of droplets?
Inlet 12
10/2/2012
33
CASE 9 PROPRIETARY SEPARATOR - EVALUATION

In September 2003 severe rotor damage of the Export compressor K-83502
occurred.
Liquid carryover from the suction scrubber vessel V-83502 was identified as a
possible cause of failure.
To quantify the level of liquid carryover and to determine the separation efficiency of
the scrubber V-83502, a dedicated isokinetic sampling campaign was carried out by
Shell Global Solution (SGSi-OGRD) over the period 10 to 12 October 2004.
The vendor guarantee specification for liquid in the off gas from this scrubber is
< 13 litres/MMsm3 (0.1 US gal/MMsft3). This translates to an actual liquid
concentration
of < 10 ppmw in the scrubber off gas.
Conclusions
The measurements from the isokinetic sampling showed an average liquidingas
concentration of 0.19wt% with a separator liquid removal efficiency of 68%.
The vendor guarantee separator performance of 0.1 Usgal/MMsft3 (or 13
liters/MMsm3) carryover in the gas, which equates to a separation efficiency of
99.8%, is by far not being achieved.
Copyright
of Shell Global Solutions International B.V.
Ref
OG.04.50720
10/2/2012
34
CASE 10 - INCORRECT INLET PIPING TO SUCTION

SCRUBBER
Case 10 Pre-start-up audit, July 2005
Bend in horizontal plane

violating 10D straight length
requirement.
V-1410
Propane
compressor
suction
scrubber
10/2/2012
35
HOW SHOULD WE GET IT RIGHT?
10/2/2012
36
HOW SHOULD WE GET IT RIGHT?

Understand the problem and how to avoid it.
Follow established good practice:
Use
the Separator DEP
Eliminate
slugs and keep them from re-forming
Pipework
configuration correct
Dont delegate design responsibility:

Put
high level philosophical requirements in BOD & BDP
Ensure that our requirements are fulfilled:

Project
spec contractor to correctly express our philosophical

requirements in the EPC bid document
EPC
contractor to purchase accordingly
EPC
contractor to construct accordingly
10/2/2012
37
RELATIONSHIPS & EXPERTISE

There is no reason for the expertise not to be at the Principals
end.
That expertise should be you!
relationship
Vendor
Fabricator
relationship
relationship
relationship
Principal
Design
(asset owner)
contractor
Technical
advisor
Who is making the decisions?

Who is truly providing the guarantee?
Where is the expertise?
Who really knows how the equipment will
perform?
Is the process engineering expertise in the project at the Principals end or the other end?
10/2/2012
38
THANK YOU FOR YOUR ATTENTION
10/2/2012
39
SURGE FACTORS For the production separator upstream of the compressor suction
scrubber
DEP 31.22.05.11-Gen. September 2002
In E&P Offshore service
Separator handling natural-flowing production from:
a) its own platform
b) another platform or well jacket in shallow water
c) another platform or well in deep water
Separator handling gas lifted production from:
a) its own platform
b) another platform or well jacket
In E&P Onshore service
Separator handling natural flowing production, or gas plant inlet separator in:
a) flat or low rolling country
b) hilly country
Separator handling gas lifted production in:
a) flat or low rolling country
b) hilly country
In Refineries and Chemical plants:
The design margin ranges typically from
1.2
1.3
1.4
1.4
1.5
1.2
1.3
1.4
1.5
1.15 to 1.25
10/2/2012
40
CORROSION EROSION
10/2/2012
41
THRUST BEARING (BOTTOM) & SEAL
10/2/2012
42
RECIPROCATING COMPRESSOR OUTBOARD

DISCHARGE VALVE
10/2/2012
43

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Design of Compressor Suction

Hans Nooijen, GSNL-PTD/TRD

Copyright of Shell Global Solutions International B.V.

Paul Clinton, GSNL-PTU/EKUW

DEFINITIONS AND CAUTIONARY NOTE

Copyright of Shell Global Solutions International B.V.

1. What is the problem?

4. Examples of getting it wrong.

Copyright of Shell Global Solutions International B.V.

WHATS THE PROBLEM?

Copyright of Shell Global Solutions International B.V.

WHAT IS THE PROBLEM?

Effect on the compressor:

Copyright of Shell Global Solutions International B.V.

COMPRESSOR FOULING - ITS AN OLD PROBLEM

The second stage discharge pressure is higher than

Copyright of Shell Global Solutions International B.V.

Copyright of Shell Global Solutions International B.V.

Copyright of Shell Global Solutions International B.V.

CASE 4 - FOULED DIFFUSER

Copyright of Shell Global Solutions International B.V.

CASE 5 - 1ST STAGE COMPRESSOR INLET EYE

Copyright of Shell Global Solutions International B.V.

CASE 6 COMPRESSOR - EROSION

Copyright of Shell Global Solutions International B.V.

CASE 7 CATASTROPHIC FAILURE

Copyright of Shell Global Solutions International B.V.

CASE 7 - PIECE BROKEN OFF IMPELLER

Copyright of Shell Global Solutions International B.V.

CASE 7 - BROKEN SEAL

Copyright of Shell Global Solutions International B.V.

WHY DO WE GET IT WRONG?

Copyright of Shell Global Solutions International B.V.

WHY DO WE GET IT WRONG?

what is happening in our own process

Copyright of Shell Global Solutions International B.V.

HOW DOES A COMPRESSOR SUCTION SCRUBBER

reduce flow velocity

Outlet nozzle & pipe

two phase flow across pipe area

Makes coarse gas/liquid

UNDERSTANDING BEGINS AT THE PFS

UNDERSTANDING CONTINUES TO PEFS

RUNNING PIPING TO COMPRESSORS - PLAN VIEW

Distance can be > 100 m

Suction scrubbers are not

This gas pipe is now similar to a two phase

RUNNING PIPING TO COMPRESSORS - ELEVATION

Worst case is starting another

I CAN SOLVE THAT WITH A DRAIN POT!

By the time you have

Copyright of Shell Global Solutions International B.V.

IF YOU CANNOT ELIMINATE SLUGS, ONLY PROPER

The slugcatcher will eliminate slugs.

Underground slugcatchers are nice for the

SUCTION SCRUBBER INLET & OUTLET PIPING

DEVIATION FROM SEPARATOR DEP

Exciting new technology

Based on many actual

field tests across Shell

Great list of installed units

(but have you spoken to

EXAMPLES OF GETTING IT WRONG