E3 Calculation Sheet

Rev Client: OGPE Calculation No:

Project: OGPE Oil Fields Rev : Date:
Subject: Inlet Gas Compressor Sizing By: K Chk'd: App'd:

Units =

Basis
Inflow = 2,631.0 1.5 MMSCMD
Inlet Pressure, Pin kPaA = 600.0
Inlet Temperature, Pout °C = 32.0 305.2 °K
Outlet Pressure kPaA = 1,500.0
Basis: 100 mol/h Property: GPSA and Elliott Manual
Inlet Flow Inlet Gas Properties
Component Mol % Mols/h kg/h Wt % Mol Wt Sp Heat Pc Tc
Methane 0.0 - - 16.04 36.31 4,599 191
Ethane 0.0 - - 30.07 53.78 4,880 305
Propane 0.0 - - 44.10 75.18 4,240 370
iso-Butane 0.0 - - 58.12 98.82 3,640 408
n-Butane 0.0 - - 58.12 99.53 3,784 425
iso-Pentane 0.0 - - 72.15 121.15 3,381 460
n-Pentane 0.0 - - 72.15 122.78 3,365 470
n-Hexane 0.0 - - 86.17 145.65 3,030 506
n-Heptane 0.0 - - 100.20 168.91 2,740 539
n-Octane 0.0 - - 114.22 192.17 2,490 568
n-Nonane 0.0 - - 128.25 214.99 2,280 595
n-Decane 0.0 - - 142.28 238.22 2,100 618
Ethylene 0.0 - - 28.05 44.24 5,040 282
Propylene 0.0 - - 42.08 64.99 4,665 366
Butylene 0.0 - - 56.10 87.10 4,043 420
Butene 0.0 - - 56.10 89.25 4,000 418
Pentylene 0.0 - - 70.13 111.17 3,513 465
Acetylene 0.0 - - 26.04 44.16 6,139 308
Benzene 0.0 - - 78.11 83.76 4,898 562
Methyl Alcohol 0.0 - - 32.04 46.73 8,097 513
Ethyl Alcohol 0.0 - - 46.07 73.79 6,148 514
Carbon Monoxide 0.0 - - 28.01 29.15 3,494 133
Carbon Dioxide 0.0 - - 44.01 37.34 7,374 304
Hydrogen Sulphide 0.0 - - 34.08 34.12 8,963 373
Sulphur Dioxide 0.0 - - 64.06 38.69 7,884 431
Ammonia 0.0 - - 17.03 35.65 11,350 406
Air 0.0 - - 28.97 29.13 3,771 132
Hydrogen 0.0 - - 2.02 28.77 1,293 33
Oxygen 0.0 - - 32.00 29.43 5,043 155
Nitrogen 0.0 - - 28.02 29.14 3,398 126
Chlorine 0.0 - - 70.91 35.35 7,977 417
Water Vapour 0.0 - - 18.02 33.66 22,064 647
Helium 0.0 - - 4.00 20.79 228 5
Methyl Chloride 0.0 - - 50.49 46.94 6,670 417
 E3 Calculation Sheet
Rev Client: OGPE Calculation No:
Project: OGPE Oil Fields Rev : Date:
Subject: Inlet Gas Compressor Sizing By: K Chk'd: App'd:

Ethyl Chloride 0.0 - - 64.52 63.00 5,270 461

Argon 0.0 - - 39.94 20.79 4,860 151
Carburated Water Gas 0.0 - - 19.48 32.28 3,130 131
Coke Oven Gas 0.0 - - 10.71 32.69 2,810 109
Flue Gas 0.0 - - 30.00 30.43 3,880 147
Natural Gas 100.00 100.0 1,882 100.0 18.82 36.23 4,650 211
Cat Cracker Gas 0.0 - - 28.83 49.74 4,650 286
AA Total 100.0 100.0 1,882.0 100.0 18.82 36.23 4,650 210.6

Inlet Fluid
Molecular Weight = 18.82
Specific Heat kJ/kg.mol°.K = 36.23
Fluid K value = 1.30
Reduced Pressure, Pr = 0.13
Reduced Temperature, Tr = 1.45
Compressibility Factor Zin = 1.00
Density kg/m³ = 4.43
Flow kg/h = 49,515 m³/h = 11,169

Compressor Av Polytropic Efficiency, ƞ = 79% 77% GPSA 79% Elliott

GPSA Elliott
Outlet
X Factor (K-1)/(K/ƞ) X= 0.29
Pressure Ratio r= 2.5
Temperature Out = Tin * r^X = °K = 398.21 125.1 °C
Tmax - oil carbonization / High pressure °C = 120 - 150
Reduced Pressure, Pr = 0.32
Reduced Temperature, Tr = 1.89
Compressibility Factor Z out = 0.99
Average Compressibility Factor Zav = 1.00

Head H = ZavRTin(r^X-1)/X kN.m/kg = 141.3

Fluid Power = mass flow*H/ƞ kW = 2,459
Mech Losses = 0.75HP^0.4 or 3% kW = 74
Shaft Power kW = 2,533 Round Off = 2,540

Discharge
Temperature Out = Tin + H.X/ZavR °K = 398.2 125.1 °C
Volumetric Flow m³/h = 5,762

Notes
Conversion Factors
Goal Seek to get reverse and inter-conversion

Pressure bar psi kg/cm² Density kg/m³ lb/ft³

1 14.5 1.01935 1 0.062428

Temperatu°F °R °C °K Sp Heat kJ/kg.°K Btu/lb.°F kWh/kg.°C

32 491.67 0 273.15 4.1868 1 0.001163

Length m ft Viscosity cP Pa.s lb/h.ft kg/h.m

1 3.28084 1 0.001 2.419088 3.6

mm inch k W/m.°K Btu/h.ft.°F kcal/h.m.°C

1 0.03937 1 0.577789 0.860421

Area m² ft² Sur Tensi dyn/cm mN/m

1 10.76391 1 1

Flow kg/h lb/h Cal Value kJ/kg Btu/lb kWh/kg kcal/kg

1 2.204622 1 0.429923 0.000278 0.238846

kg/s.m² lb/s.ft²
1 0.204816
Power MW MBtu/h Mkcal/h MJ/h
0.293071 1 0.252164 1055.056

Heat Flux kW/m² Btu/h.ft² kcal/h.m²

1 316.9983 860.4207

hi kW/m².°K Btu/h.ft².°F kcal/h.m².°C

0.005678 1 4.885696

Resistanc °K.m²/kW °F.h.m²/Btu°C.h.m/kcal

1 0.005678 0.001162
 Compressor Sizing
Read GPSA Section 13, Compressors and Expanders

Centrifugal Compressors
Good training material (PDF/PPT files) available in internet/ google search.

Sizing Suppliers provide free downloadable program that are good to select frame size, number
of stages, power and speed. Hysys routine is equally good. Use this program only if you do
not have access to any of these stuff or to estimate plot size and polytrophic efficiency to
input to Hysys.

This program is based on GPSA and the classic N Method provided in an Elliott Manual.
This has become part of "A Practical Guide to Compressor Technology" By Heinz P. Bloch's
book Appendix B: Shortcut Calculations and Graphical Compressor Selection Procedures,
available at
http://onlinelibrary.wiley.com/book/10.1002/0471929786 and
http://onlinelibrary.wiley.com/doi/10.1002/9780471929789.app2/pdf

For Dresser Rand: have a look at

http://turbocalc.dresser-rand.com/DatumCalcVersion1_0_4.pdf

Note The physical property data in Elliott manual is different from that provided in Section 23 of
GPSA for most of the common gases. GPSA values are inserted as appropriate. Appreciable
differences were observed in Tc and Pc listed in Fig 13-7 and Figure 23-2 of GPSA. For the
same flow rate, GPSA reports different polytrophic and isentropic efficiencies in its English
and SI version in Fig 13-28. English version efficiency numbers are about 9% higher than SI
version and 5% higher than industry norms.

Calc Steps
Fan Laws:
Flow α N (speed) Head, H α N² ∆t α N² Power, HP/kW α N³
Step 1 Determine gas mixture properties, MW, k, Z, mixture Pc, Tc + Pr, Tr
Step 2 Determine volumetric flow at inlet conditions, ACFM/ ACMM
Step 3 Find the likely polytrophic efficiency
Step 4 Find the total head.
Step 5 Determine Gas HP; Add 3% for mechanical losses to get Shaft HP

Note: Suppliers perform a wheel by wheel analysis. Final selection should be left to
Rotating Machinery gurus who will consider all fine aspects - critical speeds, bearings,
loads, MOC, how many similar machines are in successful service. etc

Process Issues - Not related to the calcs

No matter what the supplier says, review his gas seal system - for good filtering and
superheating. Hysys may not correctly report it but there are heavies in the compressed
gas, that on letting down to seal cavity pressure may condense, carbonate, lead to
unbalanced loads on the shaft and damage the machine. Many good compressors have
been damaged during start-up resulting in loss of production and a sense of shame on an
otherwise well engineered project.

For the same reason, do not allow a KOD supplier or project engineer undersize the
suction KODs. Minimum size should be what a standard demister sizing tells you. Liquid
carry over can form carbon deposits on the compressor blades, leading again to
unbalanced loads and machine destruction. At that time you will be left with the baby
 and all clever guys would have vanished. Cost of vessel is insignificant in a plant. Opex
penalty is high.

In oil & gas industry, it is a standard practice to specify discharge design pressure as the
surge pressure at 105-110% of speed. It is OK, as long as it is not excessive and does not
result in higher flange rating, that is from 600# to 900# or 900# to 1500#. It is a good idea
to go to the flange rating limit if it is within reasonable margin.

It is common in onshore industry such as Ammonia with a known gas composition and
plant capacity to fix discharge design pressure and PSV set pressure at 120% of normal
operating pressure. The 20% margin is to allow suitable margins for alarms and trips. They
do not consider the surge pressure at all. Anti-surge is a good proven fast acting
machinery protection.

Revision Index
Rev AA: April 2013
1 Fixed errors in SumProduct Formulae. Compressor Sheet. U58, W58 and Y58