CASE STUDY: TURBOMACHINERY PERFORMANCE AND PROCESS OPTIMIZATION CASE STUDY
CASE STUDY: TURBOMACHINERY PERFORMANCE AND PROCESS OPTIMIZATION CASE STUDY
ENERGY RECOVERY AND OPTIMIZATION FOR A
COMPLEX GAS COMPRESSION FACILITY
Executive Summary: Economic
Value
With more than four decades of proven expertise,
Compressor Controls Corporation (CCC) is the
recognized global leader in turbomachinery optimization.
Our experience spans four key domains—process,
machinery, instrumentation and control—and thousands
of machinery control solutions across industries. At
the core of CCC’s expertise is using turbomachinery
optimization to deliver tangible economic benefits for
our global customers.
When CCC conducted a Preventive Maintenance (PM)
visit for a major national oil and gas company in the
Middle East, it identified an opportunity to optimize
the turbomachinery of its gas compression facility. By
implementing our five-step turbomachinery performance
and process optimization strategy, CCC identified and
implemented improvements that saved the end user
$1.864 million per year in fuel gas consumption alone
Process Background
A major national oil and gas company in the Middle
East operates a complex gas compression facility. After
compressing natural gas from multiple feeders, the plant
supplies it to several major gas processing and Natural
Gas Liquids (NGL) facilities. The simplified process
diagram of this complex facility is illustrated in Figure 1.
The gas compression facility is equipped with two parallel
medium-pressure (MP) booster compressors (13-C102
1
and 113-C102), which are driven by Dresser-Rand and
Siemens gas turbines, respectively. Combining the MP
booster compressors and other incoming MP feeds,
the facility’s MP manifold feeds the high-pressure (HP)
trains through two flow controllers (FIC-1051A/B). An HP
compression section includes older northside parallel
trains and newer southside parallel trains that receive
the gas from the MP manifold and other feeds such as
the end users’ onshore HP feed and remote onshore HP/
lean gas feed. The main objective of the HP facilities is to
prioritize gas delivery among three main end-user gas
processing facilities.
The facility’s northside HP gas compression is achieved
by two parallel gas-turbine driven compressors supplied
by Dresser-Rand (13-C-101 A/B). The southside’s HP
gas compression is performed by two parallel gas
turbine-driven compressors supplied by Siemens (113-
C-101 A/B). All the facility’s MP and HP compressors are
equipped with CCC anti-surge controllers, which calculate
and monitor the compressor proximity-to-surge variable
and send an appropriate control response to the
respective stage recycle valve. The current CCC control
system also features a master pressure controller that
controls the suction header pressure of each pair of
MP, HP-North and HP-South compressor trains. This
master pressure controller sends its control response to
a load-sharing controller dedicated to each compressor,
ensuring that the two compressors in a parallel set
are equally loaded based on its compressor proximity-
to-surge calculated variable. The control system
 CASE STUDY: TURBOMACHINERY PERFORMANCE AND PROCESS OPTIMIZATION CASE STUDY

MP COMPRESSION HP COMPRESSION
FROM MP
SEPARATORS
20/ 21/22-V-107

FROM MP
SEPARATOR
122-V-107
PV
PIC
3125
PV
PT
PIC
3125 SP
FROM MP 3111
SEPARATOR
24-V-109 PV-3125
PV
NOT
FIC OPERATIONAL
PT
3111 1051 A SP

MP MANIFOLD
AI
FROM LP TRAINS FT
12-C-102 & UI C
1051 A
112-C-102 13-C102
PT 7638
PV 3036
FV-1051 A
PIC
3031
PV
PT
PIC AI
3031
3074
End-user’s MPIC
MP Feeder
PV-3031 PT PT 3650
3074 3650
113-C102 13-C101 End-user’s
A facility 1
PV-3074

NORMALLY FORCED
FU LLY OPEN BY HIGH
PV SET POINT VALUE

PIC 13-C101
3032 B
PT
3032
NORTH
End-use’sr PV
HP Feeder FIC
PV-3032
FIC 801
1051 B SP
13-V-107 FT
801
FT
1051 B Approx. 4 ~ 5 km of pipin g
End-user’s
dist ance b etwe en t ra ins. facility 2
FV-801
FV-1051 B

PV
PIC
113-V-107 PIC AI
802
3112
MPIC
PT
PT PT 3082 802
3112 3082
113-C101 End-user’s
A facility 1
PV-802
PV-3112

NORMALLY FORCED FIC

FU LLY OPEN BY HIGH
SET POINT VALUE 1103

End-user’s Wells 113-C101 FT

HP / LEAN GAS B 1103

Feeder End-user’s
SOU TH FV-1103
facility 3

MP COMPRESSION HP COMPRESSION

Figure 1 – Process Schematic Overview

accomplishes this by sending the control response to the equipment, associated measuring equipment and
gas turbine speed controller. control valves. We also collaborate with the end-user
personnel responsible for interpreting this gathered
Identifying the Problem data, leveraging our collective expertise to identify the
CCC has an added value service agreement with this proper course of action based on the findings.
end user, through which it conducts regularly scheduled
Preventive Maintenance (PM) visits. In addition to During recent PM visits, CCC observed that the load
verifying that the installed CCC control equipment is sharing/balancing controllers for the MP and HP
functioning correctly, we use these visits to identify machines were set to manual. Likewise, the remote
new opportunities for turbomachinery optimization anti-surge/recycle valves opening setpoints (Remote Low
and/or enhancement. For this reason, we monitor Clamp “RLOC” (1)) were set manually by the operator in
the mechanical condition of the end-user’s rotating the DCS, as shown in Table 1.

2
 CASE STUDY: TURBOMACHINERY PERFORMANCE AND PROCESS OPTIMIZATION CASE STUDY

Although CCC’s anti-surge controllers protected the only by the compressor with the lower speed. Under
compressors against surge, the RLOC high opening this strategy, the speed control is set manually, and
setting on the anti-surge/recycle valves was generating each compressor runs continuously at full load. These
significant recycle gas flow relative to the compressors’ swings in station load are met by the recirculation of gas
suction. This excessive flow caused the unit’s power/ around the compressors. This inefficient system wastes
energy significant energy.
consumption to Antisurge Valve
Antisurge Controller
Compressor Opening Load Sharing
Master During the CCC
exceed process Tag Controller
Controller turbomachinery
demand. 1st Stage 2nd Stage 1st Stage 2nd Stage
audit, we also
After conducting Auto ☒ Auto ☒ determined
Auto ☐
a turbomachinery 13-C-101A 19 % 23% Manual ☐ Manual ☐ Suction Header that surge tests
Manual ☒ Pressure Control
controls audit, had never been
RLOC(1) ☐ RLOC(1) ☐
CCC investigated conducted on
why the Auto ☒ Auto ☒ Auto ☐ most machines.
Auto ☐
load sharing 13-C-101B 19% 19% Manual ☐ Manual ☐ Manual ☒
This was likely
controllers were Manual ☒ due to the old
RLOC(1) ☐ RLOC(1) ☐
being manually conventional
operated. Auto ☒ Auto ☒ wisdom that
Auto ☐
Most likely, the 113-C-101A 7~14% 10~18% Manual ☐ Manual ☐ Suction Header having high Surge
poor behavior Manual ☒ Pressure Control Control Margins
RLOC(1) ☐ RLOC(1) ☒
of the speed usually results in
controllers and Auto ☒ Auto ☒ Auto ☐ higher machine
Auto ☐
unstable machine 113-C-101B 7~13% 10~20% Manual ☐ Manual ☐ Manual ☒
availability. Under
suction/input Manual ☒ this assumption,
RLOC(1) ☐ RLOC(1) ☒
conditions had higher energy
led the operating Auto ☒ Auto ☒ consumption is
Auto ☐
personnel to run 13-C-102 58% 48% Manual ☐ Manual ☐ Suction Header not only tolerated
the machines Manual ☒ Pressure Control but viewed as
RLOC(1) ☒ RLOC(1) ☒
manually at “inevitable.”
higher constant Auto ☒ Auto ☒ Auto ☐ Because surge
Auto ☐
speeds and 113-C-102 49% 51% Manual ☐ Manual ☐ Manual ☒ testing had not
Manual
adjust capacity via RLOC(1) ☒ RLOC(1) ☒
☒
been performed,
recycling. each machine’s
surge controller(s)
Reducing the (1)
RLOC = Remote Low Output Clamp to allow the Operator to force the Anti-surge
was configured
operating speed valve more open than required by the surge control algorithm.
with the Surge
and eliminating Table 1 – Compressors Operating Configuration And Setpoints As Found Limit Line either
excessive gas predicted by
recycle could the OEM or
deliver potentially significant savings. It could also resolve determined via the OEM’s test bench. This increases the
some unbalanced operating conditions that had resulted probability of excessive Surge Control Margins.
from manually setting the load sharing controllers. One
parallel compressor was running on a higher speed CCC typically recommends conducting an onsite surge
than its companion, with the production flow sustained test. This not only determines the true Surge Limit Line

3
 CASE STUDY: TURBOMACHINERY PERFORMANCE AND PROCESS OPTIMIZATION CASE STUDY
of the machine, but also eliminates potential errors in the
predicted or OEM PTC-10 testing. In CCC’s experience,
two types of errors can affect the predicted or OEM PTC-
10 derived Surge Limit Line:
■ Onsite piping characteristics and the actual gasses
being used can cause a significant shift in the
predicted Surge Limit Line
■ The onsite flow measurement device is different than
that being used in the OEM’s PTC-10 testing and
therefore could result in significantly different values
for the same surge point onsite.
However, in this case, the plant stakeholders had
implemented a new strategy that emphasized running
their turbomachinery in the most efficient manner and
avoiding nuisance trips.
Solution and Outcomes
After finalizing the diagnostic agreement with the end
user, CCC began conducting a detailed study that
quantified the economic value of our services. Using
the CCC TrainView historian and operational trends that
provided high-quality plant data capture and storage, we
implemented a five-step turbomachinery and process
optimization solution.
Step 1: Survey Site and Collect Data
The first step to properly quantifying the required
optimization and expected savings was to survey the
installation. During this step, CCC engaged directly
with various site stakeholders, including operation and
maintenance teams. After collecting site historical and
operational data, we conducted a preliminary review
to identify the production profile of relevant processes,
compressors and turbine parameters.
Step 2: Analyze Data and Assess
Operating Conditions
After our preliminary review of the site data, we
performed multiple analyses to assess current operating
conditions. These analyses included:
4
■ A detailed review of the site’s existing P&IDs and
piping configuration for each compressor’s anti-surge
system. Through this analysis, CCC ensured that the
systems are appropriately configured for continuous
recycle duty and do not have deficiencies.
■ A validation that the existing anti-surge valve
capacity was adequate to suit the OEM’s predicted
performance curves.
■ A validation of historical operation conditions such
as flow (differential pressure), suction and discharge
pressure and temperature transmitter, including
an analysis of the transmitter calibration spans
used onsite for all proximity-to-surge calculation
algorithms.
Step 3: Calculate Improvement,
Economic Benefits and ROI
Leveraging our operating conditions analysis, CCC
calculated the energy savings derived from two key
areas:
1. Reduced Recycled Rates: Surge protection margins
could be set too conservatively inside the anti-
surge control system, or the recycle valves could be
clamped open by the operator. This unnecessary
opening of the anti-surge valves causes excessive gas
to recycle. Because of this excessive recycle, the unit’s
power consumption exceeds process demand—
representing an associated energy penalty.
Figure 2 illustrates the first stage performance
map for the 113-C102 compressor, during which
the compressor’s operating point is away from the
Surge Control Line. CCC highlighted the benefit of
reducing the recycle valve opening from 33.84% to
3%, which subsequently allowed for the reduction
of the compressor speed to 83.5% = 4846 rpm. This
optimization would satisfy the process needs of flow
and discharge pressure, while potentially reducing the
compressor stage’s power consumption from 4690
kW to 2490 kW.
2. Automated Capacity Control and Load-sharing.
The ideal way to distribute the load between parallel
compressors is to operate each compressor at the
 CASE STUDY: TURBOMACHINERY PERFORMANCE AND PROCESS OPTIMIZATION CASE STUDY

same relative distance from its Surge Control Line.

As the load is decreased, this approach causes all
the compressors to reach their Surge Control Lines
simultaneously, allowing all anti-surge valves to be
throttled opened at the same time. Through this
strategy, the parallel network achieves the best Current
OP

possible turndown prior to any opening of the anti-

surge valves. This method helps minimize the amount

100.4 rpm
5493
%=
of recycle required for low plant loads, resulting in the
most energy-efficient operation possible.

83 67 rp
45
.5% m
As a result of CCC’s turbomachinery audit, we identified

=
potential energy savings of $4,078.4 per day per
machine. This translates to approximately $ 1.5
million of annual energy savings—achieved purely by
optimizing the existing turbomachinery control system’s
compressor operations. 100.4% =
4.69 kw 5493 rpm

Step 4: Deliver Report and Conduct

Onsite Implementation Discussion
2.49 kw
83.5% =
4846 rpm

After submitting our turbomachinery audit report, CCC

and the end user held a discussion to determine the
best strategy for implementing the recommendations.
We agreed upon detailed surge test procedures and a
full schedule of required site activities.
Step 5: Implement Site Activities and
Assess Outcomes
Figure 2 – 113-C102 1st Stage Compressor Performance
Map Showing The Expected Operating Point If The
Recycle Valve Closed
of this, performance controls remained in manual, with
some trains requiring particular RLOC setpoint values
until the speed governor issues were resolved.

CCC and the end user conducted successful surge tests Although not all CCC recommended actions have been
for all MP and HP compressors. CCC utilized the test implemented, the end user has witnessed significant
results to verify and update each compressor’s surge saving in MP and HP train fuel gas consumption. The
line. Once the anti-surge controllers’ configurations were total fuel gas savings alone equal $5,106 per day, or
optimized, the compressor speeds and RLOC setpoints
$1.864 million per year.
were both reduced successfully. Tables 2 through 4
illustrate the percentage of savings in compressor speed In addition to these fuel gas savings, the end user has
and recycle/anti-surge valve opening. achieved unquantified economic benefits: a reduction
in CO2 emissions and the machines’ speed reduction,
During the surge testing, CCC discovered that the
which enhances availability and optimizes scheduled/
machines’ speed controller functionality was unable to
unscheduled maintenance.
maintain the assigned speed set-point—an issue that
would need to be remedied with the OEMs. These speed
governor challenges prevented us from toggling the CCC
load sharing/balancing controllers to automatic. Because

5
 CASE STUDY: TURBOMACHINERY PERFORMANCE AND PROCESS OPTIMIZATION CASE STUDY

PT speed (rpm)
9,000.00

8,000.00

7,000.00

6,000.00

5,000.00

4,000.00 PTPT speed

speed (rpm)
(rpm)
9,000.00
9,000.00
3,000.00
8,000.00
8,000.00

7,000.00
2,000.00
7,000.00

6,000.00
6,000.00
1,000.00
5,000.00
5,000.00

4,000.00
4,000.00
0.00
3,000.00
3,000.00
13C102 13C101A 13C101B 113C102 113C101A 113C101B
2,000.00
2,000.00

1,000.00
1,000.00 Before mapping After mapping
0.000.00
13C102 13C101A
13C102 13C101A 13C101B
13C101B 113C102
113C102 113C101A
113C101A113C101B
113C101B
Figure 3 – PT Speed (rpm)
Before
Before mapping AfterAfter
mapping mapping
mapping

1st Anti-surge valve opening (%) 2nd Anti-surg

70
1st1st
Anti-surge valve
Anti-surge opening
valve (%)(%)
opening 2nd Anti-surge
2nd valve
Anti-surge opening
valve (%)(%)
opening
70 70
60
60 60
6060
60
50 50 50
50 50
50 40 40
40 40 40
30 30
4030
30
20 20 30
20 20
30 10 10
10 10 20
0
20
0 0
0

13C102 13C101A
13C102 13C101B
13C101A 113C102
13C101B 113C101A
113C102 113C101B
113C101A 113C101B
13C102 13C101A
13C102 13C101B
13C101A 13C101B 10
113C102 113C101A
113C102 113C101B
113C101A 113C101B
10 Before mapping
Before mapping AfterAfter
mapping
mapping
Before mapping
Before mapping AfterAfter
mapping
mapping 0
0
13C102 13C101A 13
13C102 13C101A
Figure 4 – 1st 13C101B
Anti-surge valve opening (%) 113C102 113C101A 113C101B
Figure 5 – 2nd Anti-surge valve opening (%)

Before map
Before
Fuel Gas
Fuel mapping After mapping
Flow_KNm3/h
Gas Flow_KNm3/h
16 16
14 14
12 12 6
10 10
 50
40
40
30
30
20
20
10
10
0
0
C A S E S T U D Y : T U R B O M A C H I N E R Y P E R F O R M A N13C102
CE AN D P R13C101B
13C101A OCESS O P T113C101A
113C102 T I O N C A S E S13C102
I M I Z A113C101B T U D Y13C101A 13C1
Before mappin
Before mapping After mapping

Summary Fuel Gas Flow_KNm3/h

With more than four decades of proven expertise, 16
14
Compressor Controls Corporation (CCC) is the 12
recognized global leader in turbomachinery optimization. 10

At the core of that expertise is the ability to deliver 8

6
tangible economic benefits for our global customers. By
4
implementing our proven turbomachinery performance 2

and process optimization strategy, CCC helped a gas 0

13C102, and 113C102 113C101A 113C101B
compression facility save $1.864 million per year simply 13C101A/B

by improving the existing turbomachinery control Before mapping After mapping

system’s compressor operations. The end user has

also lowered its carbon footprint and the speed of its Figure 6 – Fuel Gas Flow KNm3/h
machines, which enhances availability and optimizes
scheduled/unscheduled maintenance.