1、GEOP Gas Engineering and Operating Practices A Series by the Operating Section The American Gas Association Volume II TRANSMISSION Book T-2 Compressor Station Operations The American Gas Association Arlington, Virginia Legal Notice The Gas Engineering and Operating Practices Series was prepared by t
2、he American Gas Association (A.G.A.), its member companies and other individuals and groups with an interest in the natural gas industry. Neither A.G.A., its member companies, employees, nor any person acting on their behalf: a. Makes any warranty or representation, express or implied, with respect
3、to the accuracy, completeness, or usefulness of the information contained in this series, or that the use of any apparatus, method or process disclosed in this series may not infringe privately owned rights; or b. Assumes any liability with respect to the use of, or for damages or personal injuries
4、resulting from the use of any information apparatus, method, or process disclosed in this series, or for violation of any federal, state or municipal regulation with which it may conflict. c. Reference to trade names or specific commercial products, methods, commodities or services in this series do
5、es not represent or constitute an endorsement, recommendation or favoring by A.G.A. or any other per-son of the specific commercial product, commodity or service. d. Nothing contained in this series is to be construed as granting any right, by implication or otherwise, for the manufacture, sale, or
6、use in connection with any method, apparatus, or product covered by letters patent, nor as insuring anyone against liability for infringement of letters patent. Copyright 1985 by the American Gas Association, A.G.A. All rights reserved. Library of Congress Catalog Card Number: 8570460 ISBN 087257000
7、2 A.G.A. Catalog Number XY0185 2M02.853025 Printed in the United States of America CONTENTS FIGURES AND TABLES . viii PREFACE xi ACKNOWLEDGEMENTS . xiii CHAPTER 1. INTRODUCTION . 1 Scope and Outline . 1 Types of Stations . 2 Production Stations . 2 Storage Stations . 3 Transmission Stations . 5 CHAP
8、TER 2. ENGINEERING AND DESIGN CONSIDERATIONS 7 Siting and Location . 7 Site Selection 7 Layout and Arrangement 10 Buildings 12 Building Utilization Requirements . 13 Building Design Requirements . 13 Heating and Ventilation 19 Yard Structures . 20 Roads and Sidewalks . 20 Fencing . 21 Culverts and D
9、rainage 21 iii iv COMPRESSOR STATION OPERATIONS Prime Movers . 22 Reciprocating Engines . 22 Rotary Engines . 30 Gas Turbines 30 Steam Turbines 34 Electric Motors . 36 Gas Compressors . 39 Types of Compressors 39 Compressor Applications . 42 Compressor Calculations . 46 Compressor Characteristics an
10、d Load/Capacity Control . 66 Engine and Compressor Auxiliary Equipment . 73 Air Inlet System . 73 Exhaust System . 77 Lube Oil System . 83 Jacket Water System . 87 Starting System . 93 Fuel Gas System 93 Vents and Drains . 96 Engine and Compressor Foundations 97 Foundation Design Considerations . 97
11、 Alignment and Grouting . . 103 Gas Piping 107 Gas Piping Design Criteria . 108 Piping Valves 113 Pressure Control Devices 115 Gas Pulsation and Control 116 Overpressure Protection 118 Gas Cleaning 120 Types of Gas Cleaners . 121 Application Factors for Gas Cleaners . 126 Dump Systems 130 Gas Coolin
12、g 130 Heat Exchangers 130 Temperature Control . 134 Fan Devices 135 Compressed Air Facilities . 137 Air Volume Requirements . 137 CONTENTS v Air Compressors 138 Conditioning of Compressed Air. 140 Air Receivers . 140 Electric Power and Lighting. 141 Purchased Power . 142 Power Distribution 145 On-Si
13、te Generation . 148 Hazardous Locations 150 Lighting . 156 Motors and Generators . 158 Grounding System 162 Electrical Codes and Standards . 163 Instrumentation and Controls . 163 Control Philosophy 164 Control Requirements . 165 Instrumentation 170 Liquid Storage 172 Liquid Storage Tanks . 172 Spil
14、l Prevention . 174 Water and Waste Systems . 175 Water Supply . 175 Sanitary System 177 Plant Waste . 177 CHAPTER 3. OPERATIONS 179 Personnel Requirements 179 Attended Manual 180 Attended Automatic 182 Unattended Automatic . 182 Remote Automatic . 182 Duties of Personnel 182 Station Superintendents
15、Responsibilities in Station Operations . 183 Housekeeping 183 Records and Reports . 183 Personnel Training . 184 Training Procedures . 184 Standard and Emergency Operating Procedures . 185 vi COMPRESSOR STATION OPERATIONS CHAPTER 4. MAINTENANCE 187 Scheduling . 187 Fixed Interval Scheduling. 187 Pre
16、dictive Failures Scheduling 187 Emergency Maintenance and Scheduling . 188 Personnel Requirements . 188 Maintenance Requirements . 188 Maintaining Prime Movers 189 Maintaining Compressors 199 Maintaining Auxiliary Systems . 202 Maintaining Piping and Vessels 203 Maintaining Electrical Systems . 203
17、Maintaining Instruments and Controls 204 Maintaining Structures and Hoisting Equipment 205 Maintenance Equipment Testing, Inspection, and Monitoring 206 Test Equipment . 206 Testing and Analysis 208 Inspection 212 Operational Monitoring 213 Spare Parts . 215 Use Factor for Compressor Engines 215 Sta
18、ging Areas for Spare Parts 216 Computer-Monitored Inventories 216 CHAPTER 5. SAFETY AND SECURITY 217 Emergency Shutdown Systems . 217 Emergency Shutdown System Components 218 Design Considerations for Emergency Shutdown Systems . 218 Types of Emergency Shutdown Systems . 219 Testing, Inspection, and
19、 Maintenance of ESD Systems 220 Records and Reports for Emergency Shutdown Systems . 220 Equipment Protection Systems . 220 Engine/Compressor Protection Systems 221 Other Equipment Protection Systems . 223 Testing and Maintenance of Protection Systems 223 CONTENTS vii Environmental Monitoring System
20、s . 224 Combustible Gas Detection Equipment 225 Fire Detection and Extinguishing Systems . 226 Security Systems 227 Accident Prevention . 227 Emergency Procedures . 228 CHAPTER 6. ECONOMIC EVALUATION . 229 Capital Investment Versus Annual Cost 230 Capital Investment Method . 231 Annual Cost Method .
21、 231 Leasing Compression Equipment 232 Evaluation of Equipment . 232 Examples of Economic Analysis 234 Summary of Economic Evaluation 236 APPENDIX A. CODES AND STANDARDS 239 APPENDIX B. SYMBOLS AND ABBREVIATIONS 255 GLOSSARY 259 BIBLIOGRAPHY . 267 INDEX 271 FIGURES AND TABLES FIGURES 1. Small gas ga
22、thering compressor station with two belt-driven compressors . 4 2. Modern semiautomatic gas gathering compressor station with three skid-mounted reciprocating compressors. 4 3. Typical transmission compressor station 5 4. Maximum frost penetration in the United States 15 5. Cross-section of a typica
23、l compressor building . 18 6. Fuel efficiency for various prime mover arrangements . 23 7. Cross-section of a 2-stroke natural gas engine with integral compressors 25 8. Cross-section of a 4-stroke natural gas engine . 26 9. Top cross-section of a small reciprocating integral engine/compressor 28 10
24、. Typical heat balance diagram for 2-stroke reciprocating engine . 29 11. Cutaway view of two-shaft gas turbine engine 31 12. Turbine-driven centrifugal compressor package 33 13. Reciprocating, integral engine/compressor unit . 40 14. Skid-mounted, reciprocating, separable engine/compressor package
25、. 40 15. Cross-section of a reciprocating separable compressor 41 16. Positive displacement rotary compressor . 43 17. Centrifugal compressor unit 44 18. Exploded view of a high-speed compressor plate valve . 48 19. P-V diagram illustrating ideal reciprocating compressor cycle . 49 viii FIGURES AND
26、TABLES IX 20. Compression ratio versus volumetric efficiency . 52 21. Compressibility factor for compressor capacity calculations . 54 22. Compression ratio versus brake horsepower per MM cf/d 56 23. Cross-section of a modern pipeline cylinder . 58 24. Cutaway of centrifugal compressor . 61 25. Cuta
27、way view of centrifugal compressor 61 26. Compressor cylinder head end clearance pocket configuration . 69 27. Typical reciprocating compressor cylinder loading diagram 70 28. Typical horsepower-capacity diagram for reciprocating compressor 71 29. Typical centrifugal compressor flow nomograph 74 30.
28、 Dry type air filter 75 31. Flow diagram of glycol regeneration from engine waste heat . 78 32. Engine exhaust silencer and combustion air filter 80 33. Cross-section of typical engine exhaust silencer 81 34. Flow diagram of engine/compressor lube oil system 85 35. Shell-and-tube lube oil heat excha
29、nger showing bypass temperature control valve . 86 36. Compressor cylinder lubricator pump . 88 37. Divider block for cylinder lubricator system 88 38. Forced draft, fin fan heat exchangers . 89 39. Reciprocating engine cooling water pump 90 40. Flow diagram of engine/compressor jacket water system
30、. 92 41. Expander starter motors for reciprocating engine . 94 42. Engine fuel gas filter/separator . 95 43. Typical concrete pad compressor foundations 98 44. Concrete block and mat compressor foundation . 99 45. Direct full-bed grouting method for baseplate engine/compressor unit 103 46. Method of
31、 grouting engine/compressor units using individual chocks and soleplates . 104 47. Existing compressor unit re-grouted with steel chocks and soleplates . 108 48. Typical reciprocating compressor station piping schematic illustrating valve applications . 109 49. Compressor unit gas flow diagram for s
32、torage injection and withdrawal service . 110 50. Typical compressor station pipe yard 111 X COMPRESSOR STATION OPERATIONS 51. Adjustable pipe support with leveling block . 114 52. Cutaway of typical pulsation damper . 117 53. Cross-section of a pilot-operated relief valve 119 54. Cross-section of h
33、orizontal, impingement type separator. . 122 55. Cutaway of vertical, centrifugal gas separator 123 56. Typical gas scrubbers . 124 57. Cross-section of a motor-driven, rotating vane scrubber 125 58. Horizontal gas filter showing cylindrical type filter elements . 126 59. Horizontal filter-separator
34、 to remove liquids as well as solids . 126 60. Types of aerial heat exchangers 132 61. Examples of cooler fan drive arrangements . 136 62. Vertical air storage tanks. 141 63. Electrical transformer substation . 143 64. Compressor station electrical switchgear . 146 65. Motor control center. . 147 66
35、. Standby electrical generator 149 67. Modern control panel for reciprocating engine/compressor unit. 173 68. Typical compressor station operational personnel . 180 69. Compressor daily operating log . 190 70. Turbine daily log . 191 71. Gas generator daily log. 192 72. Base line performance calibra
36、tion . 194 73. Turbine performance calculations . 195 74. Condition monitoring performance trends . 197 75. Gas turbine performance calculations 198 76. Turbine performance record 200 77. Typical lube oil analysis report . 210 78. Typical engine coolant analysis report 211 79. Crankweb deflection re
37、port . 214 TABLES 1. Typical presumptive soil-bearing pressures for the preliminary design of foundations 101 2. Lighting illumination levels at compressor stations 159 3. Compressor station monitor and control parameters 167 4. Suggested employee complement for station with 8 to 10 units . . 181 5.
38、 Proposed compressor station economic evaluation . 235 PREFACE Arlington, Virginia February 1985 The Gas Engineering and Operating Practices Series consists of five Volumes comprising twelve separate Books addressing the various topics of gas supply, transmission, distribution, utilization, and rela
39、ted tech-nologies. Contributing authors are veteran practitioners in the gas in-dustry who were selected for their subject knowledge from 22 technical committees in the A. G. A. Operating Section, as well as academics, con-sultants, interested suppliers, and other specialists. This Compressor Statio
40、n Operations Book is one of three that will constitute the GEOP Transmission Volume, the other two being Pipeline/Transmission Planning and Economics and Gas Control/Auto-mation and Telecommunications. A work of this sort, by its nature, does not afford the detailed treat-ment possible in more speci
41、alized texts. The references provided in the footnotes and the Bibliography expand many-fold the usefulness of the Compressor Book. Readers owe a special debt of gratitude to Florine Hunt and fellow members of the special GEOP Subcommittee of the A.G.A. Library Services Committee, who did a thorough
42、ly professional job of reviewing the manuscript for helpful insertion of footnotes and assured the accuracy of the Bibliography. They also reorganized Ap-pendix A, Codes and Standards, to make it easier to understand and use. Also to be remembered is the support and wise counsel of the first GEOP Ch
43、airman, the late Ty Miller, one of the Series chief architects and principal champions. Anthony A. Bobelis Robert L. Parker Chairman, GEOP Editor Task Group xi GEOP TASK GROUP The following Operating Section members have served on the Gas Engineering and Operating Practices Task Group of the Section
44、 Manag-ing Committee through the development of the GEOP Series. Anthony A. Bobelis, Chairman (1982present), Principal Engineer, Engineering Department, The Brooklyn Union Gas Company Ty S. Miller, Chairman (19791982), Manager, Distribution (Deceased), Southern California Gas Company C. William Ade
45、(19801983), Vice President, Gas Transmission and Planning, Mississippi River Transmission Company Anthony A. Bobelis (19791982), Principal Engineer, Engineering Department, The Brooklyn Union Gas Company Alton T. Davis (19791980), Vice President, Gas Division, San Diego Gas and Electric Company Robe
46、rt H. Holder (1982present), Vice President and Chief Engineer, Wisconsin Gas Company George M. Hugh (19791983), Senior Vice President, Engineering and Operations, TransCanada PipeLines Ltd. Vernon E. Percell (1983present), Senior Vice President, Division Opera-tions, The Gas Service Company (of Kans
47、as City) Marvin D. Ringler (19791981), Engineer, Gas Supply Planning, Con- solidated Edison Company of New York, Inc. O. L. Slaughter (1983present), Senior Vice President, Gas Company of New Mexico Robert D. Stegner (1983present), Senior Vice President, Operations and Engineering, Indiana Gas Compan
48、y Andrew Tarapchak (19791984), Vice President, Distribution, Washing- ton (D.C.) Gas Light Company Milton M. Walther (19791983), General Manager, Gas Department, New Orleans Public Service, Inc. Robert L. Parker (1980present), Manager, Engineering Series Publica-tions, American Gas Association xii A
49、CKNOWLEDGEMENTS This book is a particular tribute to the management and editorial skills and efforts of Donald E. Gasser, Task Group Leader of the Operating Section Compressor Committee for the Gas Engineering and Operating Practices Series, and to the following Compressor Commit-tee members and other expert contributors. Contributing Authors: W. W. Adams, Jr., AdministratorTransmission Services, Transcontin
