El Merk Project

CENTRAL PROCESSING FACILITY

EL MERK, ALGERIA

CONTRACT NO. : SC 4012100

PETROFAC JOB NO.: JI - 195

BOOSTER COMPRESSION SYSTEM (BC)

POWERPOINT PRESENTATION

TITLE :
Plant Familiarization Training Material
A1 Issued for 31/01/2012 DS VVG KB HV Booster Compression System (BC)
implementation
PowerPoint Presentation
R2 Issued for review 08/01/2012 DS VVG KB GS

R1 Issued for review 07/09/2011 MG SK KB GS ORIG.

This is a Word document and must not be
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REV DESCRIPTION DATE PRPD CHKD APPD APPD
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APPD DOC NO. ELM-PUL-OP-PRC-0012
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 DOCUMENT TYPE

Document No. Revision

ELM-PUL-OP-PRC-0012 A1

REVISION HISTORY
Rev. Clause Description of Revision
R1 1 Issued for Review
R2 1 Issued for Review
A1 1 Issued for Implementation

HOLDS
Rev. Section Description of Hold

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 DOCUMENT TYPE

Document No. Revision

ELM-PUL-OP-PRC-0012 A1

TABLE OF CONTENTS

BOOSTER COMPRESSION SYSTEM (BC)-POWERPOINT PRESENTATION

Page 3 of 3
Engineering and Construction

Petrofac copy

El Merk Project
Booster Compression System (BC)
Document No. ELM-PUL-OP-PRC-0012/REVA1
January 2012
Session Topics

• Process Description

• Walk Through The P&IDs

• Start-Up & Shut-Down

• Troubleshooting

Booster Compression System February 12

 Booster Compressor (BC)

Booster Compression System February 12

Process Description

3 X33 % capacity trains

Booster Compressor (BC) is a motor driven, single stage, centrifugal type compressor

BC compresses gas from AGC & Slug Catchers from around 37 barg to around 70 barg and feeds it to
Dehydration unit

Each BC train consists of the following equipments:

• Booster Compressor Suction Drum (V01/02/03-2505)

• Booster Compressor (K01/02/03-2503)
• Booster Compressor After Cooler (A01/02/03-2504)

Booster Compression System February 12

Process Description

Booster Compression

Gas from the following streams are collected in a header & fed to the suction drum:

• Block 208 Condensate Inlet Separator (V08-1005)

• Block 208 Oil Slug Catcher (V08-1001-1)
• EMK Oil Slug Catcher (V08-1002-1)
• Associated Gas Compressors

The combined stream is split into three streams and sent to each train Booster Compressor Suction Drum
(V01/02/03-2505)

Process gas from the suction drum is sent to the Booster Compressor (K01/02/03-2503) where it is
compressed from around 37 barg to around 70 barg

Liquid from the suction drum is sent to the HP Separator (V01/02-2001)

Booster Compression System February 12

Process Description

Booster Compression

Process gas after compression is sent to the Booster Compressor Aftercooler

Methanol & Corrosion Inhibitor are added at the discharge of the compressor to avoid hydrate / ice
formation thus preventing blockages and minimizing corrosion, this will lead to efficient running of the
downstream processing units

Compressed process gas from the BC discharge is cooled to around 55°C in the after cooler

Temperature needs to be maintained above the dew point to avoid NGL dropout and recycle to the oil
trains

After cooling the process gas from all the three trains is mixed together in a header & sent to the Gas
dehydration Feed KO Drum

Booster Compression System February 12

Process Description

Booster Compressor – Auxiliaries

Seal system

• Primary Seal: Process fluid

• Secondary and Tertiary Seal: Nitrogen
• Booster seal gas Compressor is provided to maintain the primary seal gas pressure during
compressor startup and pressurized shutdown

Lube oil system

• Lube oil system is provided to lubricate & maintain the temperature of motor bearings
• Lube oil system consists of Lube Oil Pump, Lube Oil Heater, Storage Tank, Cooler and Rundown
Tank

To protect the compressors from surges during trips, quick opening cold gas bypass valve is provided

Booster Compression System February 12

Walk Through The P&IDs

Booster Compressor Suction Drum (V01/02/03-2505)

Equipment Information

Operating Pressure, barg 30.8 to 37.4

Operating Temperature, oC 21.4 to 61.4
Design Pressure, barg 65.0 / FV
Design Temperature (Max / Min), oC 120.0 / -20.0
MOC CS (Epoxy lined)
SS 304 L(Internals)

• Inlet device - Deflector Plate type is provided to enhance phase separation

• Double pocket type vane pack is provided at the gas outlet of the drum to remove carryover liquid
droplets

• Liquid outlet nozzle is provided with a vortex breaker

Booster Compression System February 12

Walk Through The P&IDs

Vane Pack
(Double Pocket Type )

Front View

Top View

Booster Compression System February 12

Walk Through The P&IDs
Booster Compressor Suction Drum (V01/02/03-2505)

Instrumentation for Control

Level Control

Level Controller (01/02/03-LIC-25020) maintains the liquid level in the suction drum

Instrumentation for Safeguard

• SGS Valve is provided on the process gas inlet & liquid outlet line of the suction drum
• Dedicated instruments are provided for SGS for protecting the upstream & downstream systems of
the suction drum from abnormal operating conditions i.e. LO-LO & HI-HI level (for detail refer C&E
document no. ELM-PUL-IC-CED-001 Rev R4)
• HI-HI pressure differential pressure in the Differential Pressure Indicator (01/02/03-PDI-25030)
located across the SDV (01/02/03-SDV-25015A) inhibits the SDV opening
• A bypass SDV (01/02/03-SDV-25015B) is provided to the main SDV (01/02/03-SDV-25015A) for
gradual pressurization of the downstream compressor system
• The suction drum is safeguarded by a PSV, set at 65 barg

Booster Compression System February 12

Walk Through The P&IDs

Booster Compressor (K01/02/03-2503)

Equipment Information

Type Centrifugal
Rated Flow, MMSCFD 150
Operating Discharge Pressure, barg 70.4
Operating Discharge Temperature, oC 77.5 to 114.7
Differential Pressure, bar 33.3
Duty. kW 4011.4
Design Pressure, barg 84
Design Temperature (Max / Min), oC 149.0 / -20.0

Electrical heat tracing is provided on the pressure transmitters for maintaining the required temperature

Booster Compression System February 12

Walk Through The P&IDs
Booster Compressor (K01/02/03-2503)

Instrumentation for Control

The primary control criteria for the BC are:

• To maintain a constant suction header pressure
• To ensure all the compressors operate with similar safe margin from surge line

For achieving this suction throttling valve, anti surge control, master & load sharing controller are
provided

Pressure Control
• Excess pressure in the BC suction header will be relieved by a Pressure Controller (08-PIC-25029)
located on the BC suction header. This is a split range type controller & maintains the pressure of
the booster gas compression suction header through two Control Valves (08-PV-25029A & 08-PV-
25029 B) located on the HP Flare Header

• Valve A will be operated from the 0 to 33% of the flow range and B valve will operate from 33% to
100% of capacity to take care of the BC trip

Booster Compression System February 12

Walk Through The P&IDs
Booster Compressor (K01/02/03-2503)
Instrumentation for Control

Load Control

• Load Sharing Controller (01/02/03-UIC-25402) ensures that all parallel compressors operate at an
equal margin away from the surge control line
• Load sharing control includes motor high current limiting control which will prevent the motor from
overloading

Surge Control

• Anti Surge Controller (01/02/03-UIC-25401) will avoid surge in the BC

Master Control

• Master Controller (01/02/03UIC-25403) is provided to monitors & control the overall performance of
the BC system

Booster Compression System February 12

Walk Through The P&IDs
Booster Compressor (K01/02/03-2503)
Instrumentation for Control

Compressor Operation Control

CMS
a. Auxiliaries Auto/Manual selection (Oil heaters, Oil pumps, Oil coolers)
b. Auxiliaries Start/Stop (Oil heaters, Oil pumps, Oil coolers) manually performed individually or in
sequence according to the Auto/Manual selection
c. Oil system and compressor sequences Start/Stop
d. All sequence & compressor status are implemented in CMS

UCP
a. Includes the anti-surge, load-sharing, master performance controllers
b. Vibrations / temperatures monitoring
c. Compressor casing drain has to be done manually by operator on the skid. After purging the
operator has to acknowledge this action on seal gas panel (push button) UCP. Compressor drain
shall be done after each vent and pressurization sequence or if the compressor is stopped
pressurized for more than two hours

Note: Detailed instrumentation for control will be discussed during the vendor package training

Booster Compression System February 12

Walk Through The P&IDs
Booster Compressor (K01/02/03-2503)
Instrumentation for Safeguard

Following are some of SIF of the compressor auxiliary system which will initiate depressurized trip of
the compressor

a. LO-LO shaft line lube oil pressure (01-PIT-25479 A/B/C, 2oo3)

b. LO-LO nitrogen pressure (01-PIT-25513 A/B/C, 2oo3)
c. LO-LO differential pressure across the booster (01-PIT-25562)
d. LO-LO seal gas temperature (01-TIT-25563B)

Following are some of SIF of the compressor auxiliary system which will initiate pressurized trip of the
compressor

a. HI-HI Lube oil temperature (01-TIT-25463)

b. Excessive surge
c. HI-HI Motor temperature
d. HI-HI Motor vibrations

Note: Details about the compressor safeguard will be covered during the vendor presentation

Booster Compression System February 12

Walk Through The P&IDs

Booster Compressor (K01/02/03-2503)

Instrumentation for Safeguard

• SGS Valve is provided for cold gas bypass to the antisurge valve. This valve is of fail open type

• Dedicated instruments are provided for SGS for protecting the compressor from abnormal operating
conditions i.e. LO-LO suction pressure, LO-LO discharge pressure, HI-HI discharge pressure & HI-HI
discharge temperature (for detail refer C&E document no. ELM-PUL-IC-CED-001 Rev R4)

• Multiple PSVs are provided on the discharge line of the BC, set at 84 & 88.2 barg

• The compressor can be stopped at HI-HI differential pressure across the suction strainer, this facility is
configured in the CMS

Booster Compression System February 12

Walk Through The P&IDs

Booster Compressor Aftercooler (A01/02/03-2504)

Equipment Information
Parameter Tubeside

Operating Temperature (IN / OUT), oC 115 / 55

Operating Pressure (IN / OUT), barg 70.3 / 69.6

Design Temperature (MAX / MIN) , oC 142.0 / -20.0

Design Pressure, barg 84.0 / FV

Passes / Fans per bay 2/2

Duty, MMkcal/hr 6.0

MOC CS (Tubes), Aluminium (Fins)

Fin Type Extruded

Booster Compression System February 12

Walk Through The P&IDs

Booster Compressor Aftercooler (A01/02/03-2504)

Equipment Information

• There are two bays of air cooler

• One fan per bay is provided with Variable frequency Drive (VFD) for speed control.

• Manual louvers are provided to adjust the air recirculation rate for better temperature control

• Pressure points are provided on the inlet & outlet line of the cooler for performance monitoring

Booster Compression System February 12

Walk Through The P&IDs
Booster Compressor Aftercooler (A01/02/03-2504)
Instrumentation for Control
Pressure Control
Pressure Controller (01/02/03-PIC-25050) on the BC discharge maintains the pressure at the outlet
of the BC train by the Control Valve (01/02/03-PV-25050) located on line to the HP Flare Header

Temperature Control
Temperature Controller (01/02/03-TIC-25016) maintains the cooler outlet temperature by varying the
speed of VFD fan & by ON / OFF of fixed speed fan

Instrumentation for Safeguard

• SGS Valve is provided on the process gas line to Gas Dehydration Feed KO Drum
• Dedicated instruments are provided for SGS for protecting the suction cooler from abnormal
operating conditions i.e. HI-HI fan vibrations (for details refer C&E document no. ELM-PUL-IC-CED-
001, Rev R4)
• The SDV (01/02/03-SDV-25019) located on the outlet line of the cooler will automatically open when
the compressor discharge pressure reaches 95% of compressor discharge manifold pressure

Booster Compression System February 12

 Booster Compressor Safeguarding System Flow Diagram

Booster Compression System February 12

Start Up

Normal Start up Procedure

Ensure all the prerequisites are carried out before the start-up

Ensure the After Coolers are available

Confirm “START” permissive is active to start compressor from ICSS

Check for the healthiness of the auxiliary system

Gradually the system gets pressurised and then the sequence start-up continues
based on the machine conditions like (a) Purging & pressurization (b) Pressurization
sequence (c) Pressurized start

Once the system is pressurised start then the sequence starts the main motor

Booster Compression System February 12

Start Up
Normal Start up Procedure

Gradually speed ramps up

Wait till the Anti Surge Valve stabilize/close and the machine and pressure is stabilized

Then we get the “LOAD” permissive

Monitor the rise in discharge pressure and temperature

When assured with the Anti Surge Control System in all operating cases

The train can then be put on for commercial use

On demand the machine will be placed on load

Note: For details refer the Operating manual for Booster Compressor

Booster Compression System February 12

Shutdown

Normal Shutdown Procedure

Initiate the Stop command from HMI. Ensure the following actions takes place in sequence:

• Anti Surge valve will open

• Cold gas bypass valve will open

• Load sharing will be disabled

• When the Anti Surge Valve fully opens, the main motor stops

• Relevant SDVs on the Suction / Discharge lines are closed

Note: For details refer the Operating manual for Booster Compressor

Booster Compression System February 12

Troubleshooting

This section deals with some of the important possible upset conditions & their control actions. For
comprehensive details of trouble shooting, refer the Booster Compressor Operation Manual

Booster Compressor
Problem Indications Diagnosis Control Action

Check the reason for

Failure of Fans in 2nd
failure and re-start the
Stage AGC Aftercooler.
fans.
High Discharge
01/02/03-TI-25015 Change in feed Reduce the feed to the
Temperature
composition BC system
Malfunction of Check and rectify/
Temperature Transmitter. replace with a new one.

Booster Compression System February 12

Troubleshooting

Booster Compressor
Problem Indications Diagnosis Control Action

Check for blockage in

Blockage in downstream
the discharge line and
system.
rectify.
High Discharge Pressure 01/02/03-PI-25038 Malfunction of Pressure Check and rectify/
Transmitter. replace with a new one.
Change in the Feed Reduce the feed to the
Composition. BC.
High pressure drop Clean or replace the filter
across the suction filter. element.
Low Suction Pressure 01/02/03-PI-25034
Malfunction of Pressure Check and rectify/
Transmitter. replace with a new one.

Booster Compression System February 12

 QUESTIONS

Booster Compression System February 12

 THANK YOU

Booster Compression System February 12