Operator Training Program

Unit 6
Gas Compression, Gas
Injection and Gas Lift

1 Operator Training Program Module 6.3

 Unit 6 Gas Compression,
Gas Injection and Gas Lift
6 Modules over 7 days
Module 6.1 Ideal Gas Law (1 day)
Module 6.2 Options for Gas in an Oil
Producing Field (1 day)
Module 6.3 Gas Compression (2 days)
Module 6.4 Gas Injection (1 day)
Module 6.5 Gas Lift (1 day)
Module 6.6 Flaring of Natural Gas (1 day)
Operator Training Program Module 6.3 2
 MODULE 6.3 GAS COMPRESSION

3 Operator Training Program Module 6.3

 Introduction
During this training program, gas compressors were
introduced in the common curriculum and the equipment
was explained in unit 4 Plant Equipment. This module
builds on the information on centrifugal and reciprocating
compressors that has already been covered and
provides more operational details on the selection of
compressors, their features and operational challenges.
This module also covers typical shutdown scenarios and
the process control options for the units. Simulation
exercises on surging are also included in this module.
Surging involves the discharge flow rate of a compressor
in relation to the energy or head that is required to move
that quantity of gas under specific conditions.
4 Operator Training Program Module 6.3
 Module 6.3 Gas Compression
The following are the stated objectives for this module:
Identify inlet streams and key operating information on
three compression stages.
Explain three shutdown scenarios for compressor
systems.
Perform simulated operations on a compressor and
troubleshoot flow and surge problems.

Operator Training Program 5

Module 6.3
 Daily Workplan
Day 1 Day 2 Day 3 Day 4 Day 5

Am Safety Moments Safety Moments Safety Moments Safety Moments Safety Moments

Module 6.2 Options for

Module 6.1 Ideal Gas Module 6.3 Gas Module 6.3 Gas Module 6.4 Gas
Am Gas in an Oil
Law Compression Compression Injection
Producing Field

Lunch break

Module 6.2 Options for Module 6.3 Gas Module 6.3 Gas
Module 6.1 Ideal Gas Module 6.4 Gas
Pm Gas in an Oil Compression Compression
Law Injection
Producing Field Lab 6.2 Lab 6.3

Module 6.2 Options for

Module 6.4 Gas
Module 6.1 Ideal Gas Gas in an Oil Module 6.3 Gas Module 6.3 Gas
Pm Injection
Law Producing Field Compression Compression
Safety Meeting
Lab 6.1

Operator Training Program Module 6.3 6

 Common Curriculum
Theory of Compression
Gas and air compression is a necessity in the petroleum
processing industry. Without compression, natural gas could
not be transported, pneumatic control air systems could not
function, nor could air be used as a source of motive power
and energy.
Compression is the action of taking a volume of a gas at a
low pressure and reducing the volume while the pressure is
increased. This is accomplished by the addition of energy to
the gas which is transformed by various means into
pressure energy thereby causing an increase in gas
pressure.
Operator Training Program 7
Module 6.3
 Common Curriculum
According to the gas laws, if a gas is held at a constant
temperature then the volume varies inversely with the
absolute pressure. That is, if the volume is decreased, then
the pressure increases. Consider a cylinder and piston
assembly containing a gas such as air. The gas in the
cylinder will be reduced in volume as the piston moves, thus
causing its pressure to increase.

According to Boyles Law (P1 x V1) = (P2 x V2) if

temperature is constant.

Operator Training Program 8

Module 6.3
 Common Curriculum

In reality however, during gas compression some of the

input energy is converted into heat energy which tends to
increase the temperature of the gas. This is often referred to
as the Heat of Compression. This has a negative effect on
the compression process since this heat energy will tend to
cause the gas to expand thereby tending to lower the
pressure. To achieve the desired pressure, more energy of
compression would be required. It is for this reason that
compression processes attempt to remove the heat of
compression.

Operator Training Program 9

Module 6.3
Common Curriculum

Operator Training Program 10

Module 6.3
 Objectives
Module 6.3 Objective 1: Gas COmpression

Upon completion of this module, the participant

will be able to:
Identify inlet streams and key operating information
on three compression stages.

11 Operator Training Program Module 6.3

6.3.1 Compression Stages and Operating
Features
This section is broken up into four sub-sections:
Low Pressure Compression
Intermediate Pressure Compression
High Pressure Compression
Gas Injection Compression
For each of the three stages, information on typical
pressure ranges are provided, as well as the gas
recovery into that stage and the controls and safeguards
on the compressor and associated equipment in that
stage.
Each facility must have options available to service the
production and processing systems.
12 Operator Training Program Module 6.3
6.3.1 Compression Stages and Operating
Features

13 Operator Training Program Module 6.3

6.3.1 Compression Stages and Operating
Features
Please Remember

It is important to note that this information is based

on experience and a range of project descriptions.
The numbers are not intended to be definitive or
accurate they are provided to give examples and a
relative reference point. Each operating facility will
be different.

14 Operator Training Program Module 6.3

 Low Pressure Compression
Gas Inlet to this Stage
Gas off the low pressure separator.
Gas that flashes off any accumulated liquids such as
liquids from the IP and HP suction scrubbers and the
TEG flash tank or drum.
Pressure Range
Compresses the gas from 10 psig to 110 psig (758
Kpag).

15 Operator Training Program Module 6.3

 Low Pressure Compression

Type, Vessels and Equipment

Motor driven, positive displacement type (screw
compressors are an option).
Motor driven centrifugals may also be suitable.
LP compressor suction scrubber is upstream of the
compressor.
An aftercooler ( shell and tube type is common) is
required downstream to lower the temperature of the
gas.

16 Operator Training Program Module 6.3

 Low Pressure Compression
Controls and Safeguards
Anti-surge control;
Recycle for flow rate control; and
Process shutdown if the suction or discharge pressures
are high.

Gas Discharge from this Stage

Gas discharges into the IP suction scrubber.
Discharge cooler may be a shell/tube exchanger
(temperature drop from >100C to 38C).

17 Operator Training Program Module 6.3

 Intermediate Pressure Compression
Gas Inlet to this Stage
Gas off the intermediate stage separators;
Gas discharge from the LP compressor.

Pressure Range
Compresses the gas from 101 psig (696 Kpag) to 298
psig (2055 Kpag).

18 Operator Training Program Module 6.3

 Intermediate Pressure Compression
Type, Vessels and Equipment
Motor driven, positive displacement type (screw
compressors are an option).
IP compressor suction scrubber is upstream of the
compressor.
An aftercooler is required downstream to lower the
temperature of the gas.
Controls and Safeguards
Anti-surge control;
Recycle capacity for flow rates.

19 Operator Training Program Module 6.3

 Intermediate Pressure Compression
Gas Discharge from this Stage
To the discharge scrubber and on to the high pressure
compressor.
Gas may be taken off for purge gas, blanket gas or flare
fuel gas.

20 Operator Training Program Module 6.3

6.3.1 Compression Stages and Operating
Features

21 Operator Training Program Module 6.3

 High Pressure Compression
Gas Inlet to this Stage
Gas off the high pressure separators;
Gas discharge from the IP compressor.
Pressure Range
Compresses the gas from 279 psig (1924 Kpag) to 685
psig (4723 Kpag).
Type, Vessels and Equipment
Motor driven or turbine driven centrifugal;
HP compressor suction scrubber is upstream of the
compressor; and
An aftercooler is required downstream to lower the
temperature of the gas.
22 Operator Training Program Module 6.3
 High Pressure Compression
Controls and Safeguards
Recycle line with cooling;Compressor speed control;
Recycle control valve for anti-surge and capacity control;
Surge detection system to protect the machinery; and
Blowdown valve on the header will direct the gas to the
HP flare if required.
Gas Discharge from this Stage
Gas discharge may go to a discharge scrubber;
Further dehydration may be required if the gas goes to a
gas injection compressor; and
If the gas compression is high enough, this gas may go
for gas lift.
23 Operator Training Program Module 6.3
6.3.1 Compression Stages and Operating
Features

24 Operator Training Program Module 6.3

 Gas Injection Compression
Gas Inlet to this Stage
Gas from the dehydration system downstream of the HP
compressor is the inlet to the gas injection compressor.
Pressure Range
Note that the gas injection compression may also
take place in two stages
First stage - compresses gas from 650 psig (4479 Kpag)
to 1935 psig (13350 Kpag).
Second stage - compresses gas from 1910 psig (13180
Kpag) to 3900 psig (26871 Kpag).

25 Operator Training Program Module 6.3

 Gas Injection Compression
Type, Vessels and Equipment
Gas turbine driven centrifugal compressor;
compressor suction scrubber is upstream of the
compressor; and
An aftercooler is required downstream to lower the
temperature of the gas.
Controls and Safeguards
Compressor speed control;
Recycle gas control; and
Anti-surge control and protection.

26 Operator Training Program Module 6.3

 Gas Injection Compression
Gas Discharge from this Stage
In general, gas from the first stage of this compressor would
be at the pressure for sales gas pipeline or gas lift.
Gas from the 2nd stage is at the pressure for gas injection.
Gas off the first stage of the gas injection compressor may
go through liquids recovery and the gas is sent for sales gas.
Compressed gas is sent via the gas injection header where it
is taken off through a pressure control valve to the gas lift
pipeline for wells on gas lift (2000 psig to 2300 psig range
reservoir pressure dependent).
Compressed gas is sent via a gas injection header to the
gas injection pipeline and the gas injection wells.
27 Operator Training Program Module 6.3
 Liquids Removal
Liquids Removal
As we have described in these typical systems, there are
many components in the systems where liquids are
removed.
These liquids that are collected in the scrubber bottoms are
sent to a closed drain or collection vessel at very low
pressure and then sent to a crude oil treatment vessel such
as a crude oil stabilizer.
Liquids that are removed in the gas injection compressors
(very HP compressors) are sent to the separator that is
operating at the appropriate pressure (IP or LP).
There are also mist eliminators on all gas streams
28 Operator Training Program Module 6.3
6.3.1 Compression Stages and Operating
Features

29 Operator Training Program Module 6.3

 Liquids Removal
Liquids Removal
Liquids in gas compressors will cause many problems. One
problem that is prevalent is the breaking of the plates and
springs of compressor valves.
The valve plates will not be balanced and will fail if there are
liquid droplets on the plates.
The springs may also fail if the valve plates are slammed
open and closed in an unbalanced state due to liquids.
If the small springs fail, parts of the springs may be carried
through the compressor equipment and cause many other
problems.

30 Operator Training Program Module 6.3

 Objectives
Module 6.3 Objective 2: Gas Compression

Upon completion of this module, the participant

will be able to:
Explain three shutdown scenarios for compressor
systems.

31 Operator Training Program Module 6.3

6.3.2 Compression Shutdown Scenarios
If the gas is sent through a pipeline for sales, a HP
compressor will be required to deliver the gas at the
appropriate pressure for the pipeline system and
ultimately the customer at the other end.
If the gas is required for gas lift, the compressed gas off
the HP compressor or off the first stage of the gas
injection compressor is required for delivery to the
producing wells that are on gas lift.
If the field has gas injection, the recovered gas is
compressed in multiple stages until it is above 2000 psig
and at the appropriate pressure for injection into the
reservoir via gas injection wells.

32 Operator Training Program Module 6.3

6.3.2 Compression Shutdown Scenarios

If the compressors are only used for small quantities of

gas for use in utilities on the platform or for the fuel for
the pilot for the flare, the LP and IP gas compressors are
required to make these systems work.
If this is the case, the crude oil production system can
continue to operate even if there is a problem with the
compressors.
The recovered gas is sent straight to flare and alternate
fuels are used for the drivers.

33 Operator Training Program Module 6.3

6.3.2 Compression Shutdown Scenarios
Flaring
This situation can occur but it is certainly not the desired
option and should not exist for long periods of time. If
this situation did occur the following issues would be
presented:
The permitted values on flaring would be exceeded
time, emission rates of SOX and NOX
Alternate fuel such as diesel would be consumed and
supply would run short
Gas for gas lift and gas injection would not be available

34 Operator Training Program Module 6.3

6.3.2 Compression Shutdown Scenarios
What will trigger a shutdown of a compressor???
What is the sequence of events???
How important is maintenance???
Why must we watch the discharge gas temperature???

35 Operator Training Program Module 6.3

6.3.2 Compression Shutdown Scenarios
The high pressure compressors and the gas injection
compression systems will have the most complicated
shutdown scenarios. The high pressure compression
system will probably have three options for shutdown:
Shutdown the HP compressor with blowdown
Shutdown of the HP compressor without blowdown
Trip the compressor to idle

36 Operator Training Program Module 6.3

6.3.2 Compression Shutdown Scenarios
Shutdown the HP compressor with blowdown

If this situation occurs, the HP compressor shut down

valves all close to prevent gas from entering the
compressor, and the bypass / recycle and discharge
shutdown valves all close to prevent gas from recycling
through the compressor. This stage essentially stops the
gas from flowing and will trap some gas between closed
valves.

37 Operator Training Program Module 6.3

6.3.2 Compression Shutdown Scenarios
Shutdown the HP compressor with blowdown
There is usually a brief timed delay (5 min to 8 min) to
allow any liquids to drain out of the liquids section, then
the shutdown valves on the liquids side are all closed.
Then the blowdown valve is opened to allow the gas to
go to the HP flare.
In some facilities, this may be a low pressure flare for an
LP compressor, but it is certainly more common for this
to go to a high pressure flare.
The pressure in the system is monitored, and when the
system is depressurized enough, some of the gas can
be directed to the LP flare.
38 Operator Training Program Module 6.3
6.3.2 Compression Shutdown Scenarios
Shutdown the HP compressor with blowdown

Note that if the compressors are duplicated in two trains

(Train A and Train B), there would be a timed delay on
the opening of the blowdown valves so that the gas from
both compressor systems does not hit the HP flare at the
same time creating capacity problems. One example
could be that when the pressure in the first Train has
reduced so that the LP flare can be used, the second
Train would be allowed to go to the HP flare.

39 Operator Training Program Module 6.3

6.3.2 Compression Shutdown Scenarios
Shutdown of the HP compressor without blowdown

A shutdown of the HP compression system without

blowdown due to a unit shutdown would include closure
of all shutdown valves. If this situation occurs, the HP
compressor shut down valves all close to prevent gas
from entering the compressor, and the bypass / recycle
and discharge shutdown valves all close to prevent gas
from recycling through the compressor. This stage
essentially stops the gas from flowing and will trap some
gas between closed valves.

40 Operator Training Program Module 6.3

6.3.2 Compression Shutdown Scenarios
Shutdown of the HP compressor without blowdown

There is usually a brief timed delay (5 min to 8 min) to

allow any liquids to drain out of the liquids section, then
the shutdown valves on the liquids side are all closed.
Note the compressor shutdown without blowdown is
the more common situation for LP and IP compressors.

41 Operator Training Program Module 6.3

6.3.2 Compression Shutdown Scenarios
Trip the compressor to idle
The compressor packages would include compressor anti-
surge control and capacity control. This involves the
measurement of compressor suction pressure, discharge
pressure and discharge temperature. If there is a high
pressure on either the suction or discharge, or if there is a
high temperature on the compressor discharge, the resulting
action is that the compressor will be tripped to idle.
If there is a low pressure sensed at either the suction
pressure or discharge pressure the compressor will go into
a Unit Shutdown without blowdown. There are many
operating situations or events that will initiate a shutdown of
the compressors. :
42 Operator Training Program Module 6.3
6.3.2 Compression Shutdown Scenarios
Scrubber Liquid Level Controls
High Level in a Scrubber

Low level in a Scrubber

43 Operator Training Program Module 6.3

6.3.2 Compression Shutdown Scenarios
Discharge Cooler Temperature Controls

Low Temperature in Discharge Gas

High Pressure on the Water Side of the Exchanger

Reminder hydrates are formed when natural gas and

water exist under specific temperature and pressure
ranges. To avoid hydrates, you must raise the
temperature, drop the pressure or add inhibitors.

44 Operator Training Program Module 6.3

6.3.2 Compression Shutdown Scenarios
Suction or Discharge Pressure Controls
High Pressure or Gas Injection Compressors - If there is
a high pressure on either the suction or discharge of the
compressor, this is an indication that the compressor is
heading into surge. In order to prevent surging and to
protect the compressor components, the resulting action
is that the compressor will be tripped to idle.
Low or Intermediate Pressure Compressors - If there is
a high pressure, or low pressure on either the suction or
discharge of the compressor, this is an indication that the
compressor is having problems the resulting action is an
initiation of a process shutdown of the compressor.

45 Operator Training Program Module 6.3

6.3.2 Compression Shutdown Scenarios
Discharge Temperature Controls

The compressor packages would include compressor

anti-surge control and capacity control. This involves the
measurement of gas discharge temperature. If there is a
high temperature on the compressor discharge, the
resulting action is that the compressor will be tripped to
idle.

46 Operator Training Program Module 6.3

 Unit 6 Lab 6.2
Natural Gas Production and
Compression

47 Operator Training Program Module 6.3

 Check Your Learning
Fill in the blanks on the following questions.
The temperature of the gas is lowered after each
stage of compression. The desired temperature
range is approximately dependent on the stage.
A shutdown of the HP compression system without
blowdown due to a unit shutdown would include
closure of all valves.
are formed when natural gas and water exist
under specific temperature and pressure ranges.

48 Operator Training Program Module 6.3

 Check Your Learning
If the system senses a high pressure on the water
side of the shell / tube exchanger, this could
indicate a .
gas compressors are the only ones
required if the only use is for small quantities of
gas for use in utilities on the platform or for the fuel
for the pilot for the flare.
The compressor packages would include
compressor control and capacity control.

49 Operator Training Program Module 6.3

 Check Your Learning
If there is a low pressure sensed at either the
suction pressure or discharge pressure the
compressor will go into a Unit Shutdown
blowdown.
If there is a high level in a scrubber, there is a
possibility of into the next stage.
After the gases are sent to flare through the BDVs,
there is usually a brief to allow any liquids to
drain out of the liquids section, then the shutdown
valves on the liquids side are all closed.

50 Operator Training Program Module 6.3

 Check Your Learning
If there is a low level in a scrubber, it is probably
due to the vessels being drained due to a
compressor problem. If a low level is detected, the
on the liquid outlet will close.

51 Operator Training Program Module 6.3

 Objectives
Module 6.3 Objective 3: Gas Compression

Upon completion of this module, the participant

will be able to:
Perform simulated operations on a compressor and
troubleshoot flow and surge problems.

52 Operator Training Program Module 6.3

 6.3.3 Head vs Flow Curves Simulation
Compressor Surge
Both the centrifugal compressor and the
axial flow compressor are subject to a
condition known as surging or pumping.
At low volumes (low flows or capacities),
the pressure drops off. This means that if
the volume or demand is to the left of the
point marked "surge limit" on the curve,
then the compressor will not produce a
pressure equal to that in the system.
53 Operator Training Program Module 6.3
 6.3.3 Head vs Flow Curves Simulation
Compressor Surge
A reversal of flow will occur and air will flow
from the system back to the compressor.
As soon as this occurs, the system
pressure will drop and the compressor will
begin discharging again to the system.
These events will occur rapidly as a cycle
and this is known as surging.

54 Operator Training Program Module 6.3

 6.3.3 Head vs Flow Curves Simulation

55 Operator Training Program Module 6.3

 6.3.3 Head vs Flow Curves Simulation
Compressor Surge
A reversal of flow will occur and air will flow
from the system back to the compressor.
As soon as this occurs, the system
pressure will drop and the compressor will
begin discharging again to the system.
These events will occur rapidly as a cycle
and this is known as surging.

56 Operator Training Program Module 6.3

 6.3.3 Head vs Flow Curves Simulation
Compressor Surge
Surging causes interaction between the
impeller blades and the gas or air being
compressed and produces severe shock to
the system. It may be violent enough to
damage compressor blades, shaft seals
and even the shaft itself.

57 Operator Training Program Module 6.3

 6.3.3 Head vs Flow Curves Simulation

58 Operator Training Program Module 6.3

 6.3.3 Head vs Flow Curves Simulation
Surging Control
To prevent surging, the capacity of the
compressor must not be allowed to fall
below the surge limit. One method used is
to open a discharge line blowoff (recycle)
valve to the suction side when the flow
through the compressor decreases to near
the surge point. This recycle valve can be
operated automatically be means of a flow
meter, as shown in the diagram.
59 Operator Training Program Module 6.3
 Unit 6 Lab 6.3
Compressor Operations
Head vs Flow

60 Operator Training Program Module 6.3

 Module Summary
The following points are presented to summarize
this module:
The gas compression systems for LP, IP, HP and
Gas Injection Compressors were reviewed from
specific operational aspects. These included:
Gas Inlet to this Stage
Pressure Range
Type, Vessels and Equipment
Controls and Safeguards
Gas Discharge from this Stage
61 Operator Training Program Module 6.3
 Module Summary
The high pressure compressors and the gas
injection compression systems will have the most
complicated shutdown scenarios. The high
pressure compression system will probably have
three options for shutdown:
Shutdown the HP compressor with blowdown
Shutdown of the HP compressor without blowdown
Trip the compressor to idle
Liquids in gas compressors will cause many
problems. One problem that is prevalent is the
breaking of the plates and springs of compressor
62 Operator Training Program Module 6.3
 Module Summary
valves. The valve plates will not be balanced and
will fail if there are liquid droplets on the plates.
Both the centrifugal compressor and the axial flow
compressor are subject to a
condition known as surging or pumping.
There are many operating situations or events that
will initiate a shutdown of the compressors. The
following examples are provided:
Scrubber Liquid Level Controls
High Level in a Scrubber
Low level in a Scrubber
63 Operator Training Program Module 6.3
 Module Summary
Discharge Cooler Temperature Controls
Low Temperature in Discharge Gas
High Pressure on the Water Side of the
Exchanger
Suction or Discharge Pressure Controls
High Pressure or Gas Injection Compressors
Low or Intermediate Pressure Compressors
Discharge Temperature Controls
High temperature on the compressor discharge

64 Operator Training Program Module 6.3

 Questions

Any questions?

65 Operator Training Program Module 6.3