10 replies to this topic

[zbrna]

Hello.

 

So I am currently interning in an oil&gas company. Currenlty the compressors they use are oversized, and the gas reservoir has significnalty lowered, leading to the flow rate to have dropped. However, they're using 45-50% of the compressor's capacity and is still using the oversized compressor where the power consumption is still the same regardless (2 mW). So i need to figure out if they should change the compressor or rerate it, or keep it. Can anyone help on how to start? Like is there any way of making the compressor more efficient, or consume less energy without compromising the efficiency? The current compressor being used is a booster reciprocating compressor. 

[breizh]

Hi,

You may find pointers in the document attached.

 

A few calculators if needed:

CheCalc ‐ Fluid Flow

 

Why don't you ring (e mail) the representative of compressor manufacturer and request an opinion. That the way Engineers work, he may offer you a technical solution and cost associated .

Good luck

Breizh

Attached Files

•  centrifugal or reciprocating compressor.pdf   414.19KB   14 downloads

[Pilesar]

As an intern, determine the range of operation required. Include flow rate, pressures of inlet and outlet, molecular weight of gas, temperatures. Contact the compressor vendors which have mechanical engineers on staff who know the equipment and specialize in gas compression. I have found that they generally don't know much about process operation, but they are necessary in order to get expert advice if you do not have an in-house expert. There is important work to get them the correct information and interpret their suggestions. Any modifications to the compressor will be a large project in itself. This is not a project you can handle on your own from start to finish, but you have opportunity to be the central player in what will be a team effort. This is major experience and real engineering for you. You might prefer a smaller project you can handle completely by yourself, but this one should have a much greater impact for your career.

[zbrna]

As an intern, determine the range of operation required. Include flow rate, pressures of inlet and outlet, molecular weight of gas, temperatures. Contact the compressor vendors which have mechanical engineers on staff who know the equipment and specialize in gas compression. I have found that they generally don't know much about process operation, but they are necessary in order to get expert advice if you do not have an in-house expert. There is important work to get them the correct information and interpret their suggestions. Any modifications to the compressor will be a large project in itself. This is not a project you can handle on your own from start to finish, but you have opportunity to be the central player in what will be a team effort. This is major experience and real engineering for you. You might prefer a smaller project you can handle completely by yourself, but this one should have a much greater impact for your career.

 

 

Hello, yes they also informed me when giving me this task that it will be a big project and I won't be able to complete it in the time of the  internship I have (also I won't be able to fully do it on my own) but it would be a good experience. I was able to collect the current operating conditions

 

can you give me some advice on what possible next steps i should take?

Edited by zbrna, 05 January 2026 - 07:04 PM.

[Pilesar]

If it were me, I would contact the compressor manufacturer or the trusted company that has done previous work on compressors at the site. Compressors are specialty equipment that require specialized knowledge to assess. If I were in your role, I would view it as if I owned the big expensive piece of machinery that needed fixing. My task would be to find an expert I could work with who would be honest with me and explain any proposed procedures so that I could understand them. It would be similar example if I discovered my body had a serious disease. I would not take just anyone's advice but find the best doctor I could. The expense would be a secondary concern to diagnosing correctly and prescribing a successful treatment. Your main role as I see it would be coordinating with outside support, plant maintenance, plant scheduling, presenting to management and perhaps economic evaluation. Your bosses may not expect you to be able to do all that, but they would be glad if you could. There should be help available to keep you from floundering, but they may step back some to see if you take initiative. Ask questions where you work. As intern, they do not expect you to know much, but they want to see you seek what you need. Ignorance is expected. Acting as if you know what you are doing when you do not know without asking questions is not the way to success. You should certainly accept tasks you have not prepared for. But once you accept the task, then educate yourself and communicate clearly with your boss and team.

[breizh]

Hi,

You may want to contact this manufacturer and explain to them your issue:

Energy | Natural Gas Compressor | High Speed Reciprocating Compressor - arielcorp.com

EDIT: How many units are in service at the same time? Are they working parallel? 

Can you draw a simple PFD of the set up?

Breizh 

[zbrna]

hi breizh, they are in parallel, and originally there are four units. however one does not operate anymore and 2 of them are on standby so really only one is at service.

[zbrna]

I want to ask asw as a follow up question, if lowering discharge pressure of a gas compressor lowers the energy consumption of it as well. I found this through some research but i would like to know if that is the case?

[Pilesar]

The ratio of the discharge pressure to the inlet pressure is a large factor for energy consumption. See https://myengineerin...ssor_Power.htmlfor a quick tutorial.

[breizh]

Hi,

 

To support your work:

Compressors: Selection and Sizing - Royce N. Brown - Google หนังสือ

 

Note: with the set up (1 unit in operation), you may want to consider changing the technology to suit your need .

If I was in your shoes, I will prepare a specification sheet and request a quote from a Centrifugal compressor manufacturer to get a technical proposal and a quote.

 

Centrifugal Compressor Performance Calculator

 

Breizh

[zbrna]

Thanks you guys are goats