Success Story & Application
SCFM’S CUSTOM SOLUTION UPGRADED EXISTING COMPRESSOR STATION TO INCREASE FLOW RATE BY OVER 250% WHILE REDUCING REQUIRED HP AND LOWERING MAINTENANCE COSTS BY 15%
The Challenge
We were approached about gas compression for an existing compression station for transmission service in an existing pipeline. Station consisted of 4 - 1085 hp engines driving two throw reciprocating compressors with engine drive coolers. The following are the list of challenges faced:
- High Vibration and pulsation problems
- Over horsepower at high suction high discharge pressures
- Cooler outlet temperatures are too high
- Design point had changed from 220 suction/700 discharge to 400 suction/625 discharge. Range of pressure is now 170-490 suction to 500-684 dicharge
- Make changes with minimal downtime to the station
- Original plan was potentially to install a whole new station and mothball the original.
The Solution
- Reciprocating compressor cylinders were changed from standard cylinders to pipeline cylinders to reduce hp, reduce cooler outlet temperature and increase flow rate.
- Scrubbers, bottles, cooler section and piping were all prefabricated to minimize station downtime and to lower costs. They were redesigned to increase throughput and lower vibrations, pulsations and pressure drop.
- Bottles were made new for the first unit and then the old bottles were modified for the next unit to be revamped. This saved time and money.
- We used local labor that was familiar with the station and the customer for final welds and site installation to lower delivery time.
The Results
- Flow rate increased from 15 MMSCFD to 40 MMSCFD while hp was lowered within the capabilities of the current engine limit.
- Upgrade to all four compression units was completed in 3 months time with minimal station down time.