Reciprocating Compressor
Reciprocating Compressor
Hervé Ferraris
Is reliability independent of refinery age?
Reliability and Maintenance (RAM)
Effectiveness Index, %
9/17/2018 2
Path to best performance on compressor’s basis
Situation: traditional
low reliability,
Reactive low efficiency
Response high operating cost
9/17/2018 3
Which process use reciprocating compressors?
Natural gas H2 Unit
Hydrogen
(SMR+PSA)
Gas Plant
Fuel gas, LPG,
Petro-chemicals
Gas Olefins Alkylation
Light distillates
Heavy Naphta Hydrotreating Catalytic Reforming
Gasoline
(Desulfurization) (CCR)
Atmospheric Crude
Distillation (CDU)
Middle distillates
Desalted, Distillate /
Dewatered Light Gasoil Hydrotreating Kerosene,
(Desulfurization)
Crude Oil Jet Fuel, Diesel
Residue
Fuel Oil
Light Vacuum Gas Oil
(LVGO)
Heavy Vacuum
Vacuum Gas Oil (HVGO)
Hydrocracking
distillation
Vacuum
Residue
Coker
Coke
Hydrotreating
Conversion Asphalt
Octane Process
9/17/2018 4
Recips are the heart of hydrogen compression
Natural gas H2 Unit
Hydrogen
(SMR+PSA)
Gas Plant
Fuel gas, LPG,
Petro-chemicals
Gas Olefins
Alkylation
Light distillates
Heavy Naphta Hydrotreating Catalytic
Gasoline
(Desulfurization) Reforming (CCR)
Atmospheric Crude
Distillation (CDU)
Middle distillates
Desalted, Distillate /
Dewatered Light Gasoil Hydrotreating Kerosene,
(Desulfurization)
Crude Oil Jet Fuel, Diesel
Heavy Vacuum
Vacuum Gas Oil (HVGO)
Hydrocracking
distillation
Vacuum
Residue
Coker
Coke
Hydrotreating
Conversion Asphalt
Octane Process
Reciprocating Compressor (w. stages) Hydrogen need in process Hydrogen output from process
9/17/2018 5
Average OPEX of a refinery hydrogen compressor
Annual OPEX average savings potential per compressor
26% savings potential
Planned Maintenance
Increase Maintenance Interval to 24,000hrs
Major Turnaround 5 years
Corrective Maintenance
Reduction of unexpected trips per year
- in 40% of case valve failures
LPO
Reduction of unexpected trips per year
Configuration 2oo3 compressors in operation
In case of compressor outage: 100% production
capacity, LPO due to process upset during
switch over
Electricity Consumption
21% spillback average opening – Flow control
9/17/2018 6
Case Study – Residue Hydrodesulphurization
10
9 < 9.0
New compressor design with
8 advanced technologies
7
6
10 5
9 4
8 3
7 2
6 < 6.4 1
Compressor design
5 with traditional technologies 0
4
3
2
Objective: sustainable
1 high reliability,
0 efficiency and
environmental
soundness
low total cost
ownership
9/17/2018 8
General specificities from step control
Pneumatic actuators
Clearance pocket
9/17/2018 9
Chosen configuration – the reverse-flow control
eHydroCOM
electric actuators
9/17/2018 10
What are the benefits for the process?
9/17/2018 11
Working principle
12
How reverse-flow control modify the design?
1
1
2
2
3
3
Cylinder End loaded at 100%
¾=75% Cylinder End loaded at 0%
13
9/17/2018 13 13
Reverse-flow makes compressor design leaner
Step Control 0, 50, 75, 100% Reverse Flow Control
needs two cylinders per stage Stepless from 0(..10)-100%
1
2
1 1
2
2 3
1
3 70%
3
Cylinder End loaded at 100% Cylinder End loaded at 70%
¾=75% Cylinder End loaded at 0%
Spillback closed
Spillback minimum ( 5%)
9/17/2018 14
Which valve solutions to select?
their losses
= *A
.. Valve
efficiency
9/17/2018 15
Case study: total cost of ownership over 10 years
€ million
100
90
80
70
60
Maintenance
Compressor
40
Operation
Electricity
30
20
10
0
Traditional Advanced
HydroCOM reduces 10 years TCO
Specification Technologies
by € 24.733.000.- for the 3 compressors
Asumption for the forecasted: € 110.- Cost of electricity
Average load forecast of process unit 21%
Life cycle calculator based on 1204 REE Audits
9/17/2018 16
Case study: Refinery of Taranto
Three hydrogen units upgraded with a stepless reverse flow control
www.erecip.com