centrifugal gas compressors and reciprocating gas compressors training

ESD Simulation Training

Control, Operation and Design of

Reciprocating Gas Compressors 26 – 27 October 2015 | Kuala Lumpur

ESD Simulation Training

Control and Operation of Centrifugal Gas

Compressors 28 – 30 October 2015 | Kuala Lumpur

In partnership with ESD Simulation Training

www.petroEDGEasia.net

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ESD Simulation Training Control, Operation and Design of Reciprocating Gas Compressors & Control and Operation of Centrifugal Gas Compressors 26 – 30 October 2015 | Kuala Lumpur

Conduct this training course in-house for more effective savings! Call us at +65 6741 9927 or email to [email protected]. For more information, visit us at

www.petroedgeasia.net

ESD Simulation Training Control, Operation and Design of Reciprocating Gas Compressors

26 – 27 October 2015 | Kuala Lumpur

Course Overview An intensive 2 day hands-on course using computer based training (CBT), 3D animations, and dynamic simulation models to examine the design, construction, control and operation of reciprocating compressors. Topics will include the principles of operation, how the design is adapted to a number of different configurations to meet various needs as well as strategies for providing a safe, efficient and effective means of boosting pressure of a gas stream in a number of applications. At the end of this course, delegates will:

Understand the thermodynamic principles of the compression process Demonstrate an understanding of the principles involved in the operation of reciprocating compressors and

identify the main process variables which affect compressor operations Be able to demonstrate an understanding of the terminology used to describe compressor performance

and capacity Identify the main components of the compressor and describe the variations in cylinder design for

applications involving single, double-acting and multi-stage configurations Appreciate the importance of gas valves to the service life of the compressor and be able to identify the key

issues related to the specification, operation and maintenance of its valves Demonstrate an understanding of the monitoring requirements for the compressor, both for the mechanical

integrity and performance of the machine Carry out key performance and design calculations using a computer based training (CBT) package Diagnose key fault conditions occurring on the reciprocating compressor Appreciate the key issues associated with the used of the API RP618 in the specification of reciprocating

compressors Course pre-requisites Fundamental understanding of gas behaviour will be an asset but not mandatory. Who should Attend Engineers, operations personnel who are either supervisors or are responsible for the day-to-day operations and maintenance of reciprocating compressor installations. Other categories may consist of process operators, technicians and engineers.

This 2 day course is iChemE approved. Members will receive 10% off the Normal Price

This training course has a limited attendance for up to 14 participants. Register early to secure your place!

Sessions commence at 9am on all days, with short intervals at 10.30am and 3.30pm respectively. Lunch will be

provided at 12:30pm for 1 hour. Sessions will end by 5pm on all days.

mailto:[email protected]




2 DAY COURSE AGENDA

INTRODUCTION

This course will cover the design, control and operation of reciprocating compressors of the type normally found in the process industries within the following sessions:

COMPRESSION SELECTION

Centrifugal versus reciprocating

Efficiencies

Speed

Costs

COMPRESSION PRINCIPLES

Gas law relationships

Compression processes

Compressor action and the PV diagram

Discharge temperatures and multi-staging

Volumetric efficiencies and clearance

Hands-on: using a CBT calculation package, delegates are able to determine the discharge temperature for any number of compressor applications including both single and multi-stage configurations

Hands-on: using the same package, the effects of compression ratio and clearance volumes on volumetric efficiencies are demonstrated and calculated for the different configurations already identified in the previous exercises

Hands-on: using dynamic simulation of a single stage, double-acting compressor, the principles of operation are explored based on variations in suction conditions of pressure, temperature and flow

MECHANICAL DESIGN FEATURES

Hands-on: using a combination of video and 3D animations, the main mechanical features of the compressor are explored

COMPRESSOR VALVES

Operating principles and the PV diagram

o A. Idealised operation

o B. Real operations

Valve attributes – the desirable

Types of valves

o A. Selection criteria

o B. Materials of construction

PISTON ROD LOADING AND ROD REVERSAL

Rod loading on double acting cylinders

o A. Static gas loads

o B. Inertial loads

o C. Combined effects

Frame loading and cylinder orientation

Rod reversal

o A. The principle

o B. Rod loading effects

o C. Effects of gas valve operations

Hands-on: using CBT and 3D animations, the principle of rod reversal is demonstrated. Using the calculations package, the rod loadings for the previously used configurations are calculated.

CAPACITY CONTROL

The options

Step control strategies

Shut down protection

Hands-on: using dynamic simulation for both single and multi-stage configurations, the capacity control strategies of speed variation, clearance pockets, valve unloading, and recycle are investigated

Hands-on: using the specific case of the multi-stage dynamic model, the delegates will explore a step control logic matrix

PERFORMANCE CALCULATIONS

Discharge temperature

Multi-stage configuration and process conditions

Volumetric efficiency

Volumetric throughput

Piston rod loading

Absorbed power

Hands-on: delegates will perform performance calculations on their own compressors using information from their plants

COMPRESSOR START-UP

Hands-on: using the multi-stage dynamic model, delegates will practice a start-up of the compressor to arrive at the default condition





ESD Simulation Training Control and Operation of Centrifugal Gas Compressors 28 – 30 October 2015 | Kuala Lumpur (Simulated Assisted)

Course Overview An intensive 3 day hands-on course using dynamic simulation models to give a practical introduction to centrifugal gas compressors, their performance characteristics and their operation within a process plant. Topics will include compressor performance and selection, control strategies for capacity and surge protection and compressor operations.

At the end of this course, delegates will: Identify the most common types of compressors in use today Understand the thermodynamic and physical principles of compression systems Explain the purpose and function of the main compressor components Appreciate the impact of suction condition variations (molecular weight/composition, pressure,

temperature) on compressor performance Be familiar with the most commonly used capacity control systems Appreciate how the design of an overall plant control scheme relates to the compression system Have a thorough understanding of surge and its consequences for the machine Understand the principles of more complex anti-surge control systems Set-up simple anti-surge control systems for both fixed and variable speed compressors Explore typical compressor operating scenarios (including start up) and identify commonly encountered

problems Appreciate how to prevent a compressor surging on trip and the use of hot-gas bypass valves

Course pre-requisites Fundamental understanding of gas behaviour will be an asset but not mandatory. Who should Attend Engineers, operations personnel who are either supervisors or are responsible for the day-to-day operation and maintenance of reciprocating compressor installations. Other categories may consist of process operators, technicians and engineers.

This 3 day course is iChemE approved. Members will receive 10% off the Normal Price.

This training course has a limited attendance for up to 14 participants. Register early to secure your place!

Sessions commence at 9am on all days, with short intervals at 10.30am and 3.30pm respectively. Lunch will be

provided at 12:30pm for 1 hour. Sessions will end by 5pm on all days.





3 DAY COURSE AGENDA

INTRODUCTION

This course will cover compressor performance and selection, instrumentation and control, surge protection and compressor operation within the following sessions :

COMPRESSION PRINCIPLES

Explore the differences between positive displacement (PD) and dynamic compressors and how they influence the technical selection process

Understand the principles of the compression process and how they relate to the laws which govern the performance of the machine

Learn how a centrifugal compressor raises pressure

COMPRESSOR PERFORMANCE

Explore the ways in which compressor performance is mapped and identify the important variables used (head, flow, efficiency and speed)

Study the effects on performance of changes to suction and discharge conditions, primarily pressure and gas composition

Study the main differences in performance between fixed and variable speed compressors

Explore compressor efficiencies and how they are defined and mapped

Hands-on: instructor gives a demonstration using a simulator to show how fixed and variable speed compressors move on their curves/maps

Hands-on: using dynamic simulation, participants investigate the performance of compressors (fixed and variable speed) against changing suction and discharge conditions. They are encouraged to identify the suitability of using different variables to define the performance map

CAPACITY CONTROL

The common methods of capacity control are explored for both fixed and variable speed compressors

For each method, a summary based on applicability and efficiency is considered o A. Applications o B. Energy efficiency o C. Choice of controlled variable o D. Choice of manipulated variable

The concept of shared load control for parallel compressor configurations is introduced

Hands-on: short dynamic simulation exercises are used to explore some typical applications of capacity control

Hands-on: three case studies are presented showing typical control strategies and delegates are encouraged to identify the strategies in question, identify potential problem areas and summarise the operational characteristics of each

SIMPLE ANTI-SURGE CONTROL

Explore the phenomena of surge o A. How it occurs o B. Speed of onset o C. Consequences

Introduction to the basic principles and the theory of anti-surge control

Explore the significance of the “safety margin” and its magnitude

Explore the principles and design of a flow/deltaP anti-surge control system

Hands-on: dynamic simulation is used to allow delegates to investigate the dynamics of the responses of an anti-surge control loop

Hands-on: dynamic simulation is used to allow delegates to investigate the structure and tuning of typical anti-surge control systems

Hands-on: delegates carry out a surge test on a fixed speed compressor

RECYCLE VALVE SIZING

Introduction to the theory of sizing valves, demonstrating the ways in which recycle valves are used to protect compressors during run-down and normal operation

Hands-on: participants are given some practical methods to work out the size of a recycle valve

COMPLEX ANTI-SURGE CONTROL

Demonstration of the CCC (Compressor Control Corporation) anti-surge control technology is used to explain the principles of complex anti-surge control o A. Explanation of the mapping

technologies used to determine the position of a compressor within its operating envelope

o B. Defining the surge map o C. Explore the control safety

margin o D. Explore how an anti-surge

controller is configured to provide consistent Ω surge protection

o E. Explanation of parallel compressor load share techniques

Hands-on: a dynamic model is linked to real CCC hardware to allow the tuning and configuration of the system to be explained in detail

COMPRESSOR OPERATIONS

Developing a start up strategy for a pipeline compressor

Investigating multi-stage compressor operation

Hands-on: delegates are given the opportunity to conduct a start up of a compressor using a dynamic simulation model

Hands-on: various exercises are performed on a multi-stage centrifugal compressor

COMPRESSOR PROTECTION

Explore methods of protecting compressors from surge or damage on trip o A. Parallel recycle valves o B. Hot-gas bypass valves

Understand the principles to be adopted for the optimum design and layout of equipment around the compressor o A. Non-return valves o B. Coolers o C. Scrubbers o D. Recycle lines/valves

Appreciate the impact of poor design on the performance of the anti-surge control system o A. Coolers o B. Recycle lives/valves

PERFORMANCE AND EFFICIENCY MONITORIN Introduction to factory testing (PTC10)

Methods for monitoring and tracking the performance of a centrifugal

compressor on a day to day basis





Your Faculty of Alternate Course Experts from ESD Simulations:

Mark Dixon, B.Sc. (Hons) C.Eng. MIChemE, MIGasE

Managing Director of ESD and a Chartered Chemical Engineer, Mark has been working as a Chemical Engineer and delivering

training courses for 28 years. He is a member of the Institution of Chemical Engineers (IChemE) and the Institution of Gas

Engineers.

Colin Baker, ONC Science

With 47 years’ experience in operation in the oil, gas, chemical and petrochemical industries, Colin is one of the most

knowledgeable simulator trainers in the world. His expertise extends to the operation of ethylene plants, LNG production, oil

refineries and oil and gas production facilities.

Robert Hodder, MAIChE

Robert is a member of the American Institute of Chemical Engineers and has 45 years of practical experience working as a

Process Engineer, Operations Supervisor, and Training Manager on oil refineries, LNG plants, offshore and onshore oil and gas

production facilities.

David Llewellyn, B.Sc. (Hons) C.Eng.

A fellow of the Institution of Chemical Engineers and the Institution of Gas Engineers, David is a process engineer with 47 years’

experience in the energy industry with a wealth of experience working in the production, storage and transportation of LNG,

natural gas, LPG and ammonia industries.

Peter Watson, B.Sc. (Hons), C.Eng

Peter is a fellow of the Institution of Chemical Engineers (Eur. Ing.MEI) and a Chartered Engineer with 40 years experience in

the oil and gas processing business, including many senior management positions around the world

Roger Edward, Power Engineer, First Class

Roger brings 36 years of training experience as a consultant to the industry in a wide range of process facilities on several

continents, specialising in implementing site-specific training, safety and emergency response procedures.

Gareth Pemberton, B.Sc. (Hons) A.M.I. Mech.E

Gareth has over 35 years’ experience in the Rotating Equipment Industry as a design engineer, project manager and general

manager. He has worked principally in the oil and gas, petrochemical and power generation sectors and most recently in the

LNG industry with direct involvement in many of the latest LNG projects.

Edward Dilley, B.Sc. (Hons) C.Eng.

A member of the Institution of Chemical Engineers with over 40 years of experience in process control, process engineering and

planning within the oil refining, petrochemical, synthetic rubber and power industries. Edward brings a wealth of practical

knowledge to the classroom.

Mike Tolstyko, HNC MECH Eng., ONC Bus.

Mike has over 36 years of industry experience in drilling operations worldwide. He is fully accredited by the IWCF, and is a

member of the Society of Petroleum Engineers

Mark

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EARLY BIRD NORMAL

petroEDGE recognises the value of learning in teams. Group bookings at the same time from the same company receive the following: 3 or more at 5% off 5 or more at 7% off 8 of more at 10% All promotions & group discount are applicable on normal fees only. Any promotion including early bird are exclusive of the group discount.

FULL 5 DAYS ESD Simulation Training Control, Operation and Design of Reciprocating Gas Compressors & Control and Operation of Centrifugal Gas Compressors 26 – 30 October 2015 | Kuala Lumpur

USD 5,299 (save USD 1899)

USD 5,499 (save USD 2099)

2 Days ESD Simulation Training Control, Operation and Design of Reciprocating Gas Compressors only

26 – 27 October 2015 | Kuala Lumpur USD 3,299 USD 3,499

3 Days ESD Simulation Training Control and Operation of Centrifugal Gas Compressors only

28 – 30 October 2015 | Kuala Lumpur USD 3,899 USD 4,099

In-House Training Yes, I would like to organise this training on-site and save on total course fees! For further information about On-site Solutions, please +65 67419927 or email [email protected]

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Control, Operation and Design of Reciprocating Gas Compressors & Control and Operation of Centrifugal Gas Compressors

R E G I S T R A T I O N F O R M


centrifugal gas compressors and reciprocating gas compressors training

Engineering

training course

principles of operation

compressor operations

compressor performance

gas stream

day course

training cbt package

design calculations