Preface to the First Edition Preface to the Second Edition. Acknowledgment

Transcription

1 Dedication Preface to the First Edition Preface to the Second Edition Forewords Acknowledgment iii xiii xv xvii xix Chapter 1 Introduction to Pipeline Systems Introduction Liquid Pipelines Liquid Pipeline System Liquid Pipelines and Pumping Gas Pipelines Gas Pipeline Systems Gas Pipelines and Compression Dependability of Pipeline Systems Dependability The Value of Dependability for Pipelines Dependability for Pumping and Compression 12 References 14 Chapter 2 Liquid Pipeline Pumping System Design Liquid Pipeline Design Hydraulic Gradient Pipe Size Selection Pipeline System Head Curve Pipeline System Curve Development Example Pipeline Considerations for System Curves Liquid Flow Equations Laminar Flow Colebrook White Equation Hazen Williams Equation Number of Pumps and Pump Configurations Number of Pumps Pumps in Series Pumps in Parallel Pump Station Configuration 30

2 vi Piping for Minimum Flow Protection Number of Units Exercise Pipeline Pressure 38 References 40 Chapter 3 Gas Pipeline Compression System Design Gas Pipeline Design Hydrocarbons and Natural Gas Gas Compression Calculations Driver Power Principles of Gas Pipeline Hydraulics Gas Flow Equations General Flow Properties Principles of Fluid Flow Thermal and Thermodynamic Effects Pipe-Related Parameters Friction Factor and Flow Regimes General Gas Flow Equations Generalized Isothermal Flow of Gas in Pipelines Industry-Used Flow Equations Examples Maximum (Sonic) Velocity of Compressible Fluids in Pipeline Systems Pipeline Design and Optimization for Compression Optimization With Respect to Compression Pipeline Looping and Compression (Location and Spacing) Hydraulic Simulation Driver Power Cost of Compressor Operation General Compressor Station Configuration Operating Considerations Types of Compression Equipment Parallel and Series Configuration Number of Units Case Study: NPV Comparison Between Immediate and deferred Unit Installation Standby Units Environmental Considerations Case Study: Comparison of Different Usage Scenarios for Pipeline Stations Compressor Requirements Driver Requirements Station Layout and Facilities General Station Layout Station Piping Layout Scrubbers and Filters Gas Coolers Station and Unit Auxiliary Systems Station and Unit Control Systems 88

3 vii Buildings and Weather Protection Safety Systems and Environmental Controls Codes and Standards 90 References 92 Chapter 4 Design and Operation of Pumps Pumps for Liquid Pipeline Stations Pump History Centrifugal Pumps Types of Centrifugal Pumps Centrifugal Pump Design Centrifugal Pump Mechanical Seals Centrifugal Pump Station Piping Design Centrifugal Pump Nozzle Loading Pump Operational Hazards and Risk Positive Displacement Pumps Rotary Pumps Reciprocating Pumps Pulsation Dampeners Other Pump Design Considerations 123 References 126 Chapter 5 Performance of Pumps Pump and System Design Standards System Head American Petroleum Institute Gravity and SG Relationship Performance of Centrifugal Pumps Performance Curves Centrifugal Pumps Coverage Chart Impeller Selection Pump Head-Flow and System Head Flow Curves Centrifugal Impeller Design Theory Specific Speed Impeller Curve Characteristics Affinity Laws Pipeline-Pump Operational Control Pump Sizing and Selection Pump Power and Efficiency Performance Modifications Cavitation in Centrifugal Pumps Cavitation Net Positive Suction Head Net Positive Suction Head Available Net Positive Suction Head Required Correcting for Inadequate Suction Conditions NPSHA NPHSR Criteria Centrifugal Pumps and Viscous Liquids Centrifugal Pump Limits Minimum Flow 160

4 viii Temperature Rise Re-Circulation in Centrifugal Pumps Pump Surge in System Operation Performance of Positive Displacement Pumps Rotary Pump Performance Chart Pump Power and Efficiency Net Positive Suction Heads for Rotary Pumps Rotary Pump Slips and Clearance System Head Curves and Rotary Pump Curve Reciprocating Pump Flow Characteristics Reciprocating Pump Acceleration Head Net Positive Pressures Reciprocating Pump Selection Measurement Units and Conversion Factors for Pumps 173 References 176 Chapter 6 Design and Operation of Compressors Introduction to Pipeline Compressors Compressor Types and Uses Classification of Compressors Reciprocating Compressors Rotary Compressors Centrifugal Compressors Reciprocating Compressors General Design Running Gear Frame and Cylinders Capacity Control Valves Packings Bearings and Lubrication Systems Controls and Monitoring Gas Cooling Operation and Optimization Design Standards Centrifugal Compressors General Design Compressor Internals and Sealing Bearings and Lubrication Systems Sealing System Controls and Monitoring Physical Operation Design Standards Screw Compressors Screw Compressor Design Screw Compressor Operation 217 References 218

5 ix Chapter 7 Performance of Compressors Introduction to Compressor Performance Basic Aspects of Performance General Nomenclature Gas Properties Compression Behavior Head Efficiency Flow Power Performance of Reciprocating Compressors General Flow Power Discharge Temperature Performance Maps Piston Speed Performance of Centrifugal Compressors General Dynamic Performance Characteristics Selection and Sizing Performance Testing System Characteristics General System Curves Compressor Performance Comparison Operating Limitations Compressor Performance Adjustments Operating Considerations 249 References 252 Chapter 8 Pump and Compressor Drivers Introduction to Drivers Gas Turbines Types of Gas Turbines Basic Design of a Gas Turbine Design Standards Performance Characteristics Fuel System Lubrication System Waste Heat Recovery Electric Motors General Types of Motors Motor Design Considerations Variable Speed Motors 273

6 x Hermetic Compressors Driver Economics Internal Combustion Engines General Internal Combustion Engine Design Separable Engine/Compressors Couplings Functions of Couplings Coupling Selection Gear Couplings Flexible Couplings Elastomeric Soft Couplings Steel-Spring Soft Couplings Coupling Standards 290 References 290 Chapter 9 Dynamic Behavior of Pumping Systems Introduction Unsteady Governing Equations and Solution Techniques Governing Equation for Constant Area Pipes Solution Techniques Boundary Conditions Flow Transients Across Other Elements Flow Transients of an Accumulator Dynamics Behaviour of Centrifugal Pumps Homologous Relations Full Pump Characteristics Dynamic Equation Pump and Motor Inertias Water Hammer, Cavitation, and Column Separation Water Hammer Cavitation and Column Separation Steam Condensation-Induced Water Hammer Examples and Case Studies Styrene Transfer System Lube Oil System for a Large Process Gas Compressor Pump Characteristics Control Valves First Problem Second Problem 331 References 333 Chapter 10 Dynamics of Centrifugal Compression Systems Introduction Fundamentals of Dynamic Instabilities of Compression Systems Simple Compression Systems Complex Compression Systems Control Dynamics 343

7 xi Solution Techniques Emergency Shut Down Effects of Compressor Performance Characteristics Effects of Rotor Inertia Example of Dynamic Instabilities in an Industrial Compression System Concept of Inertia Number Check Valve Dynamics Dynamics of Swing Type Check Valves Slamming Characteristics of Swing Check Valves Effects of Counterbalance on Maximum Reverse Velocity Dynamics of Piston Type Check Valves Dynamics of Wafer Type Check Valves Effects of Check Valves of Compression Recycle System Relief Valve Dynamics Dynamics of Pilot-Operated Relief Valves Solution Technique Example Field Tests Station and Gas Pipeline Blowdown Volume Model Pipe Model Comparison Between Models Non-Isothermal Blowdown 413 References 418 Chapter 11 Pulsation and Vibration Analysis of Compression and Pumping Systems Introduction Pulsation Transmission Through Piping Elements Acoustic Transfer Matrix for a Pipe Element Acoustic Transfer Matrix for a Throttle Element Acoustic Transfer Matrix for a Volume Element Acoustic Transfer Matrix for a Centrifugal Compressor Pulsation Generation Flow-Generated Pulsation from Throttling Elements Flow-Generated Single-Tone Pulsation from Closed End Side Branch Pulsation Generated by Reciprocating Compressors and Pumps Solution Techniques Acoustic Boundary Conditions and Resonance Techniques for Pulsation Suppression Reactive Silencers Spoilers for Pulsation Suppression at Source Suppression of Noise From Blowdown Stacks Liquid versus Gas Applications Standards and Guidelines API 618 Standard API 674 Standard Shaking Forces Arising from Pressure Pulsation 472

8 xii 11.9 Case Study Examples Case Study #1: Single-Source Pulsation Case Study #2: Multiple Source Pulsation Case Study #3: Pulsation Generated by a Reciprocating Compressor Case Study #4: Pulsation Generated by Plunger Pumps 482 References 486 Chapter 12 Mechanical Analysis Introduction To Mechanical Analysis Basic Aspects Of Vibration General Mechanical Natural Frequency and Resonance Mechanical Analysis of Rotating Equipment General Lateral Rotordynamics Stability Torsional Rotordynamics Specific Machinery Considerations for Rotordynamics Balancing Mechanical Analysis of Piping Systems Excitation Mechanisms Vibration and Stress Unbalanced Forces Small-Bore Attachments Thermal Analysis Centrifugal Compressors 527 References 531 Chapter 13 Environmental Issues Related to Compressor and Pump Stations Introduction Compressor and Pump Station Noise Noise Level Parameters Noise Criteria Limits Predictions of Noise Level Form Compressor Stations Noise Survey at Compressor and Pump Stations Noise Mapping Methodology Example Application on a Compressor Station NOx Emissions from Gas Turbines AP-42 Emission Factors CEM Measurements Neural Network Based PEM Models PEM Implementation Innovations in Capturing Vent Gas from Dry Gas Seals Dry-Gas Seal Leakage Rates Primary Challenges of Supersonic Ejectors Description of the Two Stages of the Ejector Performance of the Integrated Two-Stage Supersonic Ejector Supersonic Ejector in Operation 572 References 575