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
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
Conduct this training course in-house for more effective savings!
Call us at +65 6741 9927 or email to info@asiaedge.net. For more information, visit us at
www.petroedgeasia.net
ESD Simulation Training Control, Operation and Design of Reciprocating Gas Compressors
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.

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
Visit us at wwwpetroedgeasianet or contact us directly at +65 6741 9927 or email to info@asiaedgenet for more information

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
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
USD 3,299 USD 3,499
3 Days ESD Simulation Training Control and Operation
of Centrifugal Gas Compressors only
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 info@asiaedge.net
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for cancellations. For cancellations received in writing more than seven (7) days prior to
the training course you will receive a 100% credit to be used at another ASIA EDGE PTE
LTD training course for up to one year from the date of issuance. For cancellations
received seven (7) days or less prior to an event (including day 7), no credits will be
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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

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