Gas Pumping Stations Research Articles

Design of unattended gas pumping station system based on multi-source data fusion

Abstract Aiming at the problems that some data has been built and distributed in different subsystems during the transformation of the unattended system of an underground gas pumping pump station in Shanxi Tiandi Wangpo Coal industry, such as low data sharing and comprehensive utilization rate due to data isolation, and weak linkage execution ability, a method combining site-level data fusion and platform-level data fusion is proposed. The advantages and disadvantages of the fusion method are analyzed, and the PLC program and WinCC program are written for the corresponding fusion method. The practical application of the underground gas pumping pump station shows that the system has strong fusion ability, which can meet the integration of extraction parameters, environmental parameters, electric parameters, pipeline parameters, working conditions parameters, and other data required by the unattended system, improve the data utilization rate of the unattended system, and realize the complex control functions of the gas pumping system such as one-key start-stop and one-key rotation vacuum pump. The use of data-driven execution instead of manual operation effectively reduces the duty personnel of the underground gas pumping station, provides a guarantee for the less manned or unmanned operation of the gas pumping pump station, reduces the unplanned downtime of the pumping system, improves the efficiency of gas pumping, and ensures the safety of coal mine production.

Power Augmentation of Gas Turbine Using Exhaust Flue Gas Operated Vapor Absorption Machine

Industrial gas turbines (GT) that operate at constant speed are constant-volume-flow combustion machines. As the specific volume of air is directly proportional to the temperature, an increase in air density results in a higher air mass flow rate at low air ambient temperatures. This results more mass of air is now passes through same volume gas turbine space. Consequently, the gas turbine power output increases proportionally with the increase in air mass flow rate. For geographic regions where warm and humid months are predominant throughout the year, significant power loss occurs during these months, and a higher rate of expensive fuel is fired at reduced power output. A gas turbine inlet air cooling technique is a useful option to enhance GT output. One of the innovative options for power augmentation of gas turbine is inlet air conditioning using a vapor absorption machine (VAM). Using VAM for GT intake air conditioning has the advantage over other systems in that it can be operated from waste heat. Many gas turbine machines, particularly natural gas pumping stations, are operated without heat recovery steam generator (HRSG) or heat recovery option. Valuable heat energy is escaped with exhaust flue gas in these systems. This paper demonstrates how GT exhaust waste heat can be utilized for its own power generation enhancement. In this study, a flue gas-based vapor absorption machine is selected for cooling the inlet air of a 26 MW gas turbine, which is used to drive the booster compressor of a natural gas pumping station. The capacity of the VAM for the required cooling effect has been calculated. The expected GT power enhancement from intake air gas conditioning has also been estimated in this paper.

Ensuring Safety of Gas Field Infrastructure Using ALARP and a Systematic Approach

Introduction. A significant part of the global and state economy is the production and supply of hydrocarbon raw materials. The issues of safety in this area will remain important in the coming decades. The problem is actively discussed in the professional and scientific community. Theoretical and applied works are published. Local, point-based methods are calculated and implemented, which allow predicting and preventing emergencies in certain units of the considered objects. At the same time, there are no sufficiently justified and reproducible system solutions that can take into account the state of, for example, oil or gas field as a single complex and act as indicators not only of ordinary local accidents, but also of systemic accidents — catastrophes. Such a scientifically and experimentally based solution is described in this article. The approach is proposed as part of the formation of a comprehensive scientific and technical program (CSTP) to ensure the safety of natural and technogenic objects (NTO). The aim of this work was to describe the practice of its application in the conditions of specific gas fields and to justify the refusal to focus on solutions that took into account only the minimum practically acceptable risk, that is, built on the ALARP principle (as low as reasonably practicable). Materials and Methods. The article was based on the results of field tests of natural and technogenic objects (NTO) of the oil and gas complex — the Yuzhno-Russkoye field of OJSC Severneftegazprom (SNGP), LLC Gazprom Dobycha Yamburg (GDYA) and the gas pumping station (GPS) Orlovka-2 (Ukraine), conducted with the authors’ participation. Significant results were obtained and evidence-based physically interpreted during acceptance tests of an explosion-proof certified, created under the guidance of the authors of a prototype of a disaster response system (DRS) at the integrated gas treatment plant (IGTP) in LLC GDYA in 2006. At the same time, for the first time in the world practice, the fact of early detection and parrying without consequences by means of DRS on the UKPG-2 of the development of a large-scale general industrial disaster was confirmed. In the form of graphs, the revealed patterns of NTO have been visualized, which made it possible to form harbingers of the development of accidents and catastrophes at the NTO of LLC "GDYA", SNGP and GPS "Orlovka-2". Information on the high experimental reproducibility of the obtained results was presented. The technology has been developed of early detection and parrying of all types of potentially dangerous self-exciting systemic phenomena on real NTO infrastructure — self-oscillations. Three cases of their excitation in real gas fields were presented. Results. The paper shows the fragmentary nature and locality of emergency protection systems based on the ALARP principle. The consequence of this was its complete unsuitability for early detection and counteraction to the most large-scale and costly system accidents — catastrophes that were multifactorial processes, in which none of the factors was decisive. The alternative complex solution of the problem proposed by the authors and brought to working condition was based on a system approach adapted to the NTO of the oil and gas complex. The measured parameters of various NTO infrastructure — fields of LLC "GDYA" and SNGP were processed and analyzed at the moments of development of self-oscillating modes on them, due to self-sustaining nonlinear mechanisms of interaction of NTO elements with constant (non-oscillatory) sources of energy replenishment. Three such modes of self-excitation were illustrated. The most informative in this case were the transient modes of operation of the equipment. According to the technologies experimentally developed by the authors, the areas of critical operating modes of equipment with pronounced potentially dangerous bifurcation points were analyzed. The result of superimposing treatments of the measured parameters of eight full-scale tests of NTO — graphs of dimensionless amplitude-frequency characteristics of the interconnections of a real dynamic system was presented: "input — gas cooling housing" → "output — pipe casing" at the frequency of self-oscillations. Discussion and Conclusion. The capabilities of ALARP did not meet the tasks of system monitoring of the occurrence and development of dangerous incidents in gas fields. This conclusion can be attributed to all standard sizes of NTO infrastructure in Russia. Fundamentally different solutions should be used to ensure comprehensive observability, controllability, and safety of NTO. A comprehensive scientific and technical program is recommended: "Innovative hardware and software tools and technologies to ensure the observability, controllability, and safety of the NTO infrastructure of Russia".

Перспективы применения российских абсорбционных термотрансформаторов на ПГУ-ТЭЦ

The electrical power of power plants based on gas turbines (GT) decreases with an increase in air temperature and, as a result, a decrease in its mass flow at the compressor inlet. This makes it relevant to develop methods for increasing air density by lowering its temperature when wor¬king in hot arid regions and regions with a tropical humid climate. To cool the air, it is proposed to use absorption chillers (LBAC). It is shown that for air cooling in a dry hot climate, it is sufficient to use LBAC with single-stage absorption. For a humid tropical climate, where deeper air cooling is required with a simultaneous decrease in its moisture content, it is proposed to use ABCM with two-stage absorption, which are capable of producing cold at negative temperatures. To do this, it is proposed to introduce an additional evaporation and absorption unit with peri¬pheral equipment into the standard industrial design of the LBAC with single-stage absorption. Comparative energy efficiency of LBAC of standard design and LBAC with two-stage absorption during air cooling at the GT compressor inlet has been evaluated. For such critical facilities for the Russian economy as gas pumping stations using gas turbines, an LBAC unit with two-stage absorption and removal of absorption heat by water-circulating cooling systems based on cooling towers, or using air coolers (drycoolers) with the ability to turn off an additional evaporation unit if necessary, is proposed. and absorption.

Structure Formation in Antifriction Composites with a Nickel Matrix and Its Effect on Properties.

The paper is devoted to studying the chemical elements distribution in the material’s structure depending on the manufacturing technological parameters and their effect on properties of a new self-lubricating antifriction composite based on powder nickel alloy EP975 with CaF2 solid lubricant for operation at temperature 800 °C and loads up to 5.0 MPa, in air. The study is focused on the features of alloying elements distribution in the composite matrix, which depends on the manufacturing technology. A uniform distribution of all alloying elements in the studied composite was shown. The chemical elements’ uniform distribution in the material is associated with one of the most important preparatory technological operations in the general manufacturing technology used. This is a technological operation of mixing powders with subsequent analysis of the finished mixture. The uniform distribution of chemical elements determines the uniform arrangement of carbides and intermetallics in the composite. General manufacturing technology, which includes the main operations, such as hot isostatic pressing technology and hardening heat treatment, contributed to the obtainment of a practically isotropic composite with almost the same properties in the longitudinal and transverse directions. Because of the composite’s structural homogeneity, without texturing, characteristics are isotropic. Improving the material’s structural homogeneity helps to keep its mechanical and anti-friction qualities stable at high temperatures and stresses in the air. The performed studies demonstrated the correctness of the developed manufacturing technology that was confirmed by the electron microscopy method, micro-X-ray spectral analysis, mechanical and tribological tests. The developed high-temperature antifriction composite can be recommended for severe operating conditions, such as friction units of turbines, gas pumping stations, and high-temperature units of foundry metallurgical equipment.

Digitalization in the Educative Process Specialists for Gas Pumping Stations

Digitalization in the Educative Process Specialists for Gas Pumping Stations

Calculation tool NoBel for sound propagation assessment of noise from gasturbines on the ground

Gas turbine engines of aviation type are the basic element of gas-pumping stations of the pipelines around in the world. They produce harmful noise and the protection zone around the gas-pumping station must provide the safe distance to residence in its vicinity. Due to Ukrainian legal requirements for the stationary (not movable) noise sources the sound pressure levels in octave bands must be used as limits for protection of the population complementarily to equivalent and maximum sound levels at day and night periods. A new calculation tool was designed to assess the effects during sound wave propagation from stationary noise sources like gas-turbine installations, as for homogeneous atmosphere, so as for real meteorological and topographical conditions. The tool provides the possibility to predict the conditions of maximum noise exposure at point of noise control. For homogeneous atmosphere the divergence, air absorption, ground surface reflection and acoustic screens contribute to propagation effects mostly. Their formulation in accordance with current knowledge provides more accurate sound levels assessment with differences ± 2 dBA at the boundaries of protection zone in comparison with existing national legal requirements of noise protection calculations. In real atmosphere temperature and wind (in direction and speed) vary with altitude over the ground surface always. These real conditions provide the dependence of sound speed with altitude, and in consequence the refraction of sound waves. For specific conditions of positive sound refraction the tool predicts the sound levels at the receiver up to 10 dBA higher, at negative sound refraction - on 5-7 less than in homogeneous atmosphere for legal protection distances. Tool NoBel is appropriate to be used for specific airport stationary noise scenarios, like for aircraft engine run-ups after their maintenance or repair.

Assessment of the negative impact of low-frequency vibrations on technological pipelines of compressor stations

The intensive development of gas transport and compressor manufacturing aimed at increasing the unit capacities of gas pumping units, creating high-flow centrifugal compressors, increasing the productivity of compressor shops has led to the appearance of fundamentally new problems in the diagnosis of industrial pipelines. The reasons for premature failure of piping manifold of gas pumping stations can be associated with both high static voltage in the pipelines and a high level of vibration. The main reasons for the increased vibration of the technological pipelines of the centrifugal compressor can be significant disturbing forces of the gas flow, coincidence of the natural frequencies of the pipeline system elements with frequencies of the disturbing forces, low dynamic stiffness of the pipeline- support system or a combination of the above conditions. The most effective method for studying problems such as low-frequency vibrations is the combination of engineering means for calculating dynamic processes and the results of measurements of the parameters of these processes in real systems and operating modes of the compressor stations. The hypotheses of the occurrence of low-frequency vibrations in pipelines are considered during the study, the acoustic properties of the process piping, and the resonant vibrations conditions are calculated. A computer model was created in the ANSYS Workbench software in order to consider the loading conditions for process piping. Based on Gazprom company standard 2-2.3-324-2009, an algorithm is proposed that is of practical importance for engineers of plant diagnostics operating gas transmission equipment. It is proposed to combine the performance of vibroacoustic studies and computing modeling with the determination of trends in the technical condition of the system for the analysis of changes in vibro-parameters. As a result of the work, direct measurements of the vibrodiagnostic specialists of the operating compressor station were compared with the obtained modeling data. Some methods were proposed to reduce the impact of operating conditions and design of the process piping on unacceptable low-frequency vibrations.

Algorithm for the choice of power supply system rational structure of gas pumping stations

The article provides main unit and complex reliability indicators used to appreciate reliability of power supply systems for gas pumping stations. The main goals of reliability calculation are presented. The methodology for the determination rational structure of the power supply system is given. The algorithm for the choice of rational structure and its main stages are described. Recommendations for determination directions of optimization power supply system structure are given.

МОДЕЛЬ ОБЧИСЛЕННЯ РІВНІВ ЗВУКУ ШУМУ ВІД КОМПРЕСОРНИХ СТАНЦІЙ ДЛЯ ОБГРУНТУВАННЯ ГРАНИЦЬ САНІТАРНО-ЗАХИСНОЇ ЗОНИ

This article is devoted to the study of sound levels for noise from a gas turbine plant and technological equipment of a compressor station in everyday operation, in order to assess the sustainability of the conditions of sanitary protection zones around the compressor station and in order to protect the population living near the compressor station. The main purpose of the study is to assess the compliance of the sizes of sanitary protection zones in terms of noise load on environment. The main source of noise at compressor gas-pumping stations is determined by the noise regime at the industrial site, in addition to auxiliary equipment; include gas-pumping devices, systems of technological gas discharge from the blower circuits, fuel and starting gas of gas-pumping devices. The dependence of the noise conditions at the production site and in the environment on the sound power level of gas-pumping apparatuses, the installed power of gas-turbine plants, the sound power of the turbocompressor, service life of gas-pumping apparatuses, the number of simultaneously operating gas-pumping apparatuses, the characteristics of production premises, the design of the gas-pumping apparatuses, the state of means of noise absorption of gas-pumping apparatuses. In gas turbine installations of compressor stations, intense noise occurs in the air intake and exhaust systems, in the cooling system fan, in the turbomachine housing and in the generator. To calculate the sound levels at a separate point, depending on the distance to the noise source, a model was used taking into account the effects of sound wave propagation in atmospheric air and the characteristics of the noise source, such as: directivity and spectral characteristics of radiation, the height of the source above the surface; distance from the source to the point of determining the sound level; absorption of sound in atmospheric air, depends on the frequency and parameters of the state of the atmosphere; the effect of the influence of the earth; weather effects and others. The methodology of the standard and the international method CONCAW were used based on the results of calculating sound levels at the border of the sanitary protection zone at the compressor station. The calculation results, for standard atmospheric conditions, according to the international CONCAW method indicate that at a distance of 700 m from the sound source, the sound propagation will be 50.0 dBA, which coincides with the calculation results using the standard method and also exceeds the night noise standard by 5 dBA for conditions in the residential area. Development even when only one gas compressor is in operation, which proves the relevance of studying the environmental risks of compressor stations. KEY WORDS: NOISE, ENVIRONMENTAL RISKS, NOISE SOURCE, COMPRESSOR STATIONS, GAS PUMPING UNIT, GAS PUMPING APPARATUS, SOUND.

МОНІТОРИНГ ВІБРАЦІЇ У ПЕРЕДБАЧУВАЛЬНОМУ ОБСЛУГОВУВАННІ

Currently, manufacturers and operating organizations seek to operate gas turbine engines (GTE) as part of gas pumping stations from their technical condition. This allows you to reduce the cost of operation, increase the service life, reduce labor costs for maintenance, timely repair. Of great importance in this regard is the equipment of units with modern systems that allow you to diagnose the technical condition in the process of their work, among which a special place is occupied by vibration diagnostics with modern means of analog and digital computers. Unlike aircraft engines, turbine units of gas pumping stations are an object where vibration diagnostics can be implemented in its entirety. This is due to the operation of turbines in almost the same modes for a long time, which allows you to organize the so-called trend control of any feature or set of them used for diagnostic purposes. In some industries, maintenance is the second largest or even the largest element of operating costs and thus becomes a priority for cost control. Equipment failure affects not only the availability of the installation, but also the safety, environment and product quality. It can also affect customer service in terms of missed deadlines and loss of trust. The complexity and cost of modern installations and equipment means that monitoring the condition of installations is now a much more cost-effective option. Although many industries still respond to maintenance because there are no advanced costs, they pay a price due to increased downtime or loss of production. Vibration monitoring is still perhaps the most widely used method of predictive maintenance and, according to a rare with the exception, it can be applied to a wide range of rotating equipment. Vibration monitoring allows you to determine the condition of the equipment during its operation and to identify those elements that begin to show signs of wear before they really fail, sometimes catastrophically. With this approach, unplanned downtimes are reduced or eliminated, which increases the availability and efficiency of the installation and reduces costs in addition to an experienced vibration analyzer. However, in the case of rolling bearings, the characteristic vibrating signatures are often formed in the form of modulation of the basic frequencies of the bearings. This can be used to advantage, and vibration control software is often designed to detect these characteristics and provide early warning of an approaching problem. This usually takes the form of a demodulation of the signal and the envelope spectrum, indicating early deterioration of the rolling / sliding surface of the contact surfaces.

Use of the process approach to improve the efficiency of the quality management system at the machine-building enterprise of Kuznetov PJSC

Aspects and features of a process approach aimed at the interaction of departments and officials, removing the barriers between them and combining the efforts of all enterprise structures to achieve strategic goals are considered. The process approach is considered one of the most effective tools for increasing business efficiency. The essence of this approach is that all the activities of the enterprise are considered as a set of processes, which are a combination of interrelated and interacting activities. Each process, in turn, has inputs that translate into outputs, resources, internal and external customers, suppliers, and other interested parties. Based on the study, the relevance and importance of applying the process approach at one of the largest enterprises producing engines for aircraft, gas pumping stations, power plants, for the rocket and space industry and outboard motors for small boats is substantiated. By industry affiliation, it belongs to machine-building enterprises. At this enterprise, significant achievements in the field of quality were noted, obtained through the introduction of a process approach, a process management methodology was recommended for use, which is suitable for enterprises in various fields of activity. This method is necessary for the tactful formation of process management. The systematic implementation of the process approach enables enterprises to increase efficiency, improve the quality of products and significantly increase their competitiveness, which is especially important in the context of the integration of the national economy into the world. The implementation of these measures will allow enterprises to achieve their goals as soon as possible at the lowest possible cost.

Utilization of heat and power complex with a capacity of 1 MW

The results of a compact and mobile heat recovery plant design based on the organic Rankine cycle (ORC) with a capacity of 1 MW, which can meet the gas pumping station auxiliaries in power, are presented. The choice of n-pentane as a working fluid, as the cheapest and most affordable on the market and providing condensation of exhaust steam at the atmospheric pressure, and thermal oil ‘Thermolan LT’ as an intermediate heat carrier has been substantiated. The choice of the work process parameters is focused on reliable long-term work with a minimum amount of maintenance. The plant is designed with the possibility to place its main units outside the technological zone of the main production. The design of the plant main components is presented. The turbine is axial, with five stages with a direct generator drive without a reduction gear. The turbine and generator are placed in a ventilated container. The steam generator is a vertically placed shell-and-tube heat exchanger. The air condenser is with horizontally arranged heat exchange tubes and screw-knurled fins. The recuperator is a shell-and-tube heat exchanger with horizontally arranged longitudinally finned tubes. It has been substantiated that for low-potential heat sources and in the conditions of low air temperatures, the use of heat-recovery plants based on the ORC is the optimal solution.

Визначення доцільного обсягу використання технології термохімічної регенерації для газотурбінних установок газоперекачувальних станцій України

We performed thermodynamic and technical-and-economic calculations of the scheme of thermochemical recuperation (based on natural gas reforming with combustion products) for 12 models of gas turbine plants of Ukrainian gas-pumping stations. It was established that, for most models, the pay-back period of investment to the TCR scheme does not exceed several months. We recommend to introduce TCR scheme at 40 gas turbine plants with a total power of 505 MW, and the cost of fuel that can be saved constitutes 420 mln. UAH per year.

Design of Elastic-damping Supports Made of MR Material for Pipeline Supports

Damping supports are used often to reduce a high level of vibration in pipeline systems of aircraft engines and power plants of gas-pumping stations. It is shown in the present paper that obtaining of little stiffness and high damping by changing of technological parameters of traditional MR material is impossible. A new technology of MR dampers manufacturing with inner regular structure of compact winded spiral parts which axis are perpendicular to pressing direction is proposed. A practical result of this work is replacing of plate damper in units of “Kuznetsov” company on elastic-damping element made of MR material with the same overall an connect dimensions of support.

Remote Diagnosis of Dug-in Areas and Bottom Pipe by Main Acoustic Emission Method Using a Self-organizing Wireless Network

This paper discusses methods of nondestructive testing, the main method is method of acoustic flue gas emission. It was found that the use of this method in the diagnosis of bottom pipe and dug-in areas allows to reduce time, does not require surface dressing to a certain value, provides almost instant information about the defect at a great distance to the nearest gas-pumping station and is not inferior to the reliability of the control other existing methods.

Analytical Design of Multivariable Control Systems by Dynamical Decomposition Method

Design of multivariable control systems for complex technical plants with several interrelated channels and controlled variables is difficult problem. Usually here it is necessary to provide either independent (autonomous, unrelated) or coherent control of output variables. This design problem can be solved by using the analytical method implying exact, dynamical decomposition of the multivariable plant to the set of an independent single input–single output channels. The dynamic decomposition method is based on decomposing property of the adjunct matrix and provides realized of control action as function of output variables, reference input and measured disturbances (control on output and inputs) of the system. The efficiency of this analytical method is shown by the numerical example of control system design for the turbojet engine of the gas-pumping station with three interrelated channels.

Community Health Assessment Following Mercaptan Spill

In 2008, a lightning strike caused a leak of tert-butyl mercaptan from its storage tank at the Gulf South Natural Gas Pumping Station in Prichard, Alabama. On July 27, 2012, the Alabama Department of Public Health requested Centers for Disease Control and Prevention epidemiologic assistance investigating possible health effects resulting from airborne exposure to mercaptan from a contaminated groundwater spring, identified in January 2012. To assess the self-reported health effects in the community, to determine the scope of the reported medical services received, and to develop recommendations for prevention and response to future incidents. In September 2012, we performed a representative random sampling design survey of households, comparing reported exposures and health effects among residents living in 2 circular zones located within 1 and 2 miles from the contaminated source. Eight Mile community, Prichard, Alabama. We selected 204 adult residents of each household (≥ 18 years) to speak for all household members. Self-reported mercaptan odor exposure, physical and mental health outcomes, and medical-seeking practices, comparing residents in the 1- and 2-mile zones. In the past 6 months, 97.9% of respondents in the 1-mile zone and 77.6% in the 2-mile zone reported mercaptan odors. Odor severity was greater in the 1-mile zone, in which significantly more subjects reported exposures aggravating their physical and mental health including shortness of breath, eye irritations, and agitated behavior. Overall, 36.5% sought medical care for odor-related symptoms. Long-term odorous mercaptan exposures were reportedly associated with physical and psychological health complaints. Communication messages should include strategies to minimize exposures and advise those with cardiorespiratory conditions to have medications readily available. Health care practitioners should be provided information on mercaptan health effects and approaches to prevent exacerbating existing chronic diseases.

Innovative methods of managing research testing of gas turbine installations for terrestrial applications

The article deals with the questions of a efficient management by research test process of the gas turbine units for terrestrial usage. Authors have executed reengineering of research test process taking into account specificity of complex research tests of the gas pumping station.

Thermodynamic Optimization of Organic Rankine Cycles at Several Condensing Temperatures: Case Study of Waste Heat Recovery in a Natural Gas Compressor Station

In this article, the authors performed the thermodynamic optimization of organic Rankine cycles (ORCs) using several working fluids and considered the effect of three heat rejection media in the condenser: cooling water, ambient air, and hot water at high temperature for co- or trigeneration applications. The ORC system was modelled and optimized using the Aspen Hysys process simulator. The objective function is the maximization of turbine power output. Most natural gas compression stations use no heat recovery system. In this study, they applied the optimization procedure to the recovery of waste heat from gas turbines used to drive natural gas compressors in natural gas pumping stations. They used operational data from an existing pumping station to illustrate the potential benefits of ORC systems for this application, taking into account also non-thermodynamic aspects such as toxicity, flammability, and investment cost return. The highest ORC turbine output powers were obtained with aromatic hydrocarbons, then with aromatic fluorocarbons, n-hydrocarbons, and siloxanes (in that order). For the case studied here — a gas turbine of 2.6 MW of mechanical power— the proposed ORC can produce around 1 MWe, with a thermal efficiency of up to 24 per cent depending on the working fluid and condensing temperature.