COMMISSIONING A GAS TURBINE-COMPRESSOR OR SINGLE

LIFT PACKAGE FOR OFFSHORE GAS REINJECTION APPLICATIONS

by
Ramada Reddy
Head of Aerodynamic Analysis
Dresser-Clark Division
Dresser Industries, Inc.

This paper describes the package and conclusions

Mr. Ramana Reddy has been u:ith drawn as a result of the experience gained -from com·
Dresser-Clark Division, Houston, missioning this unit.
since 1\'ovember 1968 as Head of
Aerodynamic Analysis. He was ll'ith NO:VIENCLATCRE
the Design and Det,elopment Group PCV Pressure control valve-See Figure l.
of Avco Lycoming Division, Strat·
TCV Temperature control valve-See Figure l.
ford, Connecticut, for t1co years; for
four years with Escher Wyss A. G., RCV Recycle vah-e-See Figure l.
Zurich, Switzerland, in their Indus­ Sl Scrubbers-See Figure l.
trial Research Department of Turbo­ 52 Scrubbers-See Figure l.
machinery; and about one year with 5.1 Scrubbers-See Figure l.
Hindustan Aeronautics, India. He is a member of ASME
Sl Scrubbers-See Figure l.
and holds an M.S. (Aero) from Indian Institute of
Science, India. IC 1 Intercoolers-See Figure l.
IC 2 Intercoolers-See Figure l.
ABSTRACT AC Aftercoolers-See Figure l.

Sixteen centrifugal stages in two cases dri\'en by GG Gas Generator

a Rolls Royce AVON jet and a single stal!e power tur­ PT Power Turbine
bine compress natural gas of Mol Weight 2.1 from a
pressure of 65 to 2000 psia. The rotating train, the PROCESS FLOW SCHEMATIC
coolers, the scrubbers and all svstems mounted on a Figure 1 illustrates the arrangement of rotating
double-deck platform weighing 200 tons is pumping gas train and process flow equipment schematically.
in the Lake Maracaibo, Venezuela, since February 1<.>72.
This paper deals with design concepts, protective ilevices, Natural gas enters the scrubber 5 1 through a station
pre-testing of package simulating field conditions, and flow measuring orifice and an inlet valve. The pressure
initial problems encountered during commissioninl! the control valve, PCV, controls the inlet pressure to the
unit. Dresser Clark Model 553B6 compressor and maintains
it at 50 psig by sensing the pressure at the inlet of 553B
compressor. The 6-stage compressor compresses gas to
INTRODl'CTION 350 psia. The fin fan intercooler IC 1 reduces the gas
temperature to ll5°F. The scrubber 52 "knocks out"
Platforms for gas lift and reinjection application
any heavy ends of the gas and the first six stages of
have been built for many years for offshore and onshore
2 72B6 -l compressor rises the gas pressure to <JBO psia.
applications, but most of these, reciprocating and cen­
The last four stages of 272B compressor raises the inter­
trifugal units, were assembled on site.
cooled and scrubbed g-as to Hll5 psia. The aftercooler
To the best of our knowledl!e. the platform package cools the gas to l05oF before it enters the scrubber S-t.
described here is the first of its kind to be desi�ned as and l,!lycol dehydrating unit. The gas then joins the
a "single lift package," manufactured, assembl � fl. and discharge header through a measuring orifice, a check
load tested at the factory slip b�- one manufacturer within ,-alve, and a station discharge ,-alve. The glycol dehy­
its own facility capabilities. This package is the first drator can be bypassed by manual operation of the
unit runninl! continuously on Lake l\Iaracaiho at a dis­ vah·es. The recycle vah-es, RCV l and RCV 2, were
charge pressure of 2000 psia which contains an aircraft designed to pass the design flow in order to facilitate
derivative gas generator, power turbine combination full load testing of the whole platform in closed loops
coupled with two high pressure barrel compressors. in addition to their function as surge control valves.

The complete plant was desil!ned to compress 52 When the unit is on recycle, the temperature drop
MMSCFD of 23.-t mol weight natural gas from 65 psia across the recycle valve, RCV 2, due to Joule Thompson
to 18 15 psia which has a nominal horsepower require­ Effect is on the order of l00°F. The inlet temperature
ment of 13,000 BHP. It is capable of being controlled of 212B compressor would rapidly reach below that of
remotely from shore or locally automatically or man­ freezing point of water and thus increase the possibility
ually. This "single lift package" with its own electric of hydrate formations. To avoid this, a thermal control
generator was pre-tested in Dresser facility, shipped on valv�, TCV, 11 hich bypasses the required quantity of hot
a barge and set on piles in the field. gases to the inlet of RCV 2, is installed.

26
 COMMISSIONING A GAS TURBINE COMPRESSOR SINGLE LIFT PACKAGE 27
FOR OFFSHORE GAS REINJECTION APPLICATION

51

INLET VAlliE

F'LOW Ol!IFICf

Figure 1. Schematic of Process Flow.

The vent valve has two functions: ll To pur�e the

system before start up, and 2) to vent the high pressure
gases stored in various scrubbers and pipin�, thus re·
lieving the compressor of back pressure and back rota·
tion during an emergency shutdown.

DESIGN ARRA N GEMENT

The components and systems are arran�ed in a
double-deck platform as shown in Figure 2. The overall
dimensions are: length 5-1 ft., width 35 ft., height -l-6 ft.,
and weight 365 tons. The lower deck consists of the air
conditioned control room, the gas generator, power tur·
bine, gearbox, two barrel compressors, lube and seal oil
system, process valves and scrubbers. These are ar·
ranged as shown in Figure 3. Mounted in the top deck
are the fin fan coolers, fuel system, glycol dehydrator,
and after-scrubber.
Figure -!., which is a view of the bottom deck looking
at the service end of high pressure compressor, shows
the inlet and discharge pipes to the compressors, the
scrubbers Sl, 52, and 53, as well as the water sprinkler
piping on the scrubbers, etc. Figure 2. The Single Lift Package.
28 l'IWCEEDI:\fGS OF THE FmST TCRllOMACHfNERY SYMPOSIL'M

�ases isentropically (efficiency = 100'/r I to ambient

pressure through a turbine. The inlet system to the
en!!ine eonsists of a filter. a silencer, and a plenum
ch�mher. The �as generator is started using a gas
tNLfT expander. The expanded is housed inside the plenum
fiLTH chamher and drin•s a shaft through the inlet bullet nose
L
SIL�NCEt
PLE.NUM o f the en�me.

FREE PO\'\'ER TCRBf�E

Thi.- is a Dresser Clark :VIodel PT 12.5 single stage
turbine 11ith adj ustable stator to facilitate matching of
any of the other gas generators in this power class like
Pratt &: \\'hitney GG:} and GE LM 1500.

Figures 6 and "i show a perspective and a sectional

dew of the turbine. The exhaust �ases are dueled hori·
zontally to a side of the platform and \'erlically clearing
the coolers on t he top deck. The exhaust system in·
dudes a silencer.
Figure 3. Arrangement on the Lmrer Deck.
Fi�ure B shows the performance o f the gas turbine
1 GG + PT or DJ 1251 . The NL\IA rating of this unit
is ]:�500 HP at a power turhine speed o f 5:330 RPli
Compollellls-Des<'riptioll am/ llwir 11 ilh a heal rate of 10,000 BTC HP - H R.

Rated Perjorma11ce
GEARS
G AS GE NE RATOR
This is a speed increasing high speed gear dri\e
The gas generator is a �as hurnin� Roll� Royce 11ith helical �ears and has a gear ratio o f 1.1:62. This
Avon MK 153.3-iS G. as shown in Fi:.wre S. This is an is connected to power turbine and the compressors hy
'
aircraft derivath·e �ngine derated to inerea;;e the time �ear type. continuously lubricated flexible couplings with
between over-all TBO. to aho1·e 20000 hr�. at hase load. In draulic fits.
The base load ISO 5<JoF and sea le1 eL ralin� hein�
. .

1<J�to0 E G HP. E G HP, exhaust �as horsepo11er, is the

LO\\' PRESSCRE COMPRESSOR
horsepower that could he produced h�· expandin� t he
This is a barrel· type Dres�er Clark Nlodel 5s:m6.
6-stage cenlrifui!al compressor. A halanee piston is used
to reduce the thrust on the thrust hearing. Two prox·
imity type probes at each o f the 1110 tilt pad bearings
sen·e to pick up the l'ihration;; of the rotor. The de><ip;n
pressure ratio is 5.11 at an inlet flow o f B2H"i ACF:\I.
The inlet pres;;ure is maintained at 50 psi� hy a pre:<sure
control \'al\'e. Figure <J shows the performarH"e o f this
compressor.

HIGH PRESSt"RE CO:\IPHESSOR

This is also a barrd type Dresser Clark :\fodel
212116 1. compressor 11ith 6 + I stages arranged back
to hack to reduce the thru;;t. Figure J. ,.bows the inlet
'
of the second section at the ;;en·ice end o f the compressor
and the final exit next to the exit o f the first section
illustrating the hack-to-hal'k arran�ement. The gas is
intercooled a fkr six sta�es o f compression. The thru;;L
hearing is housed on the sen· ice end as shm1n in Figure
10. Two pro xi mit�· t� pe prohes pick up the \·ihrations
at the lwo tilt pad hearinl!'"· The drain oil temperatures
are monitored !'ontinuousl� and re!·orded. The design
conditions and the operating range are as shown in
Figure 1 1.

COO LE RS
The two intercoolers. the a ftercooler and the lube
oil cooler are all of fin fan l� pe air coolers. The fans
Figure 4. View-Looking at Service End of Dresser­ are driven IJ\ four 50 HP electric motors. The electric
Clark 27286/4 Compressor. power is nori nully drawn from 2.50 1\:W generator which
 COMMISSTONING A GAS Tt'HBINE COJ\H'RESSOH SINGLE LIFT PACKA.GE 2\J
FOR OFFSHOHE GAS REINJECTION AI'l'LlGAT!ON

r
STAGE 7
l!LEED ALVE

FUR MANIFOLD

COOLING

I 1'2 PICK-UP
CONNECTION
AIR OUTlET

VIBRATION PICK-UP CANNON PlUGS

MOUNTING POINT -L L HARNESS

LEFT-HAND VIEW OF ENGINE

EXHAUST UNIT /
/
CENTRIFUGAl
PRESSURE BALANCE
/
lk I
CONNECTION TO OIL TAN

BREATHER INTAKE GUIDE VANE RAM

CONNECTION FUEL CONTROL BOX AND BLEED VALVE CONTROL UNIT

RIGHT-HAND VIEW OF ENGINE

AVON GAS GENERATOR WITH GAS FUEL SYSTEM

(Shown with intake flare)

Fi{!,urc 5. Cas Generator.

30 PROCEEDINGS OF THE FIRST TURBOMACHINERY SYMPOSIUM

EXHAUST
CASE

Figure 6. Cutaway-PT 125 Power Turbine.

is driven off one of the output shafts of the main gear valve, PCV, is a butterfly type and is housed at the exit
drive. The process gas coolers have a pressure drop of scrubber Sl, as seen in Figure 4. The recycle valves
of 10 to 15 psi. and the temperature control valve, TCV, are mounted
on the floor of the lower deck.
PROC ESS SCRUBBERS AND VALVES FU E L SYST EM
The scrubbers are designed to an ASM E vessel
The fuel is normally drawn from the process scrub­
code. Each vessel is provided with a relief valve set
ber S2. The external source cuts in through a check
at the corresponding over-pressure. The vented gas
valve if the process pressure is lower than that of the
through these relief valves joins a vent pipe and is piped
external source. The system is housed on the floor of
away from the platform. The liquid levels are controlled
the top deck and consists of positive shut-off valves,
by float type valves which discharge the liquids in a
regulator, filter, liquid trap, relief valve set at 230 psig,
sequence from a high pressure low pressure vessel and
and a flow measuring orifice.
finally to a sump.
CONTROL SYS T EM
All the process valves are mounted on the lower
deck and are pneumatically operated. The opening and The control panel, Figure 12, is located in the con­
closing of inlet, discharge and vent valves are built into trol room. It is a free-standing design containing all
starting and shutdown sequence. The pressure control the necessary protective relays, timing circuits and mode
 (1
0
�
�
00
en

0
"'lZ
o-
� z
CJ
� >
"'lCJ
en >
:I: en
0
��
Mr:::
CJ�
>�
rn z
�
M
1:':1
n
zo
.... �
1:':1-o
(1�
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-en
Om
Zo
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-om
-o-
t'"'Z
-CJ
(l t'"'
>tr:�
::lt'"'
o-
Z::4
�(1
�
CJ
1:':1

Figure 7. Cross Section-PT 125 Power Turbine.

�
.....
32 PROCEEDINGS OF THE FIRST TURBOMACHINERY SYMPOSIUM

S!ANnARD INLET AND ExiT losSES

BAse LoAD, 100% Pr SPEED
laiD

il
I
J3ll) 1n9 on
anti-1c

IIHH

��
"
llffiJ
I
lJJ

�
ft
��
-;.u
��-

l
II mil

-·
•

l())l) -I
•
mJ
-20 0 20 � ro 100

Figure 8. Performance-Dresser-Clark D! 125 Gas Turbine.

 COMMISSIONING A GAS TURBINE COMPRI-:SSOH SINGLE LIFT PACKAGE
FOR OFFSHORE GAS REIN.JECTION APPLICATION

c
_)
��
"" 347 ?SIA_
PIN � 64.7 PS!A � PrN
PCXlT � 352,0 PS!A
X
"' Pcxn � l8.1S PSIA
T � 9'l'F IE 3 TIN � 115'F
'!N lOS
1'oL WT. = 23.� w f'Dl Wr � 22.3
'5 2 I
Cffil SPEED
Rfl>1 = 'JJ:Xl I Rf!1
lli
ACFM = 8287 "'
Affil 1':57
� 1
�

s
0
3 8 lD

l Ni.Jo'l VOLLI"E ACFM X

Figure 9. }i;fap of 5SJB6 Compressor. ID ll Q B Y � � V �

1NLE1 � - ACf-1", X m-2

selector �.11itche� for safe op(Talion of the unit. The Figure 11. Map of 272ll6, 4 Compressor.
normal de�ig:n philosophy of fully automatic, self-protec­
.
tive �\�!.em 11hich sc<p!encc'l and ('Otllrol� Ihe unit
thnmg lwut the operating r ane:e is used. Fignn� U LtHE AND SI·: A L O I L SYS'fE.\lS
illustrates the basic control S\S!em. The primar·1· loop There are l\\ '' sYstems: one for ;.;:as generator and
is pressure control. Speed and temperature control loopc. one for po wer turhin � . gt•ar !lri1 c and �:ornpres�or�. The
are incorporated for machine protection and \\ill O\'Cr· gas generalor lubricn!ion �\ :o!.tm con;oi�!� nutinl! of a
ride the pn:ssure contr(•l if !In: load demand exceed:-; !he :SO-p:allon resenoir. :.1-;c:<dlon huppe r, a df·mi.•ler, dllpl•:x
gas tur!Jine capability. The set point of each lt�rnpera­ filler� and cookrs. The oil le1 el in the c;c �ump, � ame
lure and !'peed controller is placed a! the maxirnum r:on­ as that in the g.f.'allr>n lwppeL is maintained hy a float
linuous Yillue for oplintum machine life. The Sj skm \alve 11hich dra11s oil fron1 tlte re.'-('noir b' grm·itY.
is basintlly electronic 11ith a crHn ersion to pneumatic Lo11· h'l·el a!ann for tht: n·sennir i;• �d to ,:.:i1 e ennu;rh
and then hydraulic al the final contrn! element <Hl lhe pre-11<lrning to allo11 several days before lhe resenoir
;.ca� gellerator. The serp1encing s;stem 11hich ntonilors ; 1eed be filled.
startup and shutdt•lltl and the unit protective de1 ices
are powered !,y a 21V battery supply.
In addition to the temperature, "P''ed, and vibration
Inonitors located on the f<tce of the panel. there are
annunciator lights to indicate tlw operali11g condition
'
of the unit. I'he nect.':lS<lfY rda\,;, fc•r lo�ic and mal·
.
function indication are contained inside the panel. \\ ith
the exception of the p1s generator. all unit-nw1mted
wiring and electri<:al dcvic·�� are desi;.med in accordance
'
11ith the National Electrical Code, Class 1, Group D,
Division 1 requirements.

Figure 10. Cutaway-Compressor's Seals and Bearings. Figure 12. Control Panel.
34 PROCEEDINGS OF THE FIRST TCRBOMACHINERY SYMPOSIUM

the auxiliary and emergency pumps are off. Each pump

is capable of maintaining approximately 150/{ maximum
supply required. If the float of the operative pump falls
below 125(;i of the capacity, the other pump will start
automatically. Each pump is equipped with individual
relief and isolation valves. Air or gas driven emergency
pump will supply sufficient oil for run-down and cool­
down when neither of the electric driven pumps is avail­
able. It is necessary to maintain an oil supply after
shutdown to a\·oid overheating the forward bearing of
the power turbine due to "soakback" from the disc.
This flow is maintained for about two hours, which is
why a pump takes the place of a tank for rundown. The
lubrication circuit is as shown in Figure U. As required,
oil passes from any of the three pumps' discharge to
the cooler: excess oil being bypassed through a back­
pressure regulator and returned to the reservoir. The
oil coolers that are mounted on the top deck are tube
Figure 13. Basic Control System. type air to oil. A temperature sensing three-way valve
acts to bypass oil around the cooler as required to main·
tain the desired header temperature of about 120°F.
The turbine, gear drive, and compressor lube and After leaving the cooler circuit, the oil passes through
seal oil system have two back-up pumps and a main a duplex filter assembly before being distributed to the
pump. The main pump will normally be in service while bearings and seal oil tanks through one of the seal oil

,----------.
I I Turbine
I I Compressor
I I Coupling
Return t o
: !Juplex I neservofr
I 10 r�i cron "===
.,. F i1 ters V

...
I
I
I
I
I
I
I
I
I
I
Emergency
Lube 011
Pump
n
Differential
Pressure
Reference
Control
Valve
1-
--+ ...- Gas
Pressure

Sweet Oil
Compressor
Return To
Seals
Reservoir

DeQassifyfng
Sour 011
Tanir
Traps

Figure 14. Schematic of Turbine/Compressor Lube and Seal Oil System.

 COMMISSIONING A GAS TURBINE COMPRESSOR SINGLE LIFT PACKAGE 35
FOR OFFSHORE GAS REINJECTION APPLICATION

3
TIME IN MUfUTES

Figure 15. Starting Sequence.

pumps. The seal oil tanks maintain a gas to oil differ· Then the recycle valves automatically take over control
ential of 5 psi across the seals. Gravity drains from and start closing as the gas turbine puts out more power
the bearing cases to the tank complete the cycle. to meet the demand of the controller.
9. The unit is fully on line.
STARTING S EQU ENC E
Time relays will abort the sequence if any of the
Figure 15 illustrates the starting sequence. The unit
functions are not fulfilled within the pre-set time. For
may be started by contact closure from a remote loca­
example, if the gas generator exhaust gas temperature
tion or by pushbutton actuation on the control panel.
does not record at least 450°F in ten seconds after the
The sequence, once initiated, is automatic, as follows:
ignition signal, the sequence will be aborted.
1. Auxiliaries are started.
2. Unit valves are programmed. PROTECTIVE D EVICES

3. System is pressurized. The whole unit is protected from the following

hazards:
4. Gas generator starter is energized.
1. overspeed
5. Ignition occurs.
2. high pressure
6. Unit accelerates to idle, gas generator at 3-tOO
RPM, power turbine at 1200 RPM. a. Starter is dis­ 3. high temperature
engaged; b. Ignitor is de-energized; c. Warm · up 4. fire
timer energized {IS minutes).
5. surging of compressors
7. Unit accelerates at end of warm-up period at a
rate determined by acceleration rate control setting until 6. excessive vibration
discharge pressure controller regulates the signal to the ·

governor. 7. lube oil failure and consequent high bearing

temperatures
8. During acceleration the recycle valves are fully
open till the unit attains a certain discharge pressure. 8. high liquid levels in scrubbers
36 PROCEEDINGS OF THE FIRST TCRBOMACHINERY SYMPOSICM

9. proper deceleration during an emeqrenc�- shut­ d. Liquid entrainment-Automatic discharging of

down caused by any o f the mal functions causing a shut­ liquids from \ arious \·essels protects the compressor from
down, etc. an�· liciuids entering the compreEsor. Eaeh scrubber has
a float operated ,-ah·e and an alarm and shutdo wn are
10. hazardous atmosphere
initiated i f high liquid le,·els are experienced.
Each o f the components are protecterl from any or
e. Hil!h discharge temperature - An emergency
all of these possible hazards.
shutdown is initiated if the discharge temperature o f the
The gas generator is protected from excessi\·e ,-ihra­ compressors reaches 31)0°F.
tions, lo w fuel gas pressure. high liquid lew! in the filter,
f. Surge-The surge control system is designed to
alarms and shutdowns due to low or high lube oil level,
in addition to overspeed and o\·ertempe i ·ature. etc. The enable running the compressors away from surge line
by recycling the extra flo w required i f the process line
gas generator is enclosed in an acoustic enclosure and
kept at moderate temperatures by a fan blower. A ther­ flo w were to drop. The ,-alves are controlled to enable
the compressors to follow the control line automaticallv
mal fire sensing element triggers the emeqrency shut­
down as well as carbon dioxide fire extinguisher system. by sensing the di f ferential static pressure. �Pr, acro �s
the inner and outer radii o f a 90° bend which measures
Fusible links, set to fuse at 260°F, close, allowing the \·olume flo w through the compressor and by sensing
louvers to contain the carbon dioxide being spray e d a di fferential pressure, �P. across the compressor. The
inside the enclosure. equation of the control line in the control range from
The control room is air-conditioned and is equipped about ao;,; speed to 1().')'.; speed is given by
with a smoke detector and a combustible mixture de­
�P .... '""'''''"'"' = K1 .lPr + K� fl I
tector. The combustible mixture detector will both
alarm and shut the unit do wn depending upon the where K1 and K � are constants that depend upon the
strength of the mixture. elbo w size. gas gravity, compressor characteristic, etc.
The surge control system becomes e ffective only above
To protect the po wer turbine from dangerously
a pre-set pressure di f ferential across the compressor.
excessive speed in case o f an abrupt drop in load, an
Belo w this, the recycle valves are kept open so as to keep
overspeed trip set at l lOij; o f design RPM is built into
the compressor a way from the surge during startup and
the emergency shutdown circuit. This overspeed trip
was required even though the po wer turbine speed is one shutdown. The recycle valves are sized for full design
o f the controller set points of the basic control system. flo w in order to fa �ilitate the testing o f this platform �at
design condition in essentially t wo closed loops.
The three drain oil bearing temperatures are a measure
of bearing temperatures and are monitored and recorded g. Lo w inlet temperature-The high pressure com­
continuously. An emergency shutdown is initiated if pressor, 212B, is protected from exce�si,·ely low inlet
any of these temperatures reach a pre-set value. A temperatures when the unit is on recycle through the
velocity pickup serves as a vibration monitor and the use o f a thermal control valve, TCV. This TCV bypasses
amplitude is displayed in the control room. Vibration the required amount o f hot gases to the inlet o f RCV 2
levels are alarmed at pre-set levels and the unit is shut and maintains a set temperature o f ll.5°F at the inlet
down in the event o f excessive vibration. o f 212B6 -1- compressor by sensing the temperature do wn­
Vibrations on the gearbox are sensed by a velocity stream of RCV 2. An a dditional thermocouple senses
pickup. Alarm and shutdo wn are executed at pre-set the inlet temperature o f 272 to cause a shutdo wn i f the
levels, and the amplitude is displayed in the control room. temperature drops belo w 6.5°F. This protection is not
The six bearing drain oil temperatures are continuously required across 553B compressor because of small drop
recorded. The unit will he shut do wn if any of these in temperature due to Joule Thompson effect.
temperatures exceed a pre-set value.
h. Excessive thrust and re\·erse rotation-The com­
All the scrubbers are protected from excessive pres­ pressors are further protected from reverse rotation and
sure by relief valves. They are also protected against high thrust condition on 212B during an emergency
overheating in case o f a fire by a thermal sensing element shutdown. This is accomplishe d by 11 sizing the ,-ent
which activates the water sprinkler system. valve as a compromise between high thrust and re\·erse
Compressor Protection. rotation and opening it at the instant o f an emergency
shutdown: 21 delaying the closing o f the station inlet
a. High vibration-by proximity type probes which
vah·e: and, 31 opening the recycle valves in�tantaneously
measure the amplitude and frequency o f the sha ft near
on an emergency shutdo wn.
the four bearings. The amplitude is displaye d in the
control room. The alarms and shutdo wns are initiated Hand-operated liquid drain valves are installed at
at pre-set amplitudes. several places in order to purge the system of any liquids
that may accumulate.
b. High hearing temperatures-The drain oil tem·
peratures are continuously recorded and serve to alarm
T EST ING OF CO:\IPONENTS
and shut down if excessive.
Total testing was accomplished m four stages as
c. Seal leakage-The oil side pressures of the seals
follows:
are maintained at .5 psi above the gas pressure across
the seal bv overhead tanks whose le,·els are controlled. 1. Full load test of Dresser Clark Model DJ 125
Low and high level alarms are incorporated in a ddition gas turbine for mechanical integrity, controls, and per­
to a low level shutdown. formance in the closed loop test facility.
 COMMISSIONING A GAS TCRBL\'E COMPRESSOR SIXGLE LIFT PACKAGE 37
FOR OFFSHORE GAS HEIXJECTIOX Al'I'LICATIOX

2. Performance tests of compressors ;).'):lB6 and Carbon dio\ ide 11 a:; clw,.en a"' the ;ras to be mixed
272B 6 -!. 11ere conducted at full speed but under re duced 11ith the local natural ;ras in order to "imulate the mol
pressures in a closed loop test facility. :\lechanical tests 11ei;rht of field gas. Th� ,-tation inlet pipe 11as con­
were conducted on seal and hearing test rig that simu­ neded to the local gas line 11ith a regulator. The plat­
lates the dynamics of the rotor. form 11as fully instrumented and included a graYitome­
ter. pressure probes. etc.. and the inlet pipe elbows 1rere
3. The total platform package 11as tested at full
used to measure the ,-olume flow through the com­
speed and reduced pressure conditions 11ith low mol
pressors.
weight local natural gas and at full loa d conditions 11ith
natural gas and carbon dioxide mixture. The process s� stem 11as hydroteste d to conform with
the AS:\.IE code. A series of static and dmamic checks
..t.. Final acceptance test at the site under field
11as made on the con trol system 11ith th� compressors
design conditions during February 1<J72.
uncoupled from the turbine. A complete control system
check was made 11ith the compressors coupled using
G AS TCRBINE
natural gas alone. followed 1)\- a few intentional emer­
The purpose of this test was to insure the mechanical .
gency shutdowns to ensure the operation of \·enting
integrity, proper function of all controls of gas turbine. system, etc.
matchinl,! of free power turbine and the !!as l,!enerator
:Many normal assembly and starting problems were
and measuring the power output at design conditions.
corrected in addition to a djusting and calibrating of con­
The Houston test facility enables us to test gas turbines
trol circuit and auxiliary systems. The performance
under full load conditioi1s of up to 17,500 HP by using
results indicated that the unit would exceed the design.
a pipeline compressor as the load device. The closed
The control sYstem demonstrated that it would auto­
loop is designed for a maximum pressure of l 000 psia,
matically start the unit. accelerate to full speed, shift
and nitrogen is normally the working medium e1·en
e!ectrical power to p'atform generator, control to any
though any desired combination ma1· be used. The heat
of the three settings on the controller and shut do wn o�
of compression or power is dissipated by heat exchangers
command.
using channel water. An electronic torque meter meas­
ures the power at the turbine shaft. A data acquisition CO:\L\I ISSIO�I�G THE C\'I T ON SITE
system 11ith BK memory and magnetic tape device col­
The unit 11as shipped from Dresser. Packaged Com­
lects data and e\·aluates it by the use of pre-written pro­
pressor Division's slip with some precautionary meas­
grams while testinl,! is in progress.
ures, such as, disassembling the couplings, clo�inrr all
"
The performance evaluation showed that the unit intakes and discharges, sealing the control room, etc.
would produce the required po wer at site and the heat The 365-ton platform was set on piles as seen in firrure
!'
rate would be better than expected. This test also ��
sho wed that the matching between free power turbine
Though many of the normal starting problems in
and the gas generator could be improved before re­
auxiliary and control systems were eliminated during
assembling the turbine on the platform in the slip.

COMPRESSOR TESTS
The closed loop facility in Olean, New York facili­
tates testing of compressors at full speed and at reduced
pressure levels. Production tests were conducted in a
closed loop using Freon 12 for 553B6 and nitrogen for
27286 ·-1. as the working mediums.
The results showed that the non-dimensional head­
flo w characteristics and the efficiencies were as expected.
The vibrations were normal on both the inlet and dis­
charge ends of the compressors. The surge line was
also checked, both at high and lo w speeds, and was
within the expected tolerance.

P L ATFOR:\.I TEST I� T HE SLIP

The platform was completely assem bled in the slip
and the test was conducted inside the slip. A special
duct was built to dump the exhaust gases of the power
turbine outside the slip.
The objectil·es of this test were: 11 to insure the
mechanical integrity of the platform, 21 to demonstrate
the satisfactory operation of the total rotating train:
gas turbine, gear drive and compressors, 31 to e liminate
the normal startup and assembly problems, -l-1 to cali­
brate the auxiliary and control systems, and 51 to verify Figure 16. Dresser-Clark Single Lift Package on the
the package performance. Piles of Offshore Platform.
38 PROCEEDINGS OF THE FIRST TCRBOMACHINERY SYMPOSIUM

the platform test in the slip, a fe w check s like liquid incident; results of the final performance test after being
knock-out systems, surge control system calibration, etc., evaluated and reduced to design conditions showed that
had to he done on the si te. The unit was run on recvcles the unit exceeded the design flow by about 2 percent at
and data points were taken including gas sampl�s in the design discharge pressure and the heat rate was 5
order to establish a surge control line for both com· percent better than design.
pressors which would maximize the operating area.
CONC LUSIONS
During an emergency shutdo wn and a command
shutdown, the high pressure gas contained in the process l. The advantages of custom-built platforms such
system was designed to be vented through the vent valve as this, designed, manufactured and commissioned by
and through the station inlet valve by delaying the clos· one manufacturer, become evident in the expeditious
ing of the inlet vah·e. This calibration of inlet valve handling of the design, testing, and commissioning of
closing was demonstrated on site as this could not be the unit.
done in the platform test on the slip.
2. The interaction and dependence of the compo·
Hot optical alignment readings were taken in order nents-compressor, turbine, controls, process system, etc.
to evaluate the train alignment under running conditions. -on each other demonstrated the advantage of one engi·
This was done by running the unit continuously on re· neering team being responsible for the analysis of the
cycles for about 8 hours in order to thermally soak the unit as a whole instead of separate components during
unit. design phase.
The unit was checked for integrity of all devices. 3. The importance and economics of pre-testing,
During these checks any engineering problems requiring and simulating field conditions as much as possible,
engineering attention were analyzed and resolved by the were demonstrated by the number of problems corrected
engineering department. on the test stand prior to shipment.
The surge control system was set and the unit was
put on stream in manual code but with the surge control ACKNOWLEDGMENT
system in automatic mode to ensure the proper takeover The efforts of my colleagues in the division who
of the surge control system at the pre-set pressure and helped me put this paper together are gratefully ac·
speed. knowledged. Special acknowledgment is due to the late
The unit was put on stream in late February 1972 Mr. James McDaniel who was the project engineer on
and has been running continuously since then with no this job.