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Article Type

Original Study

Abstract

This paper is a field-based performance assessment of a multi-stage natural gas compressor that is operating in realistic industrial conditions. The data is analyzed using the real operating data taken in a particular oil and gas plant and, therefore, the actual operating data is used to determine the trends of thermodynamic behavior, energy consumption, and efficiency, instead of theoretical or simulation-based assumptions. The analysis was performed phase by phase in order to examine the distribution of pressure ratios, temperature increase and power consumption in the compressor stages. The findings demonstrate that there is a significant difference between the power of compressing calculated and measured electrical which is an important data of mechanical and electrical loss as compared to the total energy power consumption. The efficiency analysis has shown that compressor is most efficient at intermediate values of operation but deteriorates at high pressure ratios because it has more irreversibility's and less effective intercooling. Stage-wise analysis shows that the first compression stage occupies the most power consumption and is the one with the worst thermal loading. The performance analysis of intercoolers establishes that it is a key component in compressing work and managing discharge temperatures and downstream intercoolers has more performance and is more effective than the first one. The results have highlighted the importance of making an overall compressor efficient; this calls on an integrated approach that incorporates thermodynamic optimization, reduction in losses, and proper thermal management. The results of this research offer implications to practical operations optimization, maintenance and energy efficiency improvement in multi-stage gas compression system in industries.

Keywords

Multi-stage gas compressor, Energy efficiency, Intercooling effectiveness, Power losses, Stage-wise analysis, Industrial operation

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