What is Natural Gas Compressor?

A natural gas compressor is a mechanical device that increases the pressure of natural gas by reducing its volume. This process is essential throughout the natural gas industry, including in gas lift, reinjection of gas for pressure maintenance, gas gathering, processing operations, transmission and distribution systems, and even reducing gas volume for shipment by tankers or for storage .

These compressors enable the efficient movement of natural gas from production sites all the way to customer distribution systems . Operating at higher pressures provides significant benefits, such as the ability to transmit larger gas volumes through a given pipeline size, lower transmission losses due to friction, and the capability to transmit gas over long distances without needing additional boosting stations .
 

Types of Natural Gas Compressors

In gas transmission, two basic types of compressors are predominantly used :

• Reciprocating Compressors: These are typically driven by electric motors or gas engines and use piston-like movements to compress gas. They are often configured as stationary units with features like air cooling and oil-free lubrication .

• Centrifugal Compressors: These utilize rotating impellers to accelerate gas and convert velocity to pressure, often driven by gas turbines or electric motors.

Another specialized category is the natural gas booster compressor, which is specifically designed for pressure enhancement applications. These devices can use various drive sources including compressed air, nitrogen, water steam, or natural gas itself . They're commonly used in industrial applications for tasks such as,high-pressure bottle filling, and converting low-pressure gas to high-pressure gas .

Key Applications of Natural Gas Compressors

Natural gas compressors serve critical functions across multiple sectors:

• Transmission Pipelines: Moving large volumes of natural gas over long distances 

• Storage Applications: Compressing gas for storage in underground facilities or high-pressure tanks

• Distribution Systems: Maintaining pressure throughout local distribution networks 

• Processing Operations: Circulating gas through treatment and processing systems 

• Gas Lift & Reinjection: Enhancing oil recovery through gas lift or maintaining reservoir pressure through gas reinjection 

• CNG Applications: Compressing natural gas for use as vehicle fuel or for specialized transport

Understanding Natural Gas Compressor Cost

The natural gas compressor cost varies significantly based on type, capacity, specifications, and application requirements. Several factors influence the overall investment:

• Initial Equipment Cost: Basic industrial natural gas compressors can range from approximately $10,000 for standard units up to $30,000 or more for specialized configurations with enhanced capabilities .

• Drive Systems: Units powered by electric motors (common voltage includes 380V/3ph/50Hz)  may have different cost structures compared to those driven by natural gas engines .

• Additional Features: Factors like air cooling systems, noise reduction capabilities ("silent" models), lubrication methods (oil-free lubrication), and special materials can affect pricing .

• Installation & Commissioning: These costs can be substantial, including foundation preparation, piping systems, electrical connections, and startup services.

• Operational Expenses: Fuel or energy costs represent a significant portion of long-term operating expenses .

Life cycle cost analysis—considering capital cost, maintenance costs (including overhaul and spare parts), and fuel or energy costs—is crucial for making informed equipment selections .

For businesses seeking reliable natural gas compressor solutions, AZS Compressor offers a range of products designed for various applications and requirements.

Gas Compressor Maintenance Essentials

Proper gas compressor maintenance is crucial for ensuring optimal performance, extending equipment lifespan, and preventing costly downtime. As the core equipment in natural gas production enterprises, appropriate maintenance methods significantly improve efficiency and ensure normal operation .

Key maintenance practices include:

• Regular Inspection & Monitoring: Implement scheduled checks of critical components including PLC systems, pressure vessels, engines, gears, motors, pumps, bearings, and gearboxes .

• Preventive Maintenance Schedule: Establish routine maintenance intervals based on operating hours or calendar time, focusing on wear components and filtration systems.

• Performance Monitoring: Track compressor efficiency, pressure outputs, and temperature profiles to identify developing issues before they cause failures.

• Lubrication Management: Even with oil-free lubrication systems , proper maintenance of lubrication systems is essential for component protection.

• Safety System Checks: Regularly verify the operation of safety shutoff valves, pressure relief devices, and emergency shutdown systems.

A comprehensive maintenance program should include both daily operational checks and structured periodic maintenance activities. Regular training for personnel ensures proper operation and maintenance procedures are followed, enhancing safety and equipment reliability .

Natural Gas Booster Compressor Specifics

Natural gas booster compressor systems specialize in increasing gas pressure for specific applications where standard compressors may be insufficient. These systems feature unique characteristics that make them suitable for specialized duties:

• Multiple Drive Options: Can operate using various gas sources including compressed air, nitrogen, water steam, or natural gas itself as drive media .

• Automatic Pressure Maintenance: These systems automatically engage when pressure drops are detected, supplementing leakage to maintain constant circuit pressure .

• Enhanced Safety: Since they use gas drive without electricity, they eliminate arc and spark risks, making them suitable for flammable and explosive environments .

• Maintenance Advantages: Compared to other gas-driven pumps, they contain fewer parts and seals, simplifying maintenance requirements .

• Energy Efficiency: As pressure-stabilizing devices, they consume minimal energy when not actively boosting, making them cost-effective for intermittent duty cycles .

Selecting the Right Natural Gas Compressor

Choosing the appropriate compressor requires careful consideration of several factors:

• Application Requirements: Determine whether you need a standard compressor or a specialized natural gas booster compressor based on pressure and flow requirements.

• Total Cost of Ownership: Evaluate both initial natural gas compressor cost and long-term operational expenses, including gas compressor maintenance requirements.

• Drive Power Availability: Consider whether electric power (common specifications include 380V/3ph/50Hz)  or natural gas-driven units better suit your operational environment .

• Environmental Conditions: Account for ambient temperature, altitude, and potentially explosive atmospheres that might require specialized safety features.

• Space Constraints: Assess physical dimensions and layout requirements, noting that compact, integrated designs are available .

• Future Expansion: Consider scalability requirements and potential need for increased capacity over time.

Conclusion

Natural gas compressors are indispensable assets across the energy sector, enabling efficient transportation, processing, and utilization of natural gas resources. Understanding the different compressor types, their applications, cost considerations, and maintenance requirements is essential for selecting and operating these systems effectively.

Whether you're evaluating the natural gas compressor cost for a new project, implementing a gas compressor maintenance program to enhance reliability, or specifying a natural gas booster compressor for specialized pressure enhancement applications, proper knowledge and planning significantly impact operational success and profitability.

By considering the complete life cycle costs and maintaining a proactive maintenance approach, operators can ensure their compression systems deliver reliable performance while maximizing return on investment.