Patent Application
20170074274
The present disclosure relates to compressors, and more specifically to so-called back-to-back compressors having a side stream between a first compressor stage and a second compressor stage arranged in a back-to-back configuration.
Centrifugal compressors are used in a wide variety of industrial applications. For instance, centrifugal compressors are used in the oil and gas industry, for boosting the pressure of hydrocarbon gases. The compression work required for compressing gas through the rotating impellers and the diffusers of a centrifugal compressor generates an axial thrust on the compressor shaft. Balancing drums are often used for reducing the total axial thrust on the shaft bearings.
Some known compressors have a so-called back-to-back configuration, which reduces the axial thrust on the compressor shaft. The delivery side of the first compressor stage faces the delivery side of the second compressor stage, so that the processed gas flows through the first compressor stage generally in one direction and through the second compressor stage in the generally opposite direction. A main stream of gas processed by the compressor is sucked at the suction side of the first compressor stage and delivered at the delivery side of the second compressor stage.
In some applications, a side stream line is provided to inject a side stream gas between the delivery side of the first compressor stage and the suction side of the second compressor stage. In some applications, the side stream gas has a chemical composition different from the chemical composition of the gas sucked in the first compressor stage. For instance, the first gas processed by the first compressor stage has a molecular weight higher than the molecular weight of the side stream gas. The gas flowing through the second compressor stage, which is a mixture of the gas from the first compressor stage and the side stream gas, thus has a mean molecular weight lower than the gas flowing through the first compressor stage.
A seal arrangement is provided on the compressor shaft, between the first compressor stage and the second compressor stage, so as to reduce backflow from the last impeller at the delivery side in the second compressor stage towards the last impeller in the first compressor stage. The seal efficiency is usually such that approximately between 10-20% by weight of the gas delivered by the last impeller in the second compressor stage flows back towards the last impeller in the first compressor stage.
The first compressor stage is provided with an antisurge arrangement, usually including a recirculating bypass line including an anti-surge valve. The bypass line connects the delivery side to the suction side of the first compressor stage. When the operating point of the first compressor stage approaches the antisurge limit line, the antisurge valve is opened and a fraction of the gas flow delivered at the delivery side of the first compressor stage is recirculated towards the suction side of the first compressor stage.
When the antisurge valve opens, the gas from the side stream which leaks through the sealing arrangement between first and second compressor stages is recirculated at the suction side of the first compressor stage. As a consequence of the antisurge gas recirculation, low molecular weight gas accumulates in the first compressor stage. The mean molecular weight of the gas processed by the first compressor stage thus decreases. Since the pressure ratio of a compressor stage is dependent upon the molecular weight of the processed gas and drops when the molecular weight diminishes, antisurge recirculation causes a drop in the pressure ratio across the first compressor stage. This can eventually result in the gas pressure at the first stage suction header to increase. In some arrangements, the pressure of the gas delivered at the suction header is limited, and cannot increase at will. In this case, a drop of the pressure ratio and consequent increase of the pressure at the compressor suction side will reduce the gas flow delivered through the suction header. Under some circumstances this situation can finally lead to a loss of gas flow through the compressor train. This situation is particularly critical when two or more compressor trains are arranged in parallel and supplied by the same gas source. As a matter of fact, in this case a pressure increase at the suction side of one compressor will result in an unbalanced gas flow, with decreasing flow rate through the compressor where the pressure ratio has dropped, and increasing flow rate through the other paralleled compressor(s).
A need therefore exists for alleviating the risk of malfunctioning of a back-to-back compressor arrangement with a low molecular weight side stream.
According to a first aspect, the subject matter disclosed herein relates to a method for operating a gas compressor including a first compressor stage and a second compressor stage in a back-to-back arrangement, the first compressor stage arranged upstream of the second compressor stage with respect to the direction of gas processed by the compressor; a seal arrangement between the first compressor stage and the second compressor stage; and a side stream line between the first compressor stage and the second compressor stage. According to some embodiments, the method provides for feeding a first gas having a first molecular weight to a suction side of the first compressor stage and compressing the first gas through the first compressor stage. The method further provides feeding a side stream flow of a second gas through the side stream line to the second compressor stage, the second gas having a molecular weight lower than the first gas. The gas mixture formed by the first and second gas is compressed through the second compressor stage. To prevent or reduce a pressure ratio drop across the first compressor stage due to recirculation of the gas mixture, e.g. when an antisurge bypass line is opened, the side-stream gas flow is reduced. This increases the pressure ratio across the second compressor stage and thus counter-acts the reduction of pressure ratio across the first compressor stage.
The method is based on the recognition that recirculation of gas for antisurge purposes in a system where the side stream gas has a molecular weight lower than the gas entering the first, upstream compressor stage, causes a reduction of the molecular weight of the gas processed by the first compressor stage. Such alteration of the molecular weight reduces the pressure ratio across the first compressor stage. To contrast or compensate for the drop of the pressure ratio, the molecular weight of the gas processed though the second compressor stage is increased by reducing the flow rate through the side stream line.
According to a further aspect, the subject matter disclosed herein relates to a first compressor stage and a second compressor stage arranged back-to back with a seal arrangement therebetween. The system further includes a side stream line in fluid communication with the suction side of the second compressor stage, for delivering a side stream gas flow having a molecular weight lower than the molecular weight of a main gas flow delivered at the suction side of the first compressor stage. A side stream valve and a side stream controller are further provided for adjusting the flow of the second gas through the side stream line. An antisurge arrangement including a bypass line and an antisurge valve is combined with the first compressor stage. The antisurge valve is opened, if required, for recirculating a portion of the gas flow processed by the first compressor stage, in order to prevent surging phenomena in the first compressor stage. A transducer arrangement is additionally provided for detecting at least one pressure parameter of the first compressor stage, e.g. the pressure ratio and/or the suction pressure. The side stream controller is configured for reducing the flow of gas through the side stream when the pressure transducer arrangement detects an alteration of the pressure parameter indicative of a reduction of a pressure ratio across the first compressor stage provoked by a recirculation of gas through the antisurge arrangement.
Features and embodiments are disclosed here below and are further set forth in the appended claims, which form an integral part of the present description. The above brief description sets forth features of the various embodiments of the present invention in order that the detailed description that follows may be better understood and in order that the present contributions to the art may be better appreciated. There are, of course, other features of the invention that will be described hereinafter and which will be set forth in the appended claims. In this respect, before explaining several embodiments of the invention in details, it is understood that the various embodiments of the invention are not limited in their application to the details of the construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which the disclosure is based, may readily be utilized as a basis for designing other structures, methods, and/or systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
A more complete appreciation of the disclosed embodiments of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
The following detailed description of the exemplary embodiments refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. Additionally, the drawings are not necessarily drawn to scale. Also, the following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims.
Reference throughout the specification to “one embodiment” or “an embodiment” or “some embodiments” means that the particular feature, structure or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrase “in one embodiment” or “in an embodiment” or “in some embodiments” in various places throughout the specification is not necessarily referring to the same embodiment(s). Further, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.
The compressor 1 can be a vertically split compressor with a barrel 5A and two head end covers 3B, 3C. In other embodiments, not shown, the compressor can be a horizontally split compressor with a casing including two halves matching along a substantially horizontal plane containing the rotation axis of the compressor shaft.
In the embodiment shown in
The suction side 10 can include a gas inlet plenum in fluid communication with the first impeller 7. The delivery side 11 can include a volute, wherefrom the gas is collected and further conveyed through connecting ducts (not shown in
According to some embodiments, the second compressor stage 1B includes one or more impellers 13 mounted on shaft 5 for rotation around rotation axis A-A. The second compressor stage further includes diffusers 14 and return channels 15 formed in a compressor diaphragm and defining a second compression path for the gas processed by the second compressor stage 1B.
The gas enters the second compressor stage 1B at the inlet or suction side 12 and is sequentially processed through the impellers, diffusers and return channels of the second compressor stage 1B. Compressed gas is finally delivered at a delivery side 16 of the second compressor stage 1B, which also represents the delivery side of compressor 1. The delivery side 16 of compressor 1 can include a volute which collects the gas from the diffuser of the last impeller and conveys the compressed gas towards an outlet duct, not shown.
Between the last impeller 7L of the first compressor stage 1A and the last impeller 13L of the second compressor stage 113 a sealing arrangement 17 is provided around the compressor shaft 5. The sealing arrangement 17 reduces leakages along the shaft 5 from the last impeller 13L of the second compressor stage 1B, where the gas has achieved a higher pressure, towards the last impeller 7L of the first compressor stage 1A, where the gas is at a lower pressure. The sealing arrangement can be comprised of a labyrinth seal, for instance.
In spite of the sealing arrangement, during compressor operation a leakage of between 10-20%, typically between around 15% and 18% by weight flows from the second compressor stage 1B towards the first compressor stage 1A and is returned at the suction side 12 of the second compressor stage 1B.
As best shown in
In the schematic of
Reference number 21 denotes a bypass line of an antisurge arrangement for the first compressor stage 1A. Reference number 23 denotes a respective antisurge valve arranged on bypass line 21. A transducer arrangement 24 can be provided at the compressor inlet. In some embodiments the transducer arrangement 24 can include a pressure transducer 25, which detects the gas pressure at the suction side of the compressor 1, i.e. at the suction side of first compressor stage 1A. The transducer arrangement 24 can further include a flow transducer 27 to detect the gas flow rate at the suction side of compressor 1. According to some embodiments, the transducer arrangement 24 can include a temperature transducer 29, which detects the gas flow temperature at the suction side of compressor 1. In general terms, the transducer arrangement 24 is comprised of those instrumentalities which are required by the anti surge control used for the specific compressor stage 1A.
The second compressor stage 1B can be provided with a separate antisurge arrangement. Referring again to
The antisurge systems can operate according to any available antisurge algorithm known to those skilled in the art of compressor control. The details of the antisurge algorithms need not be described herein. Suffice it to recall that the antisurge valve will open when the operating point of the compressor stage approaches the surge limit line, preventing surge phenomena to arise in the compressor stage. Antisurge recirculation of the gas flow through the bypass line 21 or 31 is required when the gas flow ingested at the suction side of the compressor stage is insufficient to maintain the compressor stage in stable operation conditions.
During operation, a first or main gas flow F1 is delivered to the suction side 10 of the first compressor stage 1A and is processed through the first compressor stage 1A. The gas of the first gas flow has a first molecular weight MW1. The gas composition can be constant or variable during operation of the compressor. For the sake of the present disclosure, the molecular weight MW1 is assumed to be constant or quasi-constant.
A second gas flow F2 is delivered as a side-stream gas flow along the side stream line 19 at the suction side 12 of the second compressor stage 1B. The gas delivered through the side stream line 19 has a second molecular weight MW2, lower than the first molecular weight MW1. For the sake of the present disclosure, the second molecular weight MW2 is assumed to be constant during operation.
The side-stream gas flow F2 mixes with the main gas flow F1 delivered from the delivery side 11 of the first compressor stage 1A. The gas mixture F3 of the first gas flow F1 and second gas flow F2 is processed through the second compressor stage 1B. The mean molecular weight MW3 of the gas processed through the second compressor stage 1B is lower than the molecular weight MW1 of the first gas processed by the first compressor stage 1A, due to the contribution of the side stream gas having a molecular weight MW2 lower than MW1.
During normal operation, a leakage flow FL due to the pressure drop across the sealing arrangement 17 flows form the delivery side 16 of the second compressor stage 1B towards the delivery side 11 of the first compressor stage 1A. Even though the leakage flow FL has a molecular weight MW3 lower than the first gas flow F1, the leakage flow FL does not affect the operating conditions of the first compressor stage 1A, since the leakage flow FL is not processed through the first compressor stage, but is rather directly returned to the inlet 12 of the second compressor stage 1B.
When the first compressor stage 1A operates far from the surge limit line, the antisurge valve 23 is closed. However, if the operating point of the first compressor stage 1A approaches the surge limit line, schematically represented at SL in the flow-vs-pressure ratio (flow/head) diagram of
The pressure ratio of both compressor stages 1A, 1B is dependent upon the molecular weight of the processed gas. More specifically, the pressure ratio decreases when the molecular weight decreases, and vice-versa.
The pressure ratio across the first compressor stage 1A thus provides an indirect measure of the mean molecular weight MW1 of the gas processed through the first compressor stage 1A, When the antisurge control opens the anti surge valve 23, the pressure ratio across the first compressor stage 1A, or more generally a pressure parameter related thereto, e.g. the suction side pressure P3, will provide an indirect indication of an alteration of the molecular weight of the gas processed by the first compressor stage 1A, due to recirculation of a fraction of low-molecular weight gas from the anti surge bypass line 12.
According to some embodiments, a drop in the pressure ratio can be detected by the pressure transducers 25, 35 at the suction side 10 of the first compressor stage 1A and at the suction side of the second compressor stage 1B. The pressure ratio P2/P1 can be used as a pressure parameter of the first compressor stage, which provides indirect evidence of an alteration of the molecular weight of the gas being processed through the first compressor stage 1A.
According to other embodiments, the pressure P1 at the suction side 10 of the first compressor stage 1A can be used as a parameter to determine if the molecular weight of the gas is changing. For instance, if the pressure P3 at the delivery of compressor 1 is fixed, a drop of the molecular weight MW1 will cause an increase of the suction pressure P1, as the delivery pressure P3 and the inter-stage pressure P2 remaining constant.
If the pressure P1 at the suction header 40 increases due to the reduction of molecular weight of the gas processed by compressor stage 1A, the flow rate through the compressor 1 will also drop until finally the upstream process supplying the gas to the suction header 40 of the first compressor stage 1A will not be capable of delivering gas flow towards the compressor. Finally, the gas flow through compressor 1 will stop.
To prevent final collapse of the gas flow through the compressor 1, if an increase of the suction pressure P1 is detected, or else if a reduction of the pressure ratio P2/P1 is detected, the side-stream controller 22 acts upon the side-stream valve 20 to reduce the side-stream flow. Upon reduction of the side-stream flow, the mean molecular weight MW3 of the gas processed by the second compressor stage 1B increases, since the percentage of low molecular weight gas from the side stream line 19 reduces.
This in turn results in an increased pressure ratio P3/P2. If the delivery pressure P3 is constant, the suction pressure P2 of the second compressor stage 1B and consequently the suction pressure P1 of the first compressor stage 1A will drop as a consequence of the increase of molecular weight of the gas flow F3 processed by the second compressor stage 1B.
In some embodiments, the side stream flow control based on variations of the suction pressure P1 at the suction side 10 of compressor stage 1A is enabled only if the antisurge control of the first compressor stage 1A is active, i.e. if the antisurge valve 23 is at least partly open, and/or if the first compressor stage 1A is approaching the surge line SL. This prevents reduction of side stream flow in case of a drop of the pressure ratio P2/P1 due e.g. to the operating point of compressor stage 1A moving towards the right side of the head/flow chart (
The control of the pressure ratio via adjustment of the side-stream flow rate can be best appreciated looking at
The side-stream flow rate can thus be adjusted until the suction pressure P1 of the compressor stage 1A reaches a set point, preventing collapse of the flow through compressor 1
While the disclosed embodiments of the subject matter described herein have been shown in the drawings and fully described above with particularity and detail in connection with several exemplary embodiments, it will be apparent to those of ordinary skill in the art that many modifications, changes, and omissions are possible without materially departing from the novel teachings, the principles and concepts set forth herein, and advantages of the subject matter recited in the appended claims. Hence, the proper scope of the disclosed innovations should be determined only by the broadest interpretation of the appended claims so as to encompass all such modifications, changes, and omissions. Different features, structures and instrumentalities of the various embodiments can be differently combined.
| Number | Date | Country | Kind |
|---|---|---|---|
| FI2014A000044 | Mar 2014 | IT | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2015/054289 | 3/2/2015 | WO | 00 |
