The present disclosure relates to a natural gas reciprocating compressor and, preferably, a sealed natural gas reciprocating compressor.
Reciprocating compressors are used for natural gas applications where reduced flow and relatively high-pressure rise are needed; thus, they move a substantial portion of natural gas. Typically, reciprocating compressors utilize pressure packings to seal around the piston rod and the compression cylinder, i.e., the chamber where the gas is compressed.
The pressure packing 114 prevents pressurized gas from leaking out of the compression cylinder 112, into the distance piece 118, and out into the environment. The pressure packing 114 leaks approximately 1% of the compressed gas from the compressor. Further, as the seals wear out the leakage and emissions increase fairly dramatically. Accordingly, room for improvement remains in the design of reciprocating gas compressors.
An aspect of the present disclosure is directed to a reciprocating compressor. The compressor includes a compressor frame including a drive shaft received therein, a rotary to linear motion converter coupling the drive shaft and a first end of a piston rod, and a piston coupled to a second end of the piston rod. The piston is received in a compression cylinder. An inlet valve is coupled to the compression cylinder and a discharge valve is coupled to the compression cylinder. Further, a pressure casing encasing the compressor frame and the rotary to linear motion converter is provided. A motor is preferably coupled to the drive shaft, wherein the motor is located external to the pressure casing, and a mechanical seal coupled between the drive shaft and the pressure casing.
The mechanical seal is preferably a rotating seal and, more preferably, the rotating seal is a dry gas seal. Preferably, the rotary to linear motion converter comprises a connecting rod driven by the drive shaft, and a crosshead affixed to the connecting rod, wherein the crosshead is configured to transfer the rotational motion of the connecting road to a linear motion, the crosshead being slidably mounted in a crosshead guide and the piston rod is coupled to the crosshead. Also preferable, a distance piece is provided between the crosshead guide and the compression cylinder and the piston rod is supported by the distance piece. Further, a pressure packing is, in any of the above embodiments, received between the compression cylinder and the distance piece.
In further embodiments of the above, a second inlet valve is coupled to the compression cylinder and a second discharge valve is coupled to the compression cylinder, such that the reciprocating compressor is a double acting compressor. In any of the embodiments above, a reclamation system is provided including a flow pathway coupled to the pressure casing and to the compression cylinder inlet valve. In preferred embodiments, a filter is coupled to the flow pathway of the reclamation system and filters the reclaimed process gas.
Another aspect of the present disclosure relates to a supply line including a reciprocating compressor affixed in the supply line flow path. The reciprocating compressor includes any of the above reciprocating compressors, wherein the inlet valve couples a first portion of the supply line to the compression cylinder and the discharge valve couples the compression cylinder to a second portion of the supply line. In preferred embodiments, the supply line is a natural gas pipeline.
Yet a further aspect of the present disclosure relates to a method of supplying a compressible process fluid. The method includes providing a compressible process fluid to a reciprocating compressor as described in any of the above embodiments from a first portion of a supply line. The method further includes compressing the compressible process fluid in the compression cylinder by rotating the drive shaft, preferably with the motor, converting the rotary motion to linear motion with the rotary linear motion converter, reciprocating the piston rod and the piston within the compression cylinder, and discharging the compressible process fluid into the second portion of the supply line. Preferably, the pressure casing is held in the range of the process gas suction and discharge pressures.
The above-mentioned and other features of this disclosure, and the manner of attaining them, will become more apparent and better understood by reference to the following description of embodiments described herein taken in conjunction with the accompanying drawings, wherein:
The present disclosure relates to a natural gas reciprocating compressor and, preferably, a sealed natural gas reciprocating compressor. The natural gas reciprocating compressor now preferably includes a pressurized casing. The pressurized casing reduces or eliminates leakage through the pressure packing, which leakage increases with the wearing of the pressure packing.
Preferably, the only leakage path for process gas through the pressure casing is for accommodating the drive-shaft input. This penetration is sealed to prevent gas leakage, and preferably, with a mechanical seal, a rotating seal, or dry gas seal. A mechanical seal is reference to the use of a primary (hard) sealing surface against a secondary (carbon or the like) sealing surface. A rotating seal may be understood as a mechanical seal that allows a rotating element to pass through a sealed case. A dry gas seal is reference to a mating (rotating) ring and a primary (stationary) ring. During operation, the lifting geometry in the rotating ring generates a fluid-dynamic lifting force causing the stationary ring to separate and create a gap between the two rings. Further details of the dry gas seal are described herein. There may be circumstances where other leakage paths may be present, such as in gaps in the casing; these pathways should also be mitigated.
The pressurized casing is preferably held at a pressure in the range of the suction and discharge pressure of the compression cylinder and system including all values and ranges therein, or may be a function of the target compression pressure. Operating at this pressure now allows for a reclaiming system to collect and recompress the leakage gas. In other embodiments, the pressure casing operates at the piston suction pressure. Operating at this pressure allows for further reduced leakage out of the packing seals. It is contemplated that the arrangements herein may provide a reduction in compression power by increasing efficiency, which may also help to reduce emissions from driving equipment.
In preferred embodiments, the reciprocating compressors described herein are used to increase gas pressure relative to a given suction. In the oil and gas industry, such compressors are primarily used to move natural gas from one place to the next. The configuration herein is believed to improve on the original compressor configuration by reducing emissions resulting from leakage out of the rod-packing seals. Further, while natural gas is described above as the preferred process fluid, other compressible process fluids and applications are contemplated herein, including chemical plant and refrigeration plant applications. A compressible process fluid is understood herein as a fluid, which as a liquid or gas, which volume changes with changes in pressure acting upon the fluid.
The drive shaft 204 is driven by a motor 206. In embodiments, the drive shaft may include a crankshaft. The motor 206 may drive a gearbox 208, which in turn drives the drive shaft 204 or drives the drive shaft directly. It is noted, in particular, that the motor is located externally to the pressurized casing discussed further below. The location of the motor outside of the pressurized casing allows access to the motor for cooling with fluids, including water, hydraulic fluid or air. The motor may be powered by the process fluid, particularly when the process fluid is natural gas. In other embodiments, the motor may be an electric powered motor.
The drive shaft is coupled to a piston rod via a rotary to linear motion converter. A rotary to linear motion converter is understood herein as one or more components that convert the rotary motion input from the drive shaft to the linear motion applied to the piston rod. In preferred embodiments, the rotary to linear motion converter is provided through the coupling of the rotatable drive shaft 204 to a connecting rod 210. The drive shaft may include a crank throw having a bearing surface whose axis is offset from the axis of the crank. At the opposing end of the connecting rod a sliding crosshead 212 is connected, which transfers the rotational motion of the connecting rod into a linear motion. As illustrated the big end of the connecting rod is affixed to the drive shaft and the small end to the crosshead. The crosshead 212 is mounted in a crosshead guide 214, which is an extension on the compressor frame 202. A piston rod 216 is affixed to and driven laterally in a reciprocating manner by the crosshead 212. It may be appreciated that other rotary to linear motion converters may be used to convert rotary motion of the drive shaft into the desired linear motion of the piston, such as a cam affixed to and rotating with the driveshaft or the use of lead screws.
The piston rod 216 is supported between the compressor frame 202 and the compression cylinder 220 by a distance piece 218, which provides spacing between the compressor frame 202 and the compression cylinder 220. There may be one or more compartments 222, 224 in the distance piece 218. To prevent oil migration between the compression cylinder 220 and the compression frame 202 one or more oil slingers 226, 228 may be provided on the piston rod 216 to prevent lubrication oil from entering the compressor frame 202. In addition, an oil wiper packing 229 may be provided where the distance piece 218 meets the compressor frame 202. Further, an intermediate packing 230 may be provided in the wall 232 between compartments 222, 224. Preferably, the distance piece is vented through a distance piece vent 234 to a vent, such as a blow-down stack or flare. In addition, purge buffer gas inlets 236, 238 may be provided at either end of the distance piece 218 to prevent process gas from entering the compressor frame 202.
Turning back to the piston rod 216, the piston rod 216 reciprocates a piston 244 within the compression cylinder 220 (i.e., the compression chamber). A pressure packing 246 is positioned around the piston rod 216 where the distance piece 218 and compression cylinder 220 meet. The pressure packing is positioned between the piston rod and the compression cylinder. The pressure packing 246 is provided to prevent process gas from exiting the compression cylinder 220 and exiting through the distance piece vent 234. The piston may be fitted with one or more wear bands 248, which are typically formed of a thermoplastic material, such as nylon or polytetrafluoroethylene, or of a lubricious metal or metal alloy coating. The lateral motion of the piston 244 compresses gas that enters the compression cylinder 220 through one or more inlet valves 252, 254. Movement of the piston away from a given inlet valve, towards the other valve allows the process gas to enter the compression cylinder. In embodiments, the process gas is sucked into or inducted into the compression cylinder from the inlet valve, at a process gas suction pressure. Movement of the piston back towards the given valve compresses the process gas and the compressed process, at the discharge pressure, gas exits the compression cylinder 220 through discharge valves 256, 258. Inlet and outlet valves may be selected from a number of valves including, but not limited to plate valves, concentric ring valves, poppet-style vales.
It may be appreciated that the compression cylinder 220 generally includes two sides, a first side 260 of the compression cylinder is defined by one side of the piston and the compression cylinder and a second side of the compression cylinder 262 is defined by the other side of the piston and the compression cylinder. When the process gas is being admitted into a first side of the compression cylinder 260, flow through the discharge valve 256 on that side of the compression cylinder is blocked and when compressed gas is discharged from the compression cylinder, back flow through the inlet valve 252 on that side of the compression cylinder is blocked. Further, when process gas is being admitted into a first side of the compression cylinder 260, process gas on the second side of the compression cylinder 262 is being compressed and discharged through the other discharge valve 258. And, when process gas is being compressed and discharged from the first side of the compression cylinder 260, process gas is admitted into the second side of the compression cylinder 262 through the second inlet valve 254. Thus, each side of the piston may exhibit a different pressure in the compression cylinder.
The pressure casing 270 is provided and encases the distance pieces from the compression cylinder to and around the compressor frame 202. In preferred embodiments, the pressure casing is sealed to the compression cylinder or around the entire compressor in conjunction with the compression cylinder. Preferably, the only process gas leakage path in the pressure casing 270 is to accommodate the drive shaft 204. Again, there may be circumstances where other leakage paths may be present, such as in gaps in the casing; these pathways should also be mitigated. As alluded to above, a seal 272 is provided between the casing wall and the drive shaft 204 to prevent gas from leaking out into the environment. In a preferred embodiment, the seal 272 is a mechanical seal, and more preferably, a rotating seal, rather than sliding packing seals. In particularly preferred embodiments, the seal is a dry gas seal.
A schematic illustration of a cross-section of an embodiment of a preferred dry gas seal is provided in
The drive shaft 404 is driven by a motor 406. In embodiments, the drive shaft may include a crankshaft. In embodiments, the motor 406 drives a gearbox 408, this in turns drives the drive shaft 404. In embodiments, the motor may be powered by the process fluid, such as when the process fluid is natural gas. In other embodiments, the motor may be an electric powered motor. As in the embodiment above, the motor is located externally to the pressure casing, discussed below. The location of the motor outside of the pressurized casing allows access to the motor for cooling with fluids, including water, hydraulic fluid or air.
The drive shaft is coupled to a piston rod via a rotary to linear motion converter. A rotary to linear motion converter is understood herein as one or more components that convert the rotary motion input from the drive shaft to the linear motion applied to the piston rod. The drive shaft may include a crank throw having a bearing surface whose axis is offset from the axis of the crank. In preferred embodiments, rotation of the drive shaft 404 drives opposing connecting rods 410, connecting at the big end to the crank throw and at the little end to a sliding crosshead 412 mounted in a crosshead guide 414, which is an extension on the compressor frame 402. A piston rod 416 is affixed to and driven laterally in a reciprocating manner by the crosshead 412.
Each piston rod 416 is supported by inner and outer distance pieces 418a, 418b, respectively, which provide spacing between the compressor frame 402 and the compression cylinders 420. There may be one or more compartments 422, 424 in the distance piece 418. A packing cartridge body 421 and packing cartridge adapter 423 may be provided to hold the packing, described further herein. To prevent oil migration between the compression cylinders 420 and the compression frame 402 one or more oil slingers 426 may be provided on each piston rod 416 to prevent lubrication oil from entering the compressor frame 402. In addition, an oil wiper packing 429 may be provided where the distance piece 418 meets the compressor frame 402 and held in place by the packing cartridge adapter 424. Further, an intermediate packing 430 may be provided in the wall 432 between the distance pieces 418a, 418b. Preferably, the distance piece is vented through a vent, such as a blow-down stack or flare.
Turning back to the piston rods 416, the piston rods 416 reciprocate a piston 444 within each compression cylinder 420 (i.e., the compression chamber). A pressure packing 446 is positioned around the piston rod 416 where the distance piece 418 and compression cylinder 420 meet. The pressure packing 446 is provided to prevent process gas from exiting the compression cylinder 420. The piston may be fitted with one or more wear bands 448, which are typically formed of a thermoplastic material such as nylon or polytetrafluoroethylene, or a metal or metal alloy. The lateral motion of the pistons 444 compress the process fluid that enters the compression cylinder 420 through one or more inlet valves 452, 454 and is discharged through one or more discharge valves 456, 458. Movement of the piston away from a given inlet valve, such as valve 452, towards the other inlet valve, such as valve 454, allows the process gas to enter the compression cylinder at a suction pressure. Movement of the piston back towards the given inlet valve compresses the process gas and the compressed process gas exits the compression cylinder through the discharge valve associated with the inlet valve at a discharge pressure. Inlet and outlet valves may be selected from a number of valves including, but not limited to plate valves, concentric ring valves, poppet-style vales.
It may be appreciated that each compression cylinder 420 generally includes two sides, a first side 460 of the compression cylinder is defined by one side of the piston and the compression cylinder and a second side of the compression cylinder 462 is defined by the other side of the piston and the compression cylinder. When the process gas is being admitted into a first side of the compression cylinder 460, flow through the discharge valve 456 on that side of the compression cylinder is blocked and when compressed gas is discharged from the compression cylinder, back flow through the inlet valve 452 on that side of the compression cylinder is blocked. Further, when process gas is being admitted into a first side of the compression cylinder 460, process gas on the second side of the compression cylinder 462 is being exhausted through the other discharge valve 458. And, when process gas is being discharged from the first side of the compression cylinder 460, process gas is admitted into the second side of the compression cylinder 462 through the second inlet valve 454.
As noted, the pressure casing 470 is provided and encases the distance pieces from the compression cylinder to and around the compressor frame 402. As illustrated, the pressure casing surrounds the entire compressor, including around the compression cylinders, and creates a casing around the compressor in conjunction with the compression cylinder. Preferably, the openings in the pressure casing 470 are to accommodate the drive shaft 404 and the supply lines to the inlet valves 452, 454 and the discharge valves 456, 458. A seal 472 is provided between the casing wall and the drive shaft 404 to prevent gas from leaking out into the environment. In a preferred embodiment, the seal is a mechanical seal, and more preferably, a rotating seal, rather than sliding packing seals. In particularly preferred embodiments, the seal is a dry gas seal as illustrated in
Due to leakage in the system, the pressure casings raise the system pressure levels. This increase in system pressure levels reduces leakage from the compression cylinder through the packing seals due to a decrease in the pressure ratio between the pressure casing and the compression cylinder. The incorporation of a reclamation system may assist in maintaining elevated pressure levels, and is described further below. However, in the case of over pressure, a release valve may be coupled to the pressure casing to relieve pressure should the pressure levels exceed a value deemed to be the operating limit. Such limit may be determined based on the integrity and materials selected in the system.
As noted above, the reciprocating compressors may be incorporated into a number of systems, including oil and natural gas pipelines, chemical plant and refrigeration applications. In a particularly preferred embodiment, the reciprocating compressors described above are incorporated into natural gas pipelines in compressor stations. The compressor stations compress the natural gas as it travels through the pipelines. The compression of the gas allows the gas to continue flowing through the pipe to distribution points and end-users, including refineries, commercial customers and residential customers. Compressor stations may include auxiliary equipment to remove impurities such as liquids, dirt, particles, and other impurities including water and hydrocarbons. Such auxiliary equipment includes scrubbers, strainers, or filter separators. In addition, operating pressures may vary from 200 pounds per square inch (psi) to 10,000 psi, including all values and ranges therein. Operating pressure depend upon factors such as pipeline diameter, elevation, environment and process gas.
Referring again to
Also contemplated herein is a method of operating a reciprocating compressor as illustrated in
The above systems and methods reduce leakage of the process gas into the environment, and it is contemplated that the emission may be virtually eliminated. When considered at the amount of leakage that may be reduced worldwide, the reductions in leakage are believed to be relatively substantial.
The foregoing description of several methods and embodiments has been presented for purposes of illustration. It is not intended to be exhaustive or to limit the claims to the precise steps and/or forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be defined by the claims appended hereto.
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Number | Date | Country | |
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20180066802 A1 | Mar 2018 | US |