Patent Application
20180100497
The subject matter disclosed herein relates to reciprocating compressors and, more specifically, to a system and method for estimating flow based on detecting operating events (e.g., valve closures) of a reciprocating compressor.
Reciprocating compressors may include a piston driven to move back and forth within a chamber, such that fluid (e.g., gas) is drawn into and compressed within the chamber. For example, a portion of the chamber may be disposed above the piston. As the piston moves in a first direction (e.g., away from the portion of the chamber), a volume of the portion increases, thereby drawing gas into the portion of the chamber above the piston, for example, through a suction valve. As the piston moves in a second direction opposite to the first direction (e.g., toward the portion of the chamber), the volume of the portion decreases, thereby compressing the gas within the portion of the chamber. After a pressure of the compressed gas exceeds a threshold, a discharge valve may open such that the compressed gas is exported from the portion of the chamber elsewhere and for other purposes.
In some configurations, the compressors may have an adjustable volume. Operation of variable-volume and constant-volume compressors may be sensed using a sensing system. However, direct measurement using flow sensors through individual compressors may be impractical due to the cost prohibitive nature or unreliability of individual flow sensors over a period of time.
Certain embodiments commensurate in scope with the originally claimed invention are summarized below. These embodiments are not intended to limit the scope of the claimed invention, but rather these embodiments are intended only to provide a brief summary of possible forms of the present disclosure. Indeed, the present disclosure may encompass a variety of forms that may be similar to or different from the embodiments set forth below.
In a first embodiment, a method for monitoring reciprocating compressor operation includes determining a valve opening of a valve disposed in the reciprocating compressor using a sensor and determining a first location of a piston of the reciprocating compressor at the valve opening. The method also includes determining a valve closing of the valve using the sensor and determining a second location of the piston at the valve closing. Furthermore, the method includes estimating a volumetric efficiency based at least in part on the first and second location.
In a second embodiment, a system includes a reciprocating compressor having a piston and a valve. The system also includes a controller configured to monitor valve closures of the valve. The controller includes a processor configured to receive an indication of the valve opening from a sensor coupled to the reciprocating compressor and determine a first location of the piston at the valve opening. The processor is also configured to receive an indication of the valve closing from the sensor and determine a second location of the piston at the valve closing. The processor is configured to then estimate a volumetric efficiency based at least in part on the first and second location.
In a third embodiment, a non-transitory computer readable medium includes executable instructions that, when executed, cause a processor to receive an indication of a valve opening of a valve of a reciprocating compressor from a sensor coupled to the reciprocating compressor and determine a first location of a piston of the reciprocating compressor at the valve opening. The instructions also cause the processor to receive an indication of the valve closing from the sensor and determine a second location of the piston at the valve closing. The instructions also cause the processor to estimate a volumetric efficiency for the reciprocating compressor based at least in part on the first and second location.
These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
One or more specific embodiments of the present invention will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
When introducing elements of various embodiments of the present invention, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
The disclosed embodiments employ sensors (e.g., vibration sensors, acoustic sensors, or vibration sensors) that may be used to indirectly determine flow and/or volumetric efficiency of a compressor without knowing the geometry of a variable volume of the compressor. The sensors may measure baseline data (e.g., fingerprints of sound or vibration) to monitor, diagnose, and/or control a reciprocating compressor, more specifically, suction and discharge valves of the reciprocating compressor. When using a vibration sensor to monitor a reciprocating compressor, occasionally the vibration sensor system records a noise, such as an abnormal or undesired noise that may not be identified at that time. Additionally or alternatively, the vibration sensor may record a noise that is a normal or desired noise, where the noise has been previously identified and characterized. For example, noises emitted by the reciprocating compressor during various actions by the reciprocating compressor may be initially characterized during an in-factory baselining process. Noise signals for particular operating events and conditions (e.g., discharge and/or suction valve closures) during the baselining process may be processed and stored in a database as relating to one or more operating events. During normal operation of the reciprocating compressor, data stored in the database relating to the operating events characterized during the baselining process may be accessed to determine if operational noise corresponds to the operating events characterized during the baselining process.
Advantageously, the techniques described herein may create a sound “fingerprint” of certain reciprocating compressor sounds or noise. The fingerprint (e.g., profile, comparator, and/or reference signal) may be developed during the baselining process, as described above, and the fingerprint may correspond to a particular operating event (e.g., a valve opening or closure) tested during the baselining process. It should be noted that the baselining process may be carried out during full operation of the reciprocating compressor or while only operating certain components (e.g., the components relating to the operating event(s) being baselined) of the reciprocating compressor. For example, in some embodiments, various operating events of the reciprocating compressor may be baselined in-factory during part or full operation.
During full operation of the reciprocating compressor (e.g., after baselining), noise may be detected by the vibration sensor or vibration sensors, and a resulting noise signal may be processed and compared to various fingerprints (e.g., profiles, signatures, comparators, reference signals, unique indicia, unique representations, etc.) relating to the reciprocating compressor. If the fingerprint and the processed noise signal correspond or correlate (e.g., “match”), the signal may be confirmed as corresponding to the operating event (e.g., valve closure) relating to the fingerprint. The noise signal may also be processed to determine time-sensitive information relating to the operating event that corresponds to the matched fingerprint and noise signal. For example, if the noise signal matches a fingerprint corresponding to closure of a suction or discharge valve, the noise signal may be plotted with respect to time to determine when, e.g., the discharge or suction valve closed.
Further, in accordance with embodiments of the present disclosure, the noises recorded or detected by the sensor(s) (e.g., knock or proximity sensors) may capture multiple operating events, namely, opening or closing of multiple suction and/or discharge valves of the reciprocating compressor. The amplitudes of the noise signals corresponding with the opening or closing of the suction and/or discharge valves may be plotted against time/movement of a piston and used to determine flow rate and/or volumetric efficiency of the reciprocating compressor. For example, a period of time may be monitored between closures of different suction and/or discharge valves, and the distance traveled by the piston between the opening and the closing events may be compared to an overall stroke of the piston to determine volumetric efficiency. Volumetric efficiency may be used to determine flow. These parameters may be used to determine health and/or tune operating parameters (e.g., volume and/or RPM).
Turning to the drawings,
To actuate the piston 12, a shaft 26 may extend from an actuating source (not shown) into the cylinder 16 and through the piston 12. The shaft 26 may be rigidly coupled with, or integral to, the piston 12. Further, the actuating source (not shown) may be any suitable actuating source, including a crankshaft driven by a motor. In general, the actuating source causes reciprocating motion of the shaft 26 and corresponding piston 12 in the first direction 22 and in the second direction 24.
As shown in the illustrated embodiments, the piston 12 separates the chamber 14 into the two discrete sections 18, 20. In other words, the sections 18, 20 may be fluidly isolated from one another. The piston 12 may include rings 28 that engage or contact walls of the cylinder 16 to seal the first section 18 of the chamber 14 from the second section 20 of the chamber 14.
The reciprocating compressor 10 may also include a series of valves coupled with the sections 18, 20 of the chamber 14. For example, the reciprocating compressor 10 in the illustrated embodiments includes two discharge valves 30 and two suction valves 32. In other embodiments, the reciprocating compressor may include more than the two discharge valves 30 and more than the two suction valves 32, depending on how many of the sections 18, 20 are included in the chamber 14 of the reciprocating compressor 10, and/or depending on how many cylinders 16 (and, thus, how many corresponding chambers 14 and pistons 12) are included in the reciprocating compressor 10. As shown, each section 18, 20 of the chamber 14 includes one of the discharge valves 30 and one of the suction valves 32.
Continuing with the embodiment illustrated in
Further, as the piston 12 moves toward the first section 18 of the chamber 14 in
Continuing with the embodiment illustrated in
Further, as the piston 12 moves toward the second section 20 of the chamber 14 in
Furthermore, the compressor 10 of
By expanding a maximum volume of the chamber 14, the compressor 10 effectively increases a re-expansion period because the larger volume of fluid trapped in the cylinder needs to move further during the piston 26 stroke to re-expand out to suction pressure. On the compression cycle, the piston 26 also travels further along the stroke to reach discharge pressure as there is more volume to pressurize. The ratio of discharge stroke distance with a valve open (or suction stroke distance with valve open) over total stroke distance is the discharge (or suction) volumetric efficiency. The smaller volumetric efficiency (VE) of a cylinder, the smaller the effective displacement. Reducing the VE, reduces horsepower consumption (area inside of curve) and capacity moved.
For a gas gathering application, when the displacement is increased, the flowrate of fluid (Q) will be reduced and the suction pressure will increase (assuming no pressure restriction/control on wellhead or package).
In some embodiments, the volume inside the compressor 10 may be difficult to determine since the volume is variable. Some embodiments may include gauges 43 (e.g., ruler) on the control device 42, screw 40, or other part of the compressor that attempts to estimate the volume of the additional portion 44 with or without the volume of the chamber 14 included, but these attempts may not be accurate. Since volume may be difficult to determine, flow may also be difficult to determine. In some cases, individual flow sensors for each gas compressor unit may be impractical and expensive. Instead, a virtual flow sensor systems may be used to determine flow and/or volumetric efficiency. In some embodiments, these virtual flow sensor systems may be implemented using vibration sensors and performing analysis on the vibration sensor data.
Returning to
Additionally or alternatively, a single knock 60 sensor may be used to determine when any of the suction valves 30 have opened and/or closed while a second vibration sensor 60 may be used to determine when any of the discharge valves 32 have opened and/or closed. Alternatively, one vibration sensor 60 may monitor all four of the suction and discharge valves 30, 32. The vibration sensors 60 in the illustrated embodiment may be a Piezo-electric accelerometers, microelectromechanical system (MEMS) sensors, Hall effect sensors, magnetostrictive sensors, and/or any other sensors designed to sense vibration, acceleration, sound, and/or movement (e.g., of the valves 30, 32). In other embodiments, the sensors 60 may not be vibration sensors in the traditional sense, but any sensors (e.g., laser sensors) that may sense vibration, pressure, acceleration, deflection, proximity, and/or movement. Because of the percussive nature of the reciprocating compressor 10, the vibration sensor(s) 60 may be capable of detecting noise signatures when mounted on an interior or on an exterior of the cylinder 16.
The reciprocating compressor 10 may also include a compressor control unit (CCU) 50, which includes a processor 52 and memory 54. The memory 54 includes non-transitory, tangible, computer-readable medium storing instructions that are configured to cause the processor 52 to perform specific actions, such as the processes discussed herein.
The CCU 50 is communicatively coupled with each of the vibration sensors 60. The memory 54 of the CCU 50 may store computer instructions that may be executed by the processor 52 of the CCU 50. In general, the CCU 50 monitors and controls operation of the reciprocating compressor 10, for example, by monitoring openings and/or closures of the discharge and/or suction valves 30, 32.
Advantageously, the techniques described herein may use the CCU 50 to receive data from the vibration sensors 60, and then to create a “noise” signature by plotting the vibration sensor 60 data against time. The CCU 50 may then go through the process of analyzing the data to derive normal (e.g., known and expected noises) and, in some embodiments, abnormal signatures (e.g., unknown or unexpected noises). The CCU 50 may then characterize the signatures, as described in more detail below. By providing for signature analysis, the techniques described herein may enable a more optimal and a more efficient operation and maintenance of the reciprocating compressor 10. For example, by analyzing time delays or periods of time between cycles of closures of a single discharge or suction valve 30, 32, the CCU 50 may determine whether the valve 30, 32 is closing at an appropriate time. Additionally or alternatively, by analyzing time delays or periods of time between closures of two different discharge and/or suction valves 30, 32, the CCU 50 may determine whether the valves 30, 32 are closing at appropriate times relative to one another. In certain embodiments, the CCU 50 may be a system external to the compressor 10, such as an external computing system.
SV=πr
b
2
*S (Equation 1),
where rb is the radius of the bore 26 and S is the stroke of the piston 26. In other words, the swept volume is the volume of a cylinder through which the piston 26 travels during a suction or discharge stroke. Since the VE is a ratio of the actual volume displaced to volume within the bore, the volume within the bore may be calculated as well. The volume of the bore may be calculated using Equation 2:
V
b
=πr
b
2
*l
b (Equation 2),
where lb is the physical displacement length of the piston. VE may be estimated using Equation 3:
Furthermore, πrb2 may be canceled in the numerator and the denominator of Equation 3 to form Equation 4:
Moreover, the stroke length may be estimated as the movement of the piston 26 while one or more suction valves 30 are open in a suction stroke. In some embodiments, this length may be determined by determining an angular position of the crankshaft when a detected opening (or closing) of a respective valve has occurred. Thus, the positions of the piston 26 during the detected valve events may be used to estimate volumetric efficiency.
It is worth noting that the foregoing and following equations may further be modified with additional calibration factors to account for flow restrictions (e.g., valve partially open), pressure losses, or other flow factors.
Along with other information that may be directly measured, flow may be determined from the estimated VE without an actual physical flow sensor and without knowing an exact volume of the reciprocating compressor 10. A volumetric flow rate (Q) may be calculated using the following Equation 5:
where Ps is the pressure of suction, Ts is the temperature at suction, Zstd is the compressibility factor of the fluid at standard conditions, Zs is the compressibility factor of the fluid at actual conditions at suction, DISP is the displacement of the cylinder, CL is the clearance amount as a decimal fraction of displaced volume, R is the pressure ratio across the cylinder, and N is isentropic volume exponent at operating conditions.
The volumetric efficiency is proportional to the volumetric flow rate and may be determined using the following Equation 6:
VE=1−CL(R1/N−1) (Equation 6)
In other words, the VE be substituted into the flow rate equation as illustrated in Equation 7
Thus, by estimating the VE using the flow sensors and the position of the piston 26, the flow through the compressor 10 may be estimated using properties about the fluid, such as pressure, temperature, and compressibility factor along with a displacement property pertaining to the compressor 10. Furthermore, these measurements may be made using virtual flow sensor systems rather than direct flow sensors that may be financially impractical, unreliable, and/or difficult to implement.
Although the foregoing discussion has dealt with volumetric efficiency and flow through a suction valve, it is worth noting that similar principles may be applied to a discharge valve and state to determine a “discharge efficiency” instead of the volumetric efficiency. In other words, the volumetric efficiency equations may be modified to replace measurements at suction with measurements at discharge. For example, the temperature at suction may be replaced with temperature at discharge. The volumetric efficiency attempts to measure efficiency from the suction side in a flowing direction, and the discharge efficiency attempts to measure efficiency from the discharge side from an opposite direction. In other words, the efficiency and/or flow of the compressor may be determined using a suction valve using volumetric efficiency or may be determined using a discharge valve using discharge efficiency.
where Do is the distance to the first location at opening and Dc is the distance to the second location.
The CCU 50 may use the volumetric efficiency to operate the compressor 10. For example, if volumetric efficiency is below a threshold value, the CCU 50 may decrease volume and/or increase RPM for the compressor 10. The CCU 50 may also include other indicators for operating the compressor 10. For example, the CCU 50 may calculate a flow rate through the compressor 10 based at least in part on the estimated volumetric efficiency (block 212). These additional operational indicators (e.g., flow rate) may be determined using additional measurements such as temperature, pressure, or other sensed values in addition to the volumetric efficiency. These additional operational indicators may be used to operate the compressor 10 in addition to or in place of the volumetric efficiency.
Furthermore, since flow through a cylinder of a compressor may be determined on each stage of a multi-stage compressor, leakage through multi-stage compressors may be derived from such measurements. For example, if flow drops more than a threshold percentage from a first stage to a second stage, the loss in flow may be attributed to a leak in the first stage, a leak in the second stage, and/or between the first and second stages.
