1. Technical Field
Embodiments of the subject matter disclosed herein generally relate to rotary valves used in reciprocating compressors, and, more particularly, to actuated rotary valves having sealing profiles between the stator (sometimes also called seat) and the rotor (sometimes also called counter-seat).
2. Discussion of the Background
Compressors used in oil and gas industry, have to meet industry specific requirements that take into consideration, for example, that the compressed fluid is frequently corrosive and flammable. American Petroleum Institute (API), the organization setting the recognized industry standard for equipment used in oil and gas industry has issued a document, API618, listing a complete set of minimum requirements for reciprocating compressors.
The compressors may be classified as positive displacement compressors (e.g., reciprocating, screw, or vane compressors) or dynamic compressors (e.g., centrifugal or axial compressors). In the positive displacement compressors, the gas is compressed by trapping a fixed volume of gas and then reducing that volume. In the dynamic compressors, the gas is compressed by transferring the kinetic energy from a rotating element (such as, an impeller) to the gas to be compressed by the compressor.
Suction valves 32 and 34 open to allow the fluid that is going to be compressed (i.e., having a first/suction pressure P1) from the inlet 30 into the compression chambers 22 and 24, respectively. Discharge valves 42 and 44 open to allow the fluid that has been compressed (i.e., having a second/discharge pressure P2) to be output from the compression chambers 22 and 24, respectively, via the outlet 40. The piston 50 moves due to energy transmitted from a crankshaft 60 via a crosshead 70 and a piston rod 80.
Conventionally, the suction and the compression valves used in a reciprocating compressor are automatic valves that are switched between a close state and an open state due to a differential pressure across the valve.
In the open state illustrated in
A spring 160 is located between the shutter 130 and the counter-seat 120. Depending on its state of deformation, the spring 160 actively participates in establishing the valve's opening point, the elastic deformation force superimposing a pressure along the flow path (the superimposed pressure being equal to the force divided by the area of the shutter 130). In the open state, the first pressure p1 from the source of the fluid (not shown) and along the inlet 140 is larger than the pressure p2 at the destination of the fluid (not shown) and along the outlets 150. If the spring 160 is deformed when the shutter 130 is pushed down into the counter-seat 120 (as shown in
In the close state illustrated in
The valves described above are known as automatic valves being switched between the open state and the close state due to the pressure difference across the valve (p1−p2) (i.e., between the pressure p1 at the source of the fluid and the pressure p2 at the destination of the fluid).
One source of inefficiency in the reciprocating compressor is related to the clearance volume, that is, a volume from which the compressed fluid cannot be evacuated. Part of the clearance volume is due to volume related to the valves. Rotary valves require less clearance volume, but operate only if actuated. Another advantage of the rotary valves is an increased flow area. Rotary valves have been known for a long time, for example, they have been described in U.S. Pat. No. 4,328,831 to Wolff and U.S. Pat. No. 6,598,851 to Schiavone et al.
The conventional rotary valves are not currently used in reciprocating compressors used in oil and gas industry because the sealing between the stator and the rotor is not effective and actuation is not precise. Additionally, when actuating the rotor, high friction forces may occur due to (1) the difference of pressure pushing the rotor towards the stator and therefore increasing the friction force, and (2) the large friction surface. Moreover, static friction is likely substantially larger than the dynamic friction which difference makes it even harder to properly time and control the actuation force.
Accordingly, it would be desirable to provide valves rotary valves useable in reciprocating compressors for the oil and gas industry that avoid the afore-described problems and drawbacks.
Some of the embodiments minimize the friction forces in rotary valves, allowing a fast and precise actuation or the valves, thereby rendering these rotary valves useable in reciprocating compressors for oil and gas industry equipment. Using rotary valves in reciprocating compressors has the advantage of an increased passage flow area yielding an increased efficiency of the compressor by enhancing the suction and/or discharge phase.
According to one exemplary embodiment, an actuated rotary valve useable in a reciprocating compressor for oil and gas industry is provided, the valve being located between a nozzle and a compression chamber of the reciprocating compressor. The valve includes (1) a stator having a stator opening there-through in a direction from the nozzle to the compression chamber, (2) an actuator stem configured to be rotated by an actuator, and (3) a rotor having a rotor opening there-through in the direction from the nozzle to the compression chamber, and being fixedly attached to the actuator stem. The rotor and the stator are coaxial disks, and are coaxial with the actuator stem passing there-through. At least one of the rotor and the stator has a sealing profile extruding from a surface of the rotor or of the stator towards an interface there-between, the sealing profile surrounding a respective one of the rotor opening or the stator opening.
According to another exemplary embodiment, a reciprocating compressor used in oil and gas industry has (1) a compression chamber configured to compress a fluid that has entered the compression chamber via a suction nozzle, and is evacuated from the compression chamber via a discharge nozzle, (2) an actuator configured to provide an angular displacement, and (3) a valve configured to prevent the fluid from flowing inside or outside the compression chamber via the suction nozzle or the discharge nozzle. The valve includes (1) a stator having a stator opening there-through in a direction from towards the compression chamber, (2) an actuator stem connected to and configured to be rotated by the actuator, and (3) a rotor having a rotor opening there-through in the direction towards the compression chamber, and being fixedly attached to the actuator stem. The rotor and the stator are coaxial disks, and are coaxial with the actuator stem passing there-through. At least one of the rotor and the stator has a sealing profile extruding from a surface of the rotor or of the stator towards an interface there-between, the sealing profile surrounding a respective one of the rotor opening or the stator opening.
According to another exemplary embodiment a method for retrofitting a reciprocating compressor used in oil and gas industry and initially having an automatic valve is provided. The method includes removing an automated valve positioned to interface a nozzle and a compression chamber of the reciprocating compressor, and fixedly attaching a stator of an actuated rotary valve in-between the nozzle and the compression chamber. The method further includes providing an actuator configured to supply an angular displacement and connecting to the actuator, an actuator stem passing through the stator and having attached a rotor.
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate one or more embodiments and, together with the description, explain these embodiments. In the drawings:
The following description of the exemplary embodiments refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. The following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims. The following embodiments are discussed, for simplicity, with regard to the terminology and structure of reciprocating compressors used in oil and gas industry. However, the embodiments to be discussed next are not limited to this equipment, but may be applied to other equipment.
Reference throughout the specification to “one embodiment” or “an embodiment” means that a 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 phrases “in one embodiment” or “in an embodiment” in various places throughout the specification is not necessarily referring to the same embodiment. Further, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.
In some embodiments described below, actuated rotary valves having a sealing profile disposed on at least one surface at the interface between the rotor and the stator are used instead of automatic valves, in order (1) to enhance efficiency of a reciprocating compressor by decreasing the clearance volume and (2) to overcome the problems related to the high friction in rotary valves. When the rotary valves are used in reciprocating compressors, a passage flow area between inside and outside of the compressors increases. The increased passage flow area results in an increased efficiency of the compressor due to shorter and more efficient suction and/or discharge phase.
Suction valves 332 and 334 open to allow the fluid that is going to be compressed (i.e., having a first pressure p1) from the inlet 330 into the compression chambers 322 and 324, respectively. Discharge valves 342 and 344 open to allow the fluid that has been compressed (i.e., having a second pressure p2) to be output from the compression chambers 322 and 324, respectively, via the outlet 340. The piston 350 moves due to energy received for example from a crankshaft (not shown) via a crosshead (not shown) and a piston rod 380. In
In contrast to an automatic valve, which is in the open state or in the close state depending on a differential pressure on opposite sides of a mobile part of the valve, an actuated rotary valve, such as 332 in
In the embodiment illustrated in
The stator 510 and the rotor 520 may be made of stainless steel and alloyed steel. The sealing profiles 515 and 525 may be made of a non-metallic material such as polyether ether ketone (PEEK) or stainless steel. In one embodiment, the first sealing profile 515 and the stator 510 may be formed as a single piece and /or the second sealing profile 525 and the rotor 520 may be formed as a single piece made, for example, of stainless steel. Alternatively, the sealing profiles 515 and 525 may formed separately from (and from a different material than) the stator 510 and the rotor 520, respectively, being attached fixedly thereof. In one embodiment, a groove may be formed on a surface on which the respective sealing profile is attached, a height of the groove being smaller than a height of the respective sealing profile. The sealing profiled may be glued or welded on the respective surfaces (depending also on the material used to manufacture the sealing profiles).
In order prevent fluid from leaking between the compressor cylinder and the nozzle, a seal 550 is placed at an interface between the stator 510 and the wall 540 of the compressor's cylinder. The seal 540 may be an O-ring and may be placed in a groove carved into the body of the stator 510. Further, for the same fluid sealing purpose, a radial bushing 555 is placed between the stator 510 and the actuator stem 530.
In addition to the above described main components of the valve assembly, the actuated rotary valve 500 includes a plurality of other components provided to enhance the valve's (and/or compressor's) operation and/or as a support structure. A bushing 560 may be placed between a collar 532 of the actuator stem 530 and the stator 510. Another seal 565 of a different type and at a different location than the radial bushing 555 may be also placed between the stator 510 and the actuator stem 530. A retainer ring 570 may be placed in a groove of the stator 510 to maintain the radial bushing 555 in its intended position. A spring 575, a spacer 580 and a counter-nut 585 attached to the actuator stem 530 support and push the rotor 520 towards the stator 510.
The sealing profiles 615 and 625 protrude from the surface of the stator 610 and the rotor 620, respectively. The height of the sealing profile may be 2-3 mm. The sealing profile 615 on the surface of the stator 610 includes two adjoined similarly shaped closed perimeters 617 and 619, the first one, 617, surrounding the opening 612 through the stator 610, and the second one, 619, having a common side 618 with the first one, 617. The sealing profile 625 on the surface of the rotor 620 includes a closed perimeter 627 surrounding the opening 622 of the rotor and having substantially the same shape as the close perimeters 617 and 619, and seal extensions 629, 631, 633, and 635 circumferentially extending sides of the perimeter 627. The seal extensions 629, 631, 633, and 635 may have decreasing height (i.e., ramps down) towards the surface of the rotor 620.
In the first position, the perimeter 627 of the sealing profile 625 matches the perimeter 617of the sealing profile 615, and, in the second position, the perimeter 627 of the sealing profile 625 overlaps the perimeter 619 of the sealing profile 615.
The reduced contact area of the rotor-stator interface using the sealing profiles to only a boundary frame with small thickness leads to a smaller friction force. When the rotor is actuated to switch from the second position to the first position, the pressure inside the compressor cylinder may still exceed the pressure in the nozzle on the other side of the rotary valve. An actuation force (or torque) has to overcome both inertia and friction. The amount of friction is proportional to the area of contact. The smaller contact area is, the smaller is the friction force. Additionally, any capillary force that may occur due to liquid adhering to the rotor-stator interface is also proportional to the contact area.
As known in the art, the static friction is larger than the dynamic friction. Thus, if friction is large, a large force has to be applied at a beginning of the actuation of the rotor. The larger is the force initially applied relative to the force applied after the rotor starts moving, the harder it becomes to control the actuation. The actuation time is few milliseconds, and the angular displacement may be up to 120°. Precise timing and range of actuation are critical for achieving a good performance of the compressor. Thus, easier, providing actuated rotary valves capable of an enhanced control renders the use of rotary valves to become an attractive technical solution for reciprocating compressors used in the oil and gas industry.
The manner of arranging rotary valves in a reciprocating compressor provides leverage for enhancing sealing while the valve is closed.
To understand the advantage of arranging the rotary valves in the manner described relative to
During the compression and discharge phases of the compression cycle, the piston moves in a direction opposite to the direction of motion during the expansion and compression phases, to decrease the volume of the compression chamber. During the compression phase both the suction and the delivery valves are closed, the pressure of the fluid in the compression chamber increasing (from the suction pressure up to the delivery pressure) because the volume of the compression chamber decreases. The delivery phase of the compression cycle begins when the pressure inside the compression chamber becomes equal to the delivery pressure, triggering the delivery valve to open. During the delivery phase the fluid at the delivery pressure is evacuated from the compression chamber until the minimum (clearance) volume of the compression chamber is reached.
The pressure inside the compression chamber is larger than the suction pressure during all the phases of the compression cycle (expansion, compression and discharge) during which the suction valve is closed. Thereby, during these phases, the pressure difference across the valve causes a force pushing the rotor 730 of the rotary valve used as suction valve towards the stator 740, and, thus, enhancing sealing there-between.
The pressure inside the compression chamber is smaller than the discharge pressure during all the phases of the compression cycle (suction expansion, and compression) in which the discharge valve is closed. Thereby, during these phases, the pressure difference across the valve causes a force pushing the rotor 830 of the rotary valve used as discharge valve towards the stator 840, and, thus, enhancing sealing there-between.
Reciprocating compressors used in oil and gas industry and having automated valves may be retrofitted to use actuated rotary valves with sealing profiles. A flow diagram of a method 900 for retrofitting a reciprocating compressor (e.g., 10) used in oil and gas industry and initially having an automatic valve is illustrated in
The method 900 also includes providing an actuator configured to supply an angular displacement, at S930, and connecting the actuator to the valve via an actuator stem, at S940. In the method 900, (1) if the valve is a suction valve, the rotor may be mounted to be closer to the compression chamber than the stator, and (2) if the valve is a discharge valve, the stator may be mounted to be closer to the compression chamber than the rotor.
The method 900 may further include at least one of (1) providing a seal located and configured to prevent a fluid leak between the stator and a wall of the compression chamber, and (2) providing a radial bushing placed and configured to prevent a fluid leak between the stator and the actuator stem.
The disclosed exemplary embodiments provide actuated rotary valves with sealing profiles between a rotor and a stator thereof, reciprocating compressors using these valves and related methods. It should be understood that this description is not intended to limit the invention. On the contrary, the exemplary embodiments are intended to cover alternatives, modifications and equivalents, which are included in the spirit and scope of the invention as defined by the appended claims. Further, in the detailed description of the exemplary embodiments, numerous specific details are set forth in order to provide a comprehensive understanding of the claimed invention. However, one skilled in the art would understand that various embodiments may be practiced without such specific details.
Although the features and elements of the present exemplary embodiments are described in the embodiments in particular combinations, each feature or element can be used alone without the other features and elements of the embodiments or in various combinations with or without other features and elements disclosed herein.
This written description uses examples of the subject matter disclosed to enable any person skilled in the art to practice the same, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the subject matter is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims.
Number | Date | Country | Kind |
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MI2011A002396 | Dec 2011 | IT | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP2012/075435 | 12/13/2012 | WO | 00 | 6/26/2014 |