Presentation on,

DEVELOPMENTS IN RECIPROCATING COMPRESSOR

S. K. Deshmukh DGM-ACD (R & E)

9/12/2008

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Back Ground

1940s Lo w speed 1 80 rpm, f irst generation of reciprocating compressors dev eloped In last 10 y ears, predictions were made that Recip wi ll be tapere d down. Howev er, Recip compressors hav e ov ercome the past concerns of certain we aknesses through technol ogical adv ancements. It is a f av ored selection by all industries Genera l purpose, Po wer, Oil, Gas, Petrochemical and Ai r separatio n etc. It can handle v irtually all gases and do compression f rom v acuum to 3500 bar (Hy per compressor f or LDPE ethy lene) with power rating up to 30 MW of single compressor.

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Reciprocating Compressor Advancements (Latest Design Features)

a) b) c) d) e) f) g) h) i) j) Valv e design f or low noise (env ironment f riendly ) & high energy eff iciency (low v alv e losses) Piston ring materials Lif e enhancements & lo w f riction Sy nthetic lubricants Bio degradabl e - env ironment f riendly. Condition monitor ing f or health of Compressor web base d Digital Pulsation an aly sis High speed desig ns Air cooled packag es Integrated packages Engin e driv en direct coupled high spe ed compressor Uncooled cy linder f or gases of lower adi abatic expone nts (Jacketless)

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Reciprocating Compressor Advancements (Latest Design Features)

k) l)

Special Metallu rgy compatible f or gases inv olv ed Lif e enhancements

m) Use of jacket & intercooler / aftercooler heat f or building heatin g as low gr ade he at n) Compact design (Lo w weight to capacity ratios energy packed machines ) o) Env ironmentally f riendly materials f or construction i.e. Asbestos f ree p) q) r) s) t) Use of recy clable materials High pressure e ngine ered comp ressors Conf ormance to the international standards such as API618, API 11P etc. Electricals & Instrumentation: Suitable f or specif ied area classif ication / Gas group / Temper ature Class Integrated Engi ne Compressor.

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Reciprocating Compressor Advancements (Latest Design Features)

u) Env ironmental A ware ness : EMS (ISO 14 001) & OHS AS 18 001- ref lecting in design specif ications e.g. compliance to Bharat Stage III (Euro 3), Residential ty pe silencers, Spark Arrestor (I.S. specif ied) v ) Saf eties compliance (e.g. API RP-520 / API 526 / API 527), CCOE approv ed cy linders etc. w) Use of Computational Fluid Dy namics (CFD), Finite Element Analy sis (FEA), The rmal / Thermo dy namic Simulation study etc. x) Use of Energy Eff icient Motors matching with National Electric Manuf acturers Association's (NEMA's) MG1- 199 3 publicatio n / BIS 12615. y) z) VFD f or v ariable deman d cycles and multiple units installations. Silenced v ersions Canopy f or noise lev el of 75 dB.
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Valve Design Enhancing the Valve Life & Reliability

Compressor suction & Discharge Valv es play important role of heart of Compressor

Important components a) Valv e seats b) Valv e guard c) Mov ing / sealing element Valv e plate , channel etc. d) Springs / cushion plates

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Valve Design Valve Dynamics

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Valve Design Enhancing the Valve Life & Reliability

Use of material adv ancements such as PEEK. Design criterion f or optimization (Char acteristics of Ideal v alv e) a) The minim um clearance v olume. b) Low imp act v elocity (low lif t). c) The la rgest possible f low area & f low coeff icient. d) Light wei ght combined with lo w lif t with quick action. e) Robust construction f or long lif e. f ) Low p rice.

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Valve Design Enhancing the Valve Life & Reliability

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Torsional Vibration Analysis

The n atural f requencies of torsional v ibration of the idealized complete driv es train system comprising of motor, coupling, and compressor calculated using Torsion al Critical Spee d computer prog ram. The e quiv alent mass elastic diagram f or the complete driv es train will be used in determinati on of torsional (mechanical) natura l f requencies / critical speeds wh ere a potentia l f or resonant behav ior exists. Interf erence / Campbell Diagram dev elope d to identify & av oid harmf ul resonant beh av ior f or the operating speed ra nge. Determination of v ibratory torque & stresses on the components of the driv e train to ensure such torque & stresses v ariations are within the saf e limits of the components with ade quate sepa ration marg in as per API Standar d 618.
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Torsional Vibration Analysis

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Compressor Design Philosophy

Utilization of standards, serv ice prov en designs components and with indiv idual compressor design ed to cater to precise needs Lube oil sy stem, Pulsation dampen ers, Saf eties, Instrumentation and Controls as per API-618 with minor dev iations Gas Cooler desig ns gener ally per TE MA R / B and also as per API-660 & API-661 Pressure Vessel desig n as per AS ME section- VIII 15 Y ears of serv ice lif e and 2 Y ears without a major ov erhaul. AR M Th eme Av ailability , Reliability & Maintain ability
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Compressor Packages
A wid e range of auxiliary equipment on Process gas compressor packages includes: Forced lubrication systems a nd wat er consoles comply ing with API -618 standards. Capacity control systems inclu ding suction v alv e unloaders, v olume clearance pockets (manually or pneumatically operated), automatic by -pass sy stems and step less capacity control sy stems. Pulsation dampeners designed to attenuate pressur e pulsations in process pipe work. Digital and Analog ue computer an aly sis of the acoustic and mechanical interaction of the v essels and associated piping sy stems. Gas intercoolers and aftercoolers of shell and tube, air blast, plate ty pe or other design.

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Natural Gas Compressor

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Advancements in Pulsation Control Technology

Department of Energy (DOE) and the Gas Machine ry Research Council (GMRC) spo nsored pr ogram terme d as the Adv anced Reciprocating Compressor technolo gy (ARCT) program. Necessity of Adv anced Pulsation Control technique d ue to high speed of compressor with hig h horse po we r requi rements. This desig n tool leads to a) Filtering pulsations. b) c) d) Reduced equ ipment, pipin g v ibrations & noise. Increased sy stem reliability . Improv ed compressor eff iciency .

e) Enhanci ng compressor v alv e lif e. Design appro aches 1, 2 or 3 as per API 618 used as per ap plications The ra pid adv ancements of digital computer aided Design Sy stems enabl es to analy ze the f luid dy namics to predict attenuation characteristics, pass bands, pulsation lev els, acoustic simulation etc. Simple solutions giv e substantial power consumption sav ing.
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Advancements in Pulsation Control Technology

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Inertia Balanced with Zero Couple BOPs

Latest Balanced Op posed Compr essor v ersions are prov ided with crankshaf ts with zeroi ng couple f eature wh erei n crank throws are exactly aligne d thereby eliminating most v ibrations generally associated with reciprocating ty pe compressors. Inertia f orces balanced within 1% Enabl es use in v ibration sensitiv e application such as off shore platf orms and trailer mou nted units. Permits the compressor to run at high speed of 1800 rpm

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Truck Mounted High Pressure Reciprocating Compressor (200 Bar) - ONGC

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CNG Packages

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Advantages of Natural Gas Driven Air Compressors

Natural gas engine-driv en air compressors offer many potential benefits, inc luding:
Lower co st of producing compressed air Lower co st for pro viding steam and hot water for heating or cooling needs Lower life-cycle cost Attractive return on investment Lower co st of emergency bac kup power equipment Secured capability for supplying compressed air during power disruptions

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Focus on Life Enhancement

Fig. Primary causes of unscheduled recipr ocating compressor shutdo wns

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From Concept ( 3-D) to Manufacturing (2-D Drawing)

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Design optimisation for weight reduction (Resultant Deformation plot)

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Effective visualization
(Compre sso r Hou se )

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Energy Efficient Motors

Energy -eff icient motors, also called premium or high- eff iciency motors or EFF1, are 2 to 8% more eff icient than standard motors. Motors qu alify as "energy -eff icient" if they meet or exceed the efficiency lev els listed in the National Electric Man uf acturers Association's (NEMA's) MG 1-19 93 publication. Energy -eff icient motors generally hav e longer insulation and be arin g liv es, lower heat output, and less v ibration. In addition, these motors are of ten more tolerant of ov erload conditions and phase imbala nce. This results in low f ailure rates, which has pr ompted most manuf acturers to off er longer warra nties f or their energy -eff icient lines.

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Energy Efficient Motors

The ef f iciency of a motor sy stem depends on sev eral f actors, including: a) motor eff iciency b) c) d) e) f) g) h) motor speed control proper sizi ng powe r supply quality distribution losses mechanical transmission maintenance practices end-use mechanic al eff iciency (pump, f an, compressor, etc).

The n on-e nergy benef its of higher eff iciency sy stems are better process control, reduced disru ption and impr ov ed product quality . Energy -eff icient motors should be considere d f or all new installations, replaceme nt of f ailed motors, or as spares.
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VFD
VFD- VARI ABL E SPEED DR IVE The s ync hronous s peed of an inducti on motor is determi ned by the foll owing equati on. N s = 120 f / p ( rpm) The onl y way to c hang e the s peed, for a gi ven pole number is to var y the frequenc y VFD B ASIC PR INCIPL E The proc ess of transfor mi ng the stable power line fr equenc y i nto a vari abl e frequenc y i s basi call y done in two s teps : 1. The si nusoi dal voltag e is rec tifi ed into an DC volt age. 2. The DC vol tag e is chopped up to an DC vol tag e of the desir ed fr equenc y VFD- VARI ABL E SPEED DR IVE By Pr ovidi ng VFD i n c ompressor c ontrol we can var y the C ompr ess or R PM depending on req uirement. This c ompl etel y avoi ds unloadi ng and saves unl oad power consumption whic h is nor mall y 25- 35% of the full l oad cons umpti on. Major advantage of variable speed drive is that i f 4 to 5 c ompr ess or are c onnected to a common header, then by i nstalling VFD in one c ompres sor, the energ y s avi ng due to pr ess ure reducti on is ac hieved i n all the c ompres sor .

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