Contoured Diaphragm Coupling for High-Pressure Compressor Misalignment
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Solution Overview
Problem
High pressure ethylene polymerization reactor systems face challenges in maintaining reliable and safe operation of secondary compressors due to mechanical stresses and misalignment issues, leading to potential failures and downtime, especially at high throughputs.
Innovation Solution
A compressor system utilizing a contoured diaphragm flexible coupling to accommodate shaft misalignment between the motor driveshaft and compressor frame crankshaft, allowing for greater reliability and torque transmission without the limitations of multi-membrane couplings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the size of cylinders is increased to develop secondary compressors of higher throughput, then the gas throughput is improved, but the loads applied to the components of the cylinders and frame running gear components (connecting rods, bearings, and components resisting pressure end load) increase
Solution Approach 1:
The compressor is divided into two separate compressor frames (first and second compressor frames), each with its own cylinders and crankshafts. This segmentation allows the throughput to be distributed across multiple independent units, reducing the mechanical load on individual components while maintaining high overall throughput capacity.
2Productivity
If the number of cylinders in the compressor frame is increased to develop secondary compressors of higher throughput, then the gas throughput is improved, but the length of the crankshaft and the power transmitted through the crankshaft increase, limiting the number of cylinders that can be included
Solution Approach 1:
Instead of increasing the number of cylinders in a single compressor frame, the invention segments the system into two separate compressor frames with their own crankshafts. This allows the crankshaft length to remain manageable in each frame while achieving higher overall throughput through parallel operation of multiple frames.
3Productivity
If a second compressor frame is included on the opposite side of the motor to increase throughput, then the gas throughput is improved, but misalignment between the crankshafts of two separate compressor frames requires flexible coupling, which can fail and cause hazardous situations
Solution Approach 1:
The invention employs a flexible coupling comprising a package of thin disc membranes that can flex to accommodate misalignment between the motor driveshaft and compressor crankshafts. This flexible coupling design maintains reliability by allowing for operational misalignment without causing catastrophic failure, while still transmitting the necessary torque to drive both compressor frames at high throughput.
4Adaptability or versatility
If thin disc membrane flexible coupling is used to accommodate misalignment, then the misalignment is accommodated, but the torque transmission capacity is limited by the size of the thin disk membranes
Solution Approach 1:
The flexible coupling design merges multiple thin disc membranes into a package that collectively transmits torque. By combining the flexibility of multiple thin membranes with their cumulative torque transmission capacity, the system achieves both misalignment accommodation and sufficient power transmission capability for high throughput operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The contoured diaphragm flexible coupling enhances the reliability and longevity of secondary compressors, enabling high gas throughput and maintaining operational safety at pressures up to 2500 bar with increased torque transmission capacity, reducing the risk of sudden shutdowns and extending the compressor's working lifetime.
Implementation Method 1
A compressor system utilizing a contoured diaphragm flexible coupling to accommodate shaft misalignment between the motor driveshaft and compressor frame crankshaft
Data Source
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AI summary
The invention provides a compressor for use as a secondary compressor for an ethylene polymerization tubular reactor comprising a motor and at least two compressor frames, at least one of the compressor frames being coupled to the motor by means of a contoured diaphragm flexible coupling.