Dynamic Compressor Control for Suction Pressure Range
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Solution Overview
Problem
Conventional reciprocating compressors are restricted by static pressure and temperature safety shutdowns, which limit their operating range and production potential, often resulting in conservative operating conditions that do not maximize throughput or stimulate depleted wells.
Innovation Solution
A dynamic compressor control system that includes real-time monitoring and dynamic calculation of mechanical key performance indicators (KPIs) using a compressor analytic software package, allowing the compressor to operate over a wider suction pressure range by adjusting suction control and recycle valve setpoints, and providing alarm or shutdown signals based on actual machine limits rather than worst-case scenarios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If static pressure and temperature safety shutdowns are set to protect compressor mechanical limits, then equipment safety is ensured, but the compressor operating range and production potential are restricted
Solution Approach 1:
The patent implements dynamic safety shutdown controls that continuously monitor actual compressor operating conditions (pressure, temperature, flow rate, power consumption) and adjust shutdown setpoints in real-time based on the current operating point. This replaces static, fixed shutdown thresholds with dynamic, adaptive thresholds that move with the operating conditions, allowing the compressor to operate closer to its true mechanical limits without exceeding them. The dynamic control system calculates actual mechanical stresses and thermal loads based on real-time measurements, enabling the shutdown setpoints to reflect the true safety boundaries under varying operating conditions rather than conservative fixed values.
Solution Approach 2:
The patent employs feedback control by continuously measuring actual compressor performance parameters (discharge pressure, suction pressure, temperature, power consumption, flow rate) and using these measurements to dynamically adjust the shutdown setpoints. The system monitors the relationship between operating conditions and mechanical loads, feeding this information back to the control system which then modifies the shutdown thresholds accordingly. This closed-loop feedback mechanism ensures that the compressor operates within safe mechanical limits while maximizing its operating range, as the shutdown setpoints adapt to the actual mechanical stresses experienced rather than relying on predetermined conservative values.
2Reliability
If conservative static shutdown setpoints are used to prevent catastrophic failures, then equipment protection is achieved, but throughput and production revenue are reduced
Solution Approach 1:
The patent implements dynamic safety shutdown controls that continuously monitor actual compressor operating conditions (pressure, temperature, flow rate, power consumption) and adjust shutdown setpoints in real-time based on the current operating point. This replaces static, fixed shutdown thresholds with dynamic, adaptive thresholds that move with the operating conditions, allowing the compressor to operate closer to its true mechanical limits without exceeding them. The dynamic control system calculates actual mechanical stresses and thermal loads based on real-time measurements, enabling the shutdown setpoints to reflect the true safety boundaries under varying operating conditions rather than conservative fixed values.
Solution Approach 2:
The patent changes the parameters used for shutdown determination from fixed static values to dynamic calculated values based on actual operating conditions. The system computes real-time mechanical key performance indicators including rod loads, degrees of reversal, net ratios, and volumetric efficiencies based on measured pressure, temperature, and power consumption. These calculated parameters dynamically define the shutdown thresholds, allowing them to expand or contract based on the actual mechanical stresses and thermal loads experienced by the compressor, thereby permitting higher throughput when conditions allow while maintaining protection when limits are approached.
3Productivity
If the compressor operates at higher suction pressures to maximize throughput, then production potential increases, but the risk of exceeding mechanical ratings increases
Solution Approach 1:
The patent employs feedback control by continuously measuring actual compressor performance parameters (discharge pressure, suction pressure, temperature, power consumption, flow rate) and using these measurements to dynamically adjust the shutdown setpoints. The system monitors the relationship between operating conditions and mechanical loads, feeding this information back to the control system which then modifies the shutdown thresholds accordingly. This closed-loop feedback mechanism ensures that the compressor operates within safe mechanical limits while maximizing its operating range, as the shutdown setpoints adapt to the actual mechanical stresses experienced rather than relying on predetermined conservative values.
Solution Approach 2:
The patent replaces traditional mechanical protection methods (fixed mechanical governors, pressure relief valves set to conservative thresholds) with an electronic control system that calculates and responds to actual mechanical loads in real-time. The system uses sensors to measure operating parameters and electronically computes the actual mechanical stresses (rod loads, bearing loads, shaft torques) based on these measurements. This electronic substitution allows for precise, real-time monitoring and dynamic adjustment of operating limits, replacing crude mechanical protection with intelligent electronic control that can accurately track and respond to the true mechanical state of the compressor.
Data Source
AI summary
A dynamic compressor control is provided. The dynamic compressor control includes sensors to sense operating parameters of a compressor and a compressor analytic software package. The compressor analytic software package uses the sensed operating parameters of the compressor to generate key performance indicators. The key performance indicators are used to calculate process variables for the compressor. The dynamic compressor control uses the sensed operating parameters and the process variables calculated from the key performance indicators to provide operating alarms and/or shutdowns.