Reciprocating Compressor Train Load Control for Variable Gas Feeds
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Solution Overview
Problem
The variability and intermittency of renewable energy sources pose challenges for stable and efficient operation of industrial gas plants, leading to inefficient operation rates and potential shutdowns due to power shortages, and existing control arrangements for compressor systems are inadequate in managing wide variations in production feed rates and pressures.
Innovation Solution
A method and system for load control of reciprocating compressors that involve selectively varying the capacity of compressor trains by continuously adjusting the capacity of a first subset of trains and fully loading or unloading a second subset of trains, using a master/slave control strategy to manage variable incoming gas feeds effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If renewable energy sources are used to power industrial gas plants, then environmental sustainability is improved, but operational stability deteriorates due to variable and intermittent power supply
Solution Approach 1:
The compressor system implements dynamic capacity adjustment through continuous variation of cylinder capacity in the first subset of compressor trains, allowing the system to adapt to variable renewable power supply while maintaining stable operation. The capacity can be continuously modulated between maximum and minimum levels to match fluctuating power availability.
Solution Approach 2:
The compressor system is divided into two distinct subsets: the first subset with continuously variable capacity compression and the second subset with on/off capacity control. This segmentation allows each subset to be optimized for different control strategies, enabling the overall system to handle variable power supply effectively while maintaining operational stability.
2Adaptability or versatility
If compressor capacity is continuously varied to match variable power supply, then adaptability is improved, but device complexity increases
Solution Approach 1:
The compressor system is divided into two distinct subsets: the first subset with continuously variable capacity compression and the second subset with on/off capacity control. This segmentation allows each subset to be optimized for different control strategies, enabling the overall system to handle variable power supply effectively while maintaining manageable complexity through specialized control approaches for each subset.
3Device complexity
If known control arrangements are used for compressor systems, then device simplicity is maintained, but productivity deteriorates under wide variations in production feed rates and pressures
Solution Approach 1:
The system employs dynamic capacity control in the first subset of compressor trains, continuously adjusting compression capacity to match variable power supply and production requirements. This dynamic approach maintains high compression efficiency across a wide range of operating conditions, unlike static control arrangements that are optimized for specific operating points.
Solution Approach 2:
The system changes the operational parameters of the compressor by continuously varying the capacity of cylinders in the first subset, allowing adaptation to different production feed rates and pressures. This parameter variation enables the system to maintain optimal compression efficiency across diverse operating conditions.
Data Source
AI summary
Controlling a capacity of the compression system in response to the variable incoming gas feed by: i) selectively varying a capacity of a first subset of one or more of the compressor trains by continuously varying the capacity of one or more cylinders of the one or more reciprocating compressor stages of the one or more compressor trains of the first subset between a maximum capacity and a minimum capacity; and/or ii) selectively varying a capacity of a second subset of one or more of the compressor trains by fully loading or fully unloading one or more cylinders of the one or more reciprocating compressor stages of the compressor trains of the second subset, wherein the first and second subsets are mutually exclusive.