RU2740389C9 - Piston compressor unit and method of operation thereof - Google Patents

Abstract

FIELD: oil, gas and coke-chemical industries.

SUBSTANCE: piston compressor unit is intended for compression of gas and can be used for preparation of hydrocarbon gases for transportation or processing at gas and oil industry facilities. Installation includes a single-shaft gas turbine with an output shaft, the first step-down gearing with input and output shafts. Output shaft of the first step-down gear is rotated at a lower speed than the output shaft of the turbine. Adjustable hydrodynamic gearing is connected to the output shaft of the first step-down gearing and has input and output shafts. Second gear transmission is connected to output shaft of the hydraulic coupling and has input and output shafts, driven piston compressor connected to the output shaft of the second gear. Adjustable hydraulic coupling is used as controlled hydraulic transmission. Second gearing is made decreasing and its output shaft rotates at lower speed than output shaft of the hydraulic clutch. Hydraulic clutch is configured to control speed of its output shaft from zero to full speed by controlling supply of working fluid into working cavity of hydraulic clutch. Between the second step-down gear and the compressor there is a plate elastic coupling to compensate for radial, angular and axial displacements of the connected shafts of the second step-down gearing and the piston compressor. Also disclosed is a method of operation of a piston compressor unit.

EFFECT: piston compressor unit with a single-shaft gas turbine as its drive is provided.

7 cl, 4 dwg, 1 tbl

Description

The invention relates to reciprocating compressor units, in particular to reciprocating compressor units driven by turbines, more specifically by single-shaft gas turbine engines, and the method of their operation, is intended for compressing gas and can be used to prepare, in particular hydrocarbon gases, for transportation or processing on facilities of the gas and oil industry.

Reciprocating compressor units are widely used for the compression of hydrocarbon gases, their use is especially advantageous for compressing gas to high pressures at low flow rates (volumes), when changing modes in terms of flow and pressure, with frequent starts and stops associated with the conditions of the process. It is especially advantageous to use them at the head and booster compressor stations of the fields, as well as at the nodal compressor stations in front of the branch pipelines with a large irregularity of seasonal and daily gas consumption. The use of other types of compressors, for example, centrifugal, in such conditions is impractical or impossible for technical reasons. Reciprocating compressors are capable of maintaining low performance at the same level for a relatively long time. At the same time, reciprocating compressors are distinguished by a relatively simple design and the associated reliability, ease of maintenance and low operating costs. Reciprocating compressors are also distinguished by stable operation when pumping contaminated and aggressive working media. Reciprocating compressors are usually driven by an electric motor or a reciprocating internal combustion engine and very rarely by steam or gas turbines. The drive drives the compressor through its output shaft, transmission device, compressor input shaft.

When using a turbine as a drive for a reciprocating compressor, a number of problems arise. Attempts to solve these problems are described, for example, in patent documents RU 2635725 (publ. 11/15/2017), CN 102383866 (publ. 03/21/2012). However, the mechanical clutch used in the reciprocating systems described in these documents does not solve all the problems. The solution according to RU 2635725 is intended for twin-shaft turbines as a drive for a reciprocating compressor. The solution according to CN 102383866 is intended for a steam turbine as a drive for a reciprocating compressor, while high starting loads are not eliminated, torsional vibrations from the reciprocating compressor are not completely damped. The mechanical clutch does not provide for a wide range of piston compressor capacity regulation, which is necessary due to its operating conditions (see above).

In some applications, it is beneficial to use a single-shaft gas turbine as the drive for a reciprocating compressor. Such turbines are distinguished by their simple design and, as a result, high reliability, ease of maintenance and repair, low cost and low operating costs. Such turbines are also distinguished by smaller dimensions and weight, and a lower risk of resonance phenomena of the shafting. In addition, they are not tied to external fuel supplies and operate on the gas pumped by the compressor unit. However, such a high-speed turbine cannot be started while it is connected to a load, in this case a reciprocating compressor, since its power is taken to the turbine's air compressor at startup, and the load prevents the turbine from spinning up. Another problem is that the turbine must in some cases run continuously even if the compressor is not running. The problem is also inherent in the piston compressor torsional vibrations from unbalanced masses of the crankshaft, low speed of rotation of the input shaft. The advantage of reciprocating compressors associated with the ability to operate in a wide range of capacities and when changing modes in terms of gas flow rate and pressure cannot be realized, since control of the compressor unit capacity by changing the number of revolutions (speed) of a single-shaft gas turbine is possible only in a very narrow range due to the features inherent in such a turbine.

From the patent document US 7422543 (publ. 09.09.2008) a compressor installation is known containing a two-shaft gas turbine, a compressor driven by said turbine, a reducer located between the gas turbine and the compressor, a torque converter located between the reducer and the compressor, a gearbox between the torque converter and a compressor, wherein the torque converter has a locking mechanism for mechanically connecting the input end of the torque converter to the output end of the torque converter to form a mechanical clutch and ensure stable rotation between the turbine and the compressor at a synchronized speed. In this case, the torque converter has adjustable guide vanes, thanks to which the speed of the output shaft is regulated from zero to full speed. At the same time, the speeds provided by the reducer and the transmission are not disclosed. The disadvantage of this solution is the following. The input shaft of a reciprocating compressor, unlike centrifugal and axial compressors, has a large vibration and radial, angular and axial displacements due to torsional vibrations inherent in reciprocating compressors. Torsional vibrations during mechanical coupling during stable operation will be completely transmitted from the compressor to the turbine (turbine rotor), which is unacceptable, since this leads to a loss of vibration resistance of the installation and to an accident. In addition, permanent mechanical clutch leads to wear of the contact pairs, and, as a result, to a loss of adhesion accuracy, strength due to increased vibration, to an increase in temperature, contamination of oil in the torque converter and gear drives with wear products. In addition, capacity regulation is only possible in a narrow range by varying the turbine speed. This technical solution is preferable for centrifugal compressors. The use of a gearbox, as well as an additional starting device for the turbine and an electric motor for the compressor, complicates the design.

From the patent document US 2008/0245634 (publ. 09.10.2008) known compressor installation, containing as a drive a gas turbine with a high speed with an output shaft, a first transmission with input and output shafts, an adjustable fluid coupling (also called a hydrodynamic clutch) for starting the compressor connected to the output shaft of the first transmission and having an output shaft, a second transmission connected to the output shaft of the fluid coupling and having an output shaft, a driven compressor operating at a speed equivalent to the speed of the gas turbine, connected to the output shaft of the second transmission, while the fluid coupling is configured regulating the speed of the output shaft from zero to full speed by regulating the supply of working fluid to the working cavity of the fluid coupling, while the fluid coupling contains a friction mechanical clutch for coupling the turbine wheel with the movable casing of the impeller impeller of the fluid coupling during synchronization. The type of transmission has not been disclosed. The disadvantages of this solution are common with the device according to US 7422543: the presence of a mechanical clutch to ensure stable rotation between the turbine and the compressor at a synchronized speed is not applicable to reciprocating compressors due to their inherent torsional vibrations. In addition, permanent mechanical clutch leads to wear of the contact pairs, and, as a result, to a loss of adhesion accuracy, strength due to increased vibration, to an increase in temperature, contamination of oil in the hydraulic clutch and gear drives with wear products, all this can lead to breakdown and accidents. ... This technical solution is preferable for centrifugal compressors. The method of operation of the compressor unit is as follows. The gas turbine starts up without the compressor running. The fluid coupling is filled with fluid. The compressor is started by the drive by filling the fluid coupling until it runs synchronously with the drive. Sensors detect when synchronization occurs. Then the friction mechanical clutch is turned on, after its activation, the torque is transmitted from the gas turbine to the compressor in two ways, namely through the fluid coupling, on the one hand, and through the mechanical friction clutch, on the other. The two power streams run parallel to each other. The fluid is then freed from the fluid so that only the friction mechanical clutch transfers torque from the gas turbine to the compressor. To shut down the compressor unit:

a) the gas turbine turns off and runs on the compressor, while the clutch is turned off, the gas turbine and the compressor are completely disconnected from each other, or

b) the empty hydraulic clutch is again filled with liquid, the mechanical friction clutch is disconnected, the hydraulic clutch is released from the liquid, although the gas turbine continues to operate, the torque is not transmitted to the compressor and it stops. Thus, the compressor can run intermittently, the gas turbine can run non-stop.

This method is not applicable for compressor units with a reciprocating compressor due to mechanical coupling, in addition, capacity control is possible only in a narrow range by changing the turbine speed.

For the closest analogue of the proposed device, a technical solution was chosen according to the patent document EA 200870207 (published on 02/27/2009). The compressor unit contains rotary equipment: a single-shaft gas turbine with an output shaft; a first reduction gear train with input and output shafts, the output shaft of the gear reduction gear rotating at a lower speed than the output shaft of the gas turbine; a torque converter for starting the compressor connected to an output shaft of the reduction gear and having an output shaft; a second overdrive gear coupled to the torque converter output shaft and having an overdrive gear output shaft rotating at a faster speed than the torque converter output shaft; a driven compressor coupled to the output shaft of the overdrive gear, wherein the rotational speed of the output shaft of said torque converter can be increased by the overdrive gear to meet the operating speed requirements of the compressor. The operating speed of a single-shaft gas turbine can be 9-14 thousand rpm, the operating speed of the torque converter is 2-3 thousand rpm, the operating speed of a centrifugal compressor is 5-13 thousand rpm. The first down and second up gears are used to match these speeds. In this case, the torque converter has a locking mechanism for mechanically connecting the input end of the torque converter to the output end of the torque converter to form a mechanical clutch and ensure stable rotation between the turbine and the compressor at a synchronized speed. In this case, the torque converter has adjustable guide vanes, thanks to which the speed of the output shaft is regulated from zero to full speed. In this case, the gear drives and the torque converter can be in the same or different casings, the gear drives can be single-spiral or double-spiral.

The disadvantages of such a solution, due to the presence of a mechanical clutch to ensure stable rotation between the turbine and the compressor at a synchronized speed, are common with devices according to US 7422543 and US 2008/0245634 and are described above, although in such a device it is possible to provide a warm-up, idle and smooth loading a single-shaft gas turbine without connecting the load (with the compressor off). The disadvantage is also the following: the proposed overdrive is not applicable with reciprocating compressors having much lower rotation speeds on the input shaft (500-1500 rpm) than common gas turbines, especially single-shaft ones (9-14 thousand rpm). This technical solution is preferable for centrifugal compressors, since they have high operating speeds. In addition, the input shaft of a reciprocating compressor has greater vibration and radial, angular and axial displacements due to torsional vibrations compared to a rotary compressor (centrifugal, axial). Another disadvantage is the complex design of the torque converter blade movement unit, the presence of a blocking device and, as a consequence, the complex design of the torque converter.

For the closest analogue of the proposed method, a method was chosen for starting large rotary equipment according to patent document EA 200870207 (publ. 02/27/2009) in which a compressor unit is provided containing a single-shaft gas turbine, a reduction gear is connected to a gas turbine, a torque converter is connected to start the compressor to a reduction a gear train, an overdrive gear is connected to the torque converter, a compressor is connected to an overdrive gear, the gas turbine is started at the first output power, the first speed is reduced to a second speed lower than the first speed using a reduction gear, the increasing power is transmitted using a torque converter at output speeds from zero to a second speed lower than the first speed, by adjusting the guide vanes of the hydraulic pump to supply the working fluid to the hydraulic turbine in the torque converter, the second speed is increased to third speed, higher than second speed, by means of an overdrive gear and keep the compressor running at third speed, with the converter locked at a synchronized speed. The disadvantage of this method is the following. The proposed speed increase is not applicable in compressor units with a reciprocating compressor due to the low speed of rotation of its input shaft. The method does not provide for compensation of vibration, radial, angular and axial displacements of the input shaft of the compressor, arising from torsional vibrations of the compressor crankshaft, and which can be transmitted to the transmission devices and to the turbine rotor, which can lead to a loss of vibration resistance of the installation and to an accident. Performance regulation in this way is possible only in a very narrow range by changing the speed of a single-shaft gas turbine. This method is intended for compressor plants with a centrifugal compressor.

Thus, the task is to create a reciprocating compressor unit, in which a single-shaft gas turbine can be used as a piston compressor drive; for this, such a reciprocating compressor unit should provide a heating mode, idling and smooth loading of a single-shaft gas turbine, a wide range of capacity regulation should be provided. of the compressor unit associated with the conditions of its operation, the transfer of torsional vibrations from the unbalanced masses of the crankshaft of the piston compressor to the rotor of the gas turbine should be excluded, and compensation for the radial, angular and axial displacements of the input shaft of the reciprocating compressor should be ensured; installation, providing the mode of heating, idling and smooth loading of a single-shaft gas turbine, a wide range of regulation of the capacity of the compressor unit, excluding the transmission of torsional vibrations from balanced masses of the crankshaft of the piston compressor on the rotor of the gas turbine, and with the provision of compensation for radial, angular and axial displacements of the input shaft of the piston compressor.

To achieve the specified technical result, a piston compressor unit is proposed, including: a single-shaft gas turbine (hereinafter referred to as a turbine) with an output shaft; a first reduction gear with an input and an output shaft (hereinafter referred to as the first reduction gear), while the output shaft of the first reduction gear rotates at a lower speed than the turbine output shaft; an adjustable hydrodynamic transmission in the capacity of which an adjustable fluid coupling (hereinafter referred to as a fluid coupling) is used, connected to the output shaft of the first reduction gear and having an input and output shaft; a second reduction gear (hereinafter referred to as the second reduction gear), connected to the output shaft of the fluid coupling and having an input and output shaft, while the output shaft of the second reduction gear rotates at a lower speed than the output shaft of the fluid coupling; a driven reciprocating compressor connected to the output shaft of the second reduction gear, while the fluid coupling is configured to adjust the output shaft speed from zero to full speed by adjusting the supply of working fluid to the working cavity of the fluid coupling, between the second reduction gear and the compressor there is a lamellar elastic clutch (also called dry-type disc clutch, hereinafter referred to as the clutch) to compensate for the radial, angular and axial displacements of the connected shafts of the second reduction gear and the piston compressor. In this case, the reduction gears and the hydraulic clutch can be in the same or different casings (housings), the reduction gears can be single-spiral or double-spiral, the first reduction gear can be in the same housing with the turbine.

Distinctive features of the proposed device from the above-mentioned known, closest to it, is that a fluid coupling is used, made with the possibility of adjusting the speed of the output shaft from zero to full speed by regulating the supply of working fluid into the working cavity of the fluid coupling, after the fluid coupling, a reduction gear is applied, rotating at a lower speed than the output shaft of the fluid coupling, between the second reduction gear and the compressor there is a clutch to compensate for the radial, angular and axial displacements of the connected shafts of the second reduction gear and the piston compressor, the first reduction gear in a particular case can be in one housing with a turbine, in the other in a particular case, the reduction gears and the hydraulic clutch can be in the same or different casings, the reduction gears can be single-spiral or double-spiral.

The use of two reduction gears and an adjustable hydrodynamic transmission (fluid coupling) makes it possible to use a high-speed (high-speed) single-shaft gas turbine to drive a low-speed (low-speed) reciprocating compressor. At the same time, it becomes possible to synchronize the operation of the turbine, fluid coupling and reciprocating compressor at their optimum operating speeds (9-14 thousand rpm for the turbine, 2-3 thousand rpm for the fluid coupling and 500-1500 rpm for the compressor). It also allows for efficient transmission of power from the turbine to the compressor. The use of a fluid coupling allows completely eliminating the mechanical connection of the turbine with the piston compressor (mechanical clutch), as a result, it becomes possible to warm up, smooth loading and idle of the turbine without a connected load. In addition, this makes it possible to exclude the transmission of vibrations from the piston compressor shaft to the turbine rotor in the load mode. Wear of contact pairs and contamination with wear products are excluded. The implementation of the fluid coupling with the ability to regulate the speed of its output shaft from zero to full speed by regulating the supply of working fluid to the working cavity of the fluid coupling allows you to adjust the performance of the compressor unit from zero to the maximum values set for the reciprocating compressor, as well as smoothly start it. This allows the reciprocating compressor unit to operate at different flow rates and pressures. The development of gas fields includes three stages: increasing, constant and declining production. Table 1 shows the main operating parameters of the reciprocating compressor unit during the 2015-2030 operation period. on the example of a reciprocating compressor unit with an opposed four-row reciprocating compressor for compressing natural gas at the booster compressor station of the Pyreinoye field, Yamalo-Nenets Autonomous Okrug in a declining production mode. The service life of reciprocating compressor units is at least 20 years. During this time, due to a decrease in the flow rate of the well, their productivity can significantly decrease, in the example shown over 15 years, productivity drops by almost 4 times. At the same time, the technical re-equipment of a compressor station - for example, replacing a compressor with a compressor with a lower capacity - is associated with high costs and is impractical. The proposed reciprocating compressor unit with a single-shaft gas turbine as a drive solves the problem of regulating productivity in a wide range when the well flow rate changes (with increasing and decreasing production), as well as with seasonal and daily fluctuations associated with uneven gas consumption.

The use of a lamellar elastic coupling makes it possible to compensate for the radial, angular and axial displacements of the connected shafts of the second reduction gear and the piston compressor. All of the above makes it possible to eliminate the problems of the prior art and to use a single-shaft gas turbine as a drive for a reciprocating compressor. Some well-known single-shaft gas turbines have a reduction gearing on the output shaft, in the same housing with the turbine, for example, the D049R gas turbine engine of NPO Saturn has a built-in coaxial gearbox. In a particular case, the implementation of reduction gears and fluid couplings in one casing allows to reduce the dimensions of the device, including through the use of a common lubrication system or a common oil tank for all equipment of the compressor unit, as well as to increase the reliability of the device.

The combination of all these essential features makes it possible to create a design of a compressor unit with a reciprocating compressor and a single-shaft gas turbine as its drive, providing a heating mode, idling and smooth loading of the turbine, a wide range of regulation of the compressor unit capacity, excluding the transmission of torsional vibrations from unbalanced masses of the crankshaft compressor on the turbine rotor, and provides compensation for radial, angular and axial displacements of the connected shafts of the second reduction gear and the compressor.

To achieve the specified technical result, a method is also proposed in which:

- provide a piston compressor unit containing a single-shaft gas turbine: connect the first - reduction - gear to the turbine, connect an adjustable hydrodynamic transmission, which is used as an adjustable hydraulic clutch, to the first reduction gear, connect the second - reduction - gear to the hydraulic coupling, connect the compressor to a second reduction gear through a lamellar elastic clutch;

- in the warm-up mode, the turbine is started, while the compressor does not work, the fluid coupling is not filled with working fluid and does not work, the turbine idle speed corresponding to the idle speed of the turbine is reached;

- at idle speed, the idling speed of the turbine is maintained corresponding to the power of the turbine at idle, while the hydraulic coupling is not filled with working fluid and does not work, the compressor does not work, the power is transferred to the first reduction gear and to the input shaft of the hydraulic coupling;

- in the mode of starting the compressor and working with load, they reach the first output speed corresponding to the rated power of the turbine and maintain the operation of the turbine at the first speed, reduce the first speed to the second speed, lower than the first speed, using the first reduction gear, and smoothly transmit the increasing power to the compressor using a fluid coupling at output speeds from zero to a second speed lower than the first speed, by smoothly feeding the working fluid into the working cavity of the fluid coupling, while the power is transmitted to the output shaft of the fluid coupling and the input shaft of the second reduction gear, and the second is reduced speed up to the third speed lower than the second speed with the help of the second reduction gear and maintain the compressor operation at the third speed corresponding to the compressor power, compensating for the radial, angular and axial displacements of the compressor shafts and the second reduction gear using a lamellar elastic clutch;

- in the mode of changing the performance of the compressor unit, the second speed is changed with the help of the fluid coupling by changing the amount of working fluid in the working cavity of the fluid coupling, and the third speed with the help of the second reduction gear;

- if it is necessary to switch from the operating mode under load to the idling mode of the turbine, the fluid coupling is freed from the working fluid and the compressor is turned off;

- if it is necessary to stop the turbine: in case of an emergency shutdown, the fuel supply to the turbine is turned off and the turbine run-out is used to completely stop the compressor unit, while the hydraulic coupling is filled with working fluid; during normal shutdown, the fluid coupling is smoothly released from the working fluid, the second speed is lowered to zero, the fluid coupling is turned off, while the compressor is turned off, cooled and the turbine is stopped.

Distinctive features of the proposed method from the above-mentioned known, closest to it, is that as a controlled hydrodynamic transmission, the method uses an adjustable fluid coupling, as a second gear transmission, a reduction gear is used, the compressor is connected to a second reduction gear through a lamellar elastic clutch; in the warm-up mode, the turbine is started, while the compressor does not work, the fluid coupling is not filled with working fluid and does not work, the turbine idle speed is reached, corresponding to the idle speed of the turbine; at idle, maintain the idle speed of the turbine corresponding to the turbine power at idle, while the hydraulic coupling is not filled with working fluid and does not work, the compressor does not work, the power is transferred to the first reduction gear and to the input shaft of the hydraulic coupling; in the compressor start-up and load operation mode, they reach the first output speed corresponding to the rated power of the turbine and maintain the operation of the turbine at the first speed, reduce the first speed to a second speed lower than the first speed using the first reduction gear, and smoothly transmit the increasing power to the compressor using a fluid coupling at output speeds from zero to a second speed lower than the first speed, by smoothly feeding the working fluid into the working cavity of the fluid coupling, while the power is transmitted to the output shaft of the fluid coupling and the input shaft of the second reduction gear, and the second speed is reduced to the third speed, lower than the second speed, with the help of the second reduction gear and maintain the compressor operation at the third speed corresponding to the compressor power, compensating for the radial, angular and axial displacements of the compressor shafts and the second reduction gear with the help of a lamellar elastic clutch; in the mode of changing the productivity of the compressor unit, the second speed is changed with the help of the fluid coupling by changing the amount of working fluid in the working cavity of the fluid coupling, and the third speed with the help of the second reduction gear; if it is necessary to switch from the operating mode under load to the idling mode of the turbine, the fluid coupling is freed from the working fluid and the compressor is turned off; if it is necessary to stop the turbine: in case of an emergency shutdown, the fuel supply to the turbine is turned off and the turbine run-out is used to completely stop the compressor unit, while the hydraulic coupling is filled with working fluid; during normal shutdown, the fluid coupling is smoothly released from the working fluid, the second speed is lowered to zero, the fluid coupling is turned off, while the compressor is turned off, cooled and the turbine is stopped.

Thanks to all the essential features, the method of operation of a reciprocating compressor unit with a single-shaft gas turbine as a piston compressor drive is realized, in which the mode of heating, idling and smooth loading of the turbine is ensured, a wide range of regulation of the compressor unit capacity, the transmission of torsional vibrations from unbalanced masses of the compressor crankshaft is excluded on the turbine rotor, and compensation for radial, angular and axial displacements of the compressor input shaft is provided.

The invention is illustrated in the drawings.

Figure 1 shows a piston compressor unit - a schematic diagram - one of the specific embodiments of the invention, figure 2 schematically shows one of the examples of the reduction gears and fluid couplings in a common housing, figure 3 shows one of the examples of the elastic plate clutch, figure 4 shows block diagram illustrating the operation of the compressor unit in different modes, where 1 is a piston compressor, 2 is a single-shaft gas turbine, 3 is the first reduction gear, 4 is a hydraulic clutch, 5 is a second reduction gear, 6 is an elastic plate clutch, 7 is input shaft of the first reduction gear (3), 8 - output shaft of the second reduction gear (5), 9 - working cavity of the fluid coupling (4), 10 - working fluid in the working cavity (9) of the hydraulic clutch (4), 11 - bucket of the hydraulic clutch (4), 12 - half-coupling of the coupling (6), 13 - spacer of the coupling (6), 14 - screw of the coupling (6), 15 - keyed connection of the coupling (6), 16 - elastic elements of the coupling (6).

The compressor unit (Fig. 1) contains a reciprocating compressor (1), for example, an opposed crosshead compressor, which are widely available on the market, for example, by Ariel Corp., USA, a single-shaft gas turbine (2) is used as a drive, which are also presented On the market. The gas turbine and compressor, as a rule, are installed on a common base (frame) and are interconnected by transmission devices: the output shaft of the gas turbine (not shown) is connected to the input shaft (7) of the first reduction gear, its output shaft is connected to the input shaft (not shown) of the fluid coupling (4), the output shaft (not shown) of the fluid coupling (4) is connected to the input shaft (not shown) of the second reduction gear (5), the output shaft (8) of the second reduction gear (5) is connected to an elastic plate clutch (6 ), which in turn is connected to the input shaft (not shown) of the compressor (1). FIG. 2 shows one of the variants of the first reduction gear (3), fluid coupling (4) and the second reduction gear (5) made in a single housing. Such devices are also on the market. For example, the company Voith TurboGmbH & Co.KG, Germany, has developed a similar type R ... KGS variable reduction gear clutch for centrifugal compressors with an electric motor as a drive. The housing of such a transmission device has a lower part made in the form of a container (not shown) for oil, which, as a rule, serves as a working fluid (10) for a fluid coupling (4) and for lubricating gears (3, 5). The filling of the working cavity (9) of the fluid coupling (4) with oil (10) during start-up and operating mode is changed with the help of the scoop (11) in any degree - from full filling to complete emptying. In this way, the transmitted power and the speed from the drive to the load are infinitely variable. The bucket (11) can have an electro-hydraulic servo drive with automatic control. In this case, the output shaft of the first reduction gear (3) and the input shaft of the hydraulic clutch (4) can be made as a single whole, as well as the output shaft of the hydraulic clutch (4) and the input shaft of the second reduction gear (5). Such a device, using the example of a centrifugal compressor and an electric motor as its drive, works as follows. When starting, the bucket (11) is in the 0% position, the working chamber (9) of the fluid coupling (4) is not filled with oil (10), there is no load on the electric motor shaft, the compressor shaft does not rotate, the oil supply is turned on, the fluid coupling (4) and the compressor is stopped. condition, the bearings are lubricated. The electric motor is started up to the rated speed without load, the hydraulic coupling (4) is filled with oil (10) and rotates, the compressor shaft begins to rotate. The working cavity (9) of the fluid coupling (4) continues to gradually fill with oil (10), the compressor starts to rotate at the desired speed, the scoop is in position n% ... 100%, gears (3, 5) allow synchronizing the speed of the electric motor and compressor. The principle of operation of such a device with a piston compressor (1) and a single-shaft gas turbine (2) as its drive is similar. The person skilled in the art understands that the arrangement of gears (3, 5) and variable fluid clutch (4) may be different. Some single-shaft gas turbines (2) may have a reduction gear (3) on their output shaft, for example, the above-mentioned D049R gas turbine engine of NPO Saturn. In this case, the hydraulic clutch (4) and the second reduction gear (5) can be in one casing (casing) (for example, an adjustable gear clutch type R ... GS from Voith Turbo GmbH & Co.KG) or they can be in different casings. Both gears (3, 5) and the fluid coupling (4) can have their own covers; such devices are also available on the market. Flexible plate couplings (6) are widely available on the market, for example, by Rexnord Corp., USA. FIG. 3 shows one of the examples of its implementation. The design of the clutch is a torsionally rigid device and consists, as a rule, of a half-coupling (12) of the engine (drive), a half-coupling (12) of a compressor and a spacer (13), which are interconnected by screws (14). The half-couplings are connected to the drive shaft (in the device according to the invention with the output shaft of the second reduction gear) and the input shaft of the compressor (1) by means of a keyed connection (15). The design of the spacer (13) of the clutch (6) includes elastic elements (16), due to the complex deformation of which the clutch (6) compensates for the deviations in the relative position of the shafts connected by it. The elastic plate coupling (6) is provided with a cover for safety reasons. The connection of the shafts of the turbine, reduction gears, fluid couplings, clutches and compressor can be keyed, flanged, or can be performed in any other known way.

FIG. 4 illustrates the operation of the compressor unit in different modes. In the warm-up mode, fuel is supplied to the turbine (2) and the turbine is started, then the idle speed of the turbine (2) is reached, corresponding to the power of the turbine (2) at idle speed, and the turbine (2) is idle, while the bucket (11) of the hydraulic coupling (4) in the 0% position, the working chamber (9) of the fluid coupling (4) is not filled with oil (10), the output shaft of the fluid coupling (4) does not rotate, the compressor (1) does not work. At idle, the idling speed of the turbine (2) is maintained, corresponding to the power of the turbine (2) at idle, the bucket (11) of the fluid coupling (4) is still in the 0% position, the working cavity (9) of the fluid coupling (4) is not filled oil (10), the output shaft of the fluid coupling (4) does not rotate, the compressor (1) does not work, the power is transmitted to the first reduction gear (3) and to the input shaft of the fluid coupling (4).

In the mode of starting the compressor and working with load, the first output speed is reached corresponding to the rated power of the turbine (2) and the operation of the turbine (2) is maintained at the first speed, the first speed is reduced to a second speed lower than the first speed using the first reduction gear (3), and smoothly transmit the increasing power to the compressor (1) using the fluid coupling (4) at output speeds from zero to the second speed, lower than the first speed, by smoothly feeding oil (10) into the working cavity (9) of the fluid coupling (four). For this, the scoop (11) is moved from the 0% position to the n% ... 100% position. The working cavity (9) of the fluid coupling (4) is gradually filled with oil (10). In this case, power is transmitted to the output shaft of the fluid coupling (4) and the input shaft (8) of the second reduction gear (5), with the help of which the second speed is reduced to a third speed lower than the second speed and the operation of the compressor (1) is maintained at the third speed, corresponding compressor capacity (1). By means of a lamellar elastic clutch (6), radial, angular and axial displacements of the input shaft of the compressor (1) and the output shaft (8) of the second reduction gear (5) are compensated. Due to this, as well as due to the use of a fluid coupling (4), the transmission of torsional vibrations from the unbalanced masses of the compressor crankshaft (1) to the shaft line and through it to the turbine rotor (2) is not allowed.

In the mode of changing the performance of the compressor unit, the second speed is changed with the help of the fluid coupling (4) by changing the amount of oil (10) in the working cavity (9) of the fluid coupling (10), and the third speed with the help of the second reduction gear (5). In this case, the scoop (11) is moved to the n% position. The position of the scoop (11) for different capacities of the compressor unit is determined by calculation or experimentally. If it is necessary to switch from the operating mode under load to the idling mode of the turbine (2), the fluid coupling (4) is freed from the oil (10), while the scoop (11) is smoothly moved to the 0% position and the compressor (1) is turned off. If it is necessary to stop the turbine (2) in case of an emergency shutdown, the fuel supply to the turbine (2) is turned off and the turbine (2) run-out is used to completely stop the compressor unit, while the hydraulic coupling (4) is filled with oil, the scoop is in position n% ... 100%. During normal shutdown, fluid coupling (4) is smoothly freed from oil (10). For this, the scoop (11) is moved from the n% ... 100% position to the 0% position. The second speed is lowered to zero, the fluid coupling (4) is turned off, while the compressor (1) is turned off, cooled and the turbine (2) is stopped.

The authors have developed a piston compressor unit, which involves the use of: a piston opposed cross-head six-cylinder compressor from Borsig, Germany, with two stages of pressure increase; gas turbine engine D049R of JSC NPO Saturn as a drive, with a built-in coaxial gearbox (first reduction gear); variable speed reduction clutch from Voith TurboGmbH & Co.KG type R… GS - a combination of variable hydraulic clutch and reduction gear (second reduction gear) in a single housing; flexible plate coupling Rexnord Thomas. The rotor speed of the power turbine is 14 thousand rpm, the speed of the output shaft of the gas turbine engine reducer is 3000 rpm, the speed of the output shaft of the adjustable gear clutch is 0 ... 3000 rpm, the speed of the input shaft of the piston compressor is 0 ... 469 rpm min. The unit is designed to compress hydrocarbon gas. Gas pressure at the inlet to the reciprocating compressor unit from 0.71 to 3.41 MPa (abs.), Gas pressure at the outlet from the unit from 3.38 to 5.40 MPa (abs.), Capacity from 1367.3 to 3553, 4 thousand stm ³ / day (at a temperature of 20 ° C and a pressure of 760 mm Hg).

The claimed technical solution of the reciprocating compressor unit can be implemented in industrial production using standard equipment and technology. The installation is assembled from standard compressor, gas turbine, electrical, gas, tank and heat exchange equipment; the installation uses well-known transfer devices, standard control and regulating devices, pipeline fittings, pipelines, and an automatic control system. The unit can be used for field gathering of natural and associated petroleum gas, for transporting gas for processing in field units or at gas processing plants, for re-injection of gas into a reservoir or underground gas storage facilities, for gas lift in oil fields, for increasing gas pressure for GPU and etc.

Claims (7)

1. Piston compressor unit, including a single-shaft gas turbine with an output shaft, a first reduction gear with input and output shafts, while the output shaft of the first reduction gear rotates at a lower speed than the turbine output shaft, an adjustable hydrodynamic transmission connected to the output shaft the first reduction gear and having input and output shafts, a second gear gear connected to the output shaft of the fluid coupling and having an input and output shafts, a driven piston compressor connected to the output shaft of the second gear, characterized in that an adjustable fluid coupling is used as an adjustable hydrodynamic transmission, the second gear transmission is made downward and its output shaft rotates at a lower speed than the output shaft of the fluid coupling, the fluid coupling is made with the ability to regulate the speed of its output shaft from zero to full speed by regulating the supply of the working fluid to the working cavity by the hydraulic couplings, a lamellar elastic clutch is located between the second reduction gear and the compressor to compensate for the radial, angular and axial displacements of the connected shafts of the second reduction gear and the piston compressor. 2. A piston compressor installation according to claim 1, characterized in that the first reduction gear is made in the same housing with a single-shaft gas turbine. 3. A piston compressor unit according to claim 1, characterized in that the reduction gears and the hydraulic clutch are made in one casing. 4. Piston compressor unit according to claim 1, characterized in that the reduction gears and the hydraulic clutch are made in different casings. 5. Reciprocating compressor unit according to claim 1, characterized in that the reduction gears are single-spiral. 6. Reciprocating compressor unit according to claim 1, characterized in that the reduction gears are double-helical. 7. A method of operation of a piston compressor unit, in which a piston compressor unit containing a single-shaft gas turbine is provided with a first reduction gear to be connected to the turbine, an adjustable hydrodynamic transmission is connected to the first reduction gear, a second gear transmission is connected to an adjustable hydrodynamic transmission, a piston compressor is connected to a second gear train, characterized in that an adjustable fluid coupling is used as a variable hydrodynamic gear, a reduction gear is used as a second gear gear, a piston compressor is connected to a second reduction gear through a lamellar elastic clutch, a turbine is started in a warm-up mode, while the compressor does not work, the fluid coupling is not filled with working fluid and does not work, they reach the idle speed of the turbine corresponding to the power of the turbine at idle speed, at idle speed, the idle speed is maintained and the turbines corresponding to the turbine power at idle, while the hydraulic coupling is not filled with working fluid and does not work, the compressor does not work, the power is transferred to the first reduction gear and to the input shaft of the hydraulic coupling, in the compressor start-up mode and operating with a load, they reach the first output speed, corresponding to the rated power of the turbine, and maintain the operation of the turbine at the first speed, reduce the first speed to a second speed lower than the first speed using the first reduction gear and smoothly transfer the increasing power to the compressor using a fluid coupling at output speeds from zero to second speed , lower than the first speed, by smoothly supplying the working fluid to the working cavity of the hydraulic clutch, while the power is transmitted to the output shaft of the hydraulic clutch and the input shaft of the second reduction gear, and the second speed is reduced to a third speed lower than the second speed with the help of the second reduction transmission, and support the work of of the compressor at the third speed corresponding to the compressor power, compensating for the radial, angular and axial displacements of the compressor shafts and the second reduction gear using a lamellar elastic clutch, in the mode of changing the performance of the compressor unit, the second speed is changed using the hydraulic clutch by changing the amount of working fluid in the working cavity of the hydraulic clutch, and the third speed with the help of the second reduction gear, if it is necessary to switch from the operating mode under load to the idling mode of the turbine, release the hydraulic coupling from the working fluid and turn off the compressor, if it is necessary to stop the turbine, in case of an emergency stop, turn off the fuel supply to the turbine and use the turbine run-out to completely stop the compressor unit, while the fluid coupling is filled with working fluid, during normal shutdown, the fluid coupling is smoothly released from the working fluid, the second speed is lowered to zero, the fluid coupling is turned off, while the compressor is turned off, cooled and rest pouring in the turbine.

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