Abstract
Large reciprocating compressors are important equipment used in a wide range of process industries. Most of these compressors have huge power requirements and their capacity often needs to be regulated. Advanced technologies in compressor capacity control are effective approaches for saving large amounts of energy in process industries. This paper reviews the basic theories and the state of the art of the capacity control technologies. In particular, a compressor working procedure is first presented using an analogy to the pulse signal concept. Compressor capacity control methods are classified into pulse frequency modulation and pulse amplitude modulation from a perspective of pulse signal processing. The mechanisms and feasibility of some important methods, including dead volume variable control, partial-stroke and full-stroke suction valve opening, are reviewed. Based on the pulse signal concept, a duty cycle regulation method for capacity control is introduced, and the performance and implementation of the new method are compared with those of the existing suction valve opening methods. The duty cycle regulation method has integrated advantages over the other methods in terms of regulating precision, pressure stability, energy saving and reliability. All the suction valve opening methods can cause gas reflux, resulting in the so-called breathing effect. The breathing effect has negative effects on regulation performance and compressor security, which needs further investigation in the future.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Yu Y Z. Technical Manual of Volumetric Compressor for Application in Chemical, Power and Refrigeration Industries (in Chinese). Bei**g: China Machine Press, 2005. 44–56
Ren Z, Wang C Z. Brief analysis on flow rate regulating method of reciprocating compressor (in Chinese). Petro-Chemical Equipment Technology, 2003, 24: 21–23
** J M, Hong W R, Liang M, et al. Research progress on capacity control method of reciprocating compressor (in Chinese). Compressor Technology, 2007, 4: 28–32
API Standard 618: Reciprocating Compressors for the Petroleum, Chemical and Gas Industry Services, 5th edition. Washington D.C.: American Petroleum Institute Publishing Services, 2007
Danny M D, Klaus B, Ralph E H, et al. Advanced Reciprocating Compression Technology. Technical Report. San Antonio: Southwest Research Institute, 2005
Bauer F. Method for Continuous Control of Delivery Rate of Reciprocating Compressors and Device for Carrying Out the Method. US Patent, US 5244357A, 1993-9-14
Steinruck P, Ottitsch F, Oberhuber A, et al. Better reciprocating compressor capacity control. Hydrocarb Process, 1997, 76: 79–83
McKinney G D, Foreman M L. Active compressor valve control provides maximum unit flexibility. In: Proceedings of the Gas Machinery Conference, Austin, Texas, 2001. Dallas: Gas Machinery Research Council, 2001. 357–362
White K H. Infinitely variable capacity control. In: Proceedings of the 1972 International Compressor Technology Conference at Purdue, July 25–27, 1972, West Lafayette, Indiana. West Lafayette: Purdue University Press, 1972. 47–51
Hong W, ** J, Wu R, et al. Theoretical analysis and realization of stepless capacity control for reciprocating compressors. Proc Inst Mech Eng Part E-J Process Mech Eng, 2009, 223: 205–213
Song J. Development of Full-Range Capacity Stepless Control System in Reciprocating Compressor. Dissertation for Master’s Degree (in Chinese). Hangzhou: Zhejiang University, 2006
Sun X L. Theory and experiment study on capacity control of reciprocating compressor by unloading inlet valves at partial stroke. Dissertation for Master’s Degree (in Chinese). Hangzhou: Zhejiang University, 2006
Zhang R. The Research of the Variable Displacement Control System of Piston Compressor. Dissertation for Master’s Degree (in Chinese). Hangzhou: Zhejiang University, 2006
Guan Y H. Theory and experiment study on full range stepless regulating valve of reciprocating compressor. Dissertation for Master’s Degree (in Chinese). Hangzhou: Zhejiang University, 2005
** J M. Key Technology research on stepless capacity control system for reciprocating compressor. Dissertation for Doctor’s Degree (in Chinese). Hangzhou: Zhejiang University, 2010
Wu R R, Liu S L, Lu J Y. Analysis of gas pressure in the cylinder when inlet valve being pressed off during partial stroke (in Chinese). Cryogenics, 2000, 5: 37–40
Wu R R, Guan Y H. Regulation device in infinitely variable capacity valve and analysis on optimized regulation force (in Chinese). Fluid Mach, 2005, 33: 22–25
Wu R R, Xuan H J, Hong W R. Rupture failure analysis of the executing fork of the flow regulating apparatus in a partial stroke press-off inlet valve (in Chinese). Chem Engin Mach, 2001, 28: 277–280
Wu C H. Pneumatic device with indicator for suction valve opening regulation. Comp Techn, 2005, 6: 29–30
Liang Y. Principle and application of the infinitely variable capacity control system for reciprocating compressors (in Chinese). Comp Techn, 2007, 3: 13–17
Shen S C, Rao S. Application of PLC in capacity control system in reciprocating compressor (in Chinese). J Wuhan Univer Technol (Information and Management Engineering), 2009, 31: 275–277
Rao S. A Study on a time-division gas flow adjustment system of reciprocating compressor. Dissertation for Master’s Degree (in Chinese). Wuhan: Wuhan University of Technology, 2009
Ji Y F. Design and Application of the gas quantity control devices of labyrinth compressor (in Chinese). Chem Engin Mach, 2008, 35: 4–6
Gu Z L, Hou X P, Li Y, et al. A stepless capacity control method for reciprocating compressor (in Chinese). China Patent, CN 101173658B, 2010-08-25
Li H. Capacity control of reciprocating compressor: Methodology and design. Dissertation for Master’s Degree (in Chinese). **’an: **’an Jiaotong University, 2009
Author information
Authors and Affiliations
Corresponding authors
Additional information
This article is published with open access at Springerlink.com
Rights and permissions
This article is published under an open access license. Please check the 'Copyright Information' section either on this page or in the PDF for details of this license and what re-use is permitted. If your intended use exceeds what is permitted by the license or if you are unable to locate the licence and re-use information, please contact the Rights and Permissions team.
About this article
Cite this article
Gu, Z., Hou, X., Wang, Z. et al. Methods for large reciprocating compressor capacity control: A review based on pulse signal concept. Chin. Sci. Bull. 56, 1967–1974 (2011). https://doi.org/10.1007/s11434-011-4530-z
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11434-011-4530-z