壳牌高压往复式压缩机组应用经验课件

1、壳牌高压往复式压缩机组应用经验Shell high-pressure reciprocating compressor experience Reciprocating Compressors part 1:1Gas Compressor Usage 气体压缩机的用途Reciprocating Gas Compressors 往复式气体压缩机Low pressure machines used in a wide variety of applications in the petroleum industry低压压缩机广泛的用于石油行业Medium/high pressure machine

2、s used for natural gas reinjection, refinery and general gas compression中/高压力机组用于天然气注气，炼厂和普通的气体压缩Hyberbaric machines are used for the compression of ethylene ( 3000 bar) in the manufacture of of low density polyethylene超高压压缩机组用于生产低密度聚乙烯时压缩乙烯（3000巴）Rotary Gas Compressors (screw or vane)旋转式气体压缩机(螺杆式或叶

3、片式)Relatively new for gas compression应用于气体压缩，最近才开始使用May be used for natural gas compression 可用于天然气的压缩Dynamic gas Compressors (axial flow, centrifugal)动力型压缩机(轴流式，离心式)Widely used in all processes of the hydrocarbons industries广泛用于所有烃类工业的生产过程中Animated cross-section of compressor动态压缩机剖面图Crank case曲轴箱Con

4、necting rod attached to crank shaft bybig-end bearing 连杆通过轴承大端与曲轴相连Connecting rodattached tocross-head bysmall-end bearing连杆通过小头轴承与十字头相连Partition seal分割密封Piston Rod活塞杆Piston Rod Packing活塞杆填料（盘根）Classification of wearing parts磨损部件的分类rod packing活塞杆填料rider / piston ring支撑/活塞环Valves阀piston rod活塞杆wiper r

5、ings刮油环compartment seals间隔密封valve un-loader device卸压阀packing box填料盒Fast wearing易损件 4 years 4 years1 - 3 years2 - 10 years 4 years 丙烷propane 乙烷ethane 甲烷methaneGases are less soluble at higher temperature在高温下气体的溶解性小Gases are less soluble at lower pressures 气体在低压下溶解性小Reduction of viscosity by dissolved

6、 gas 因溶解气体导致粘度下降Lubricant wash-off by liquid components in the gas润滑油被气体中的液相冲刷掉Loss of lubricant into high pressure gas stream高压气体蒸汽造成润滑油损耗Compatibility with well fluids 与油井使用液体的相容性Key effects in the compression of hydrocarbon gases压缩烃类气体对润滑油的主要影响Viscosity of Madrela E at 70C with various hydrocarbo

7、n gases莫雷拉俄E在70度时与不同烃类气体环境下的粘度0102030405060708090100020406080100120Pressure / bar 压力/巴残余粘度Remaining Viscosity / cStMethaneEthaneEthenePropanePropeneButaneBenefits of PAGs PAG类润滑油的优势Operate at high temperatures - up to 250C 运行于高温下-高达250 C PAGs unzip at higher temperatures - clean burning PAG类润滑油在高温下裂

8、解-燃烧更清洁Some inherent antiwear properties - long polar molecules一些固有的抗磨损特性-更长的极性分子链Wide viscosity range 10 - 100,000 cSt at 40C宽粘度范围， 40C粘度从10-100,000厘斯Superior performance compared with mineral oils与矿物油相比性能优越许多lower hydrocarbon gas solubility improves viscosity retention更低的烃类气体溶解性，保持粘度稳定less lubrica

9、nt lost into high pressure gas stream在高压气流下，更少的润滑油损耗oil film more resistant to wash-off by liquid components in gas油膜抵御气体中液体组份冲刷的能力更强compatible with gas processing fluids 与气体加工液相容+ ve: can be water soluble, very high VI, clean burning, will not dissolve petroleum gases readily, non-toxic in liquid f

10、orm, low volatility and pour point 与水相容，高粘度指数，燃烧清洁，不会溶解石油气，液相下无毒，低倾点- ve: in general not compatible with mineral oils, esters & HCs 与矿物油，酯类和烃类不相容Benefits of using Shell Madrela GP in compression of high pressure hydrocarbon gases高压烃类气体中使用莫雷拉GP的优势 ISO 680 矿物油(temperature 100C温度)No GasAtmos pressureMe

11、thane at 340 barNo Gas at340 barEthane at340 bar粘度Viscosity Cp0102030405060 Shell Madrela GPReduced loss in viscosity with Shell Madrela GP使用莫雷拉GP减少粘度损失不含烃常压下不含烃340巴含甲烷340巴乙烷常压下 温度Temperature 100C 压力Pressure 408 barTallow动物脂ShellMadrela GP050100150200250300Shell吸收量Absorption ppmwMineral OilTallowShe

12、ll Madrela GPReduced absorption into natural gas phase with Shell Madrela GP减少被天然气吸收的润滑油量 Benefits of using Shell Madrela GP in compression of high pressure hydrocarbon gases高压烃类气体中使用莫雷拉GP的优势平均密封寿命Average Packing Life, (000)hSignificant increase in pressure packing life with Shell Madrela GP极大的增加压力密

13、封的寿命0246810121416ISO 680 Mineral Oil Shell Madrela GPBenefits of using Shell Madrela GP in compression of high pressure hydrocarbon gases高压烃类气体中使用莫雷拉GP的优势050100150200250300350400Shell Madrela GPISO 680 Mineral Oil损失的工作时间Lost Production Time - h/annum/compressorSignificant reduction in lost productio

14、n time with Shell Madrela GP大大降低停机时间Benefits of using Shell Madrela GP in compression of high pressure hydrocarbon gases高压烃类气体中使用莫雷拉GP的优势Liquid heptane wash-off test液体庚烷冲刷试验010203040506070809010001020304050Cycles% Wt. of oil on platesShell Madrela GPSignificantly reduced heptane wash-off with Shell

15、Madrela GP莫雷拉GP极大的减少被庚烷的冲刷ISO 460 Mineral OilUK North Sea Brent A, B, C, D. 英国北海 布伦特A, B, C, DOperation commenced 1976-7 自1976年开始运营One large recip (14,000 HP/10 MW) per platform. Dresser Clark CLBA6.每个海上平台一个往复式压缩机6 cylinder, double acting, two stage machines 6缸双作用，2级压缩机Cylinder lubricant Valvata 680

16、J使用威华达J680润滑油Suction pressure 100 bar, reinjection pressure 410 bar. Piston speed 4.76 m/2 (937 fpm)入口压力100巴，注气压力410巴，活塞速度4.76 m/2 (937 fpm)UK North Sea Fulmar A 英国北海油田Two four-cylinder Borsig machines installed 两个4缸Borsig压缩机Plunger type with PTFE rings and rider bands使用PTFE活塞环和支撑环Operation commence

17、d 1982 on Madrela G自年起使用莫雷拉GSuction pressure 130 bar, discharge 360 bar 进气压力巴，排气巴No significant problems 没有遇到故障Machines continue to run in pipeline mode, 130 bar discharge压缩机继续用于管道气输送，巴压力P.D. Oman Birba阿曼Borsig, four cylinder machine operating since 1990Borsig缸压缩机，自年使用Natural gas, 8% H2S, 486 bar，天然

18、气，%H2S含量Originally on mineral lubricant原使用矿物油Reliability very poor, many ring and valve failures可靠性极差，许多活塞环和阀损坏Madrela GP commenced in operation, 2000莫雷拉GP 2000年开始使用Reliability greatly improved, 8000 hours ring life可靠性极大提高，活塞环寿命达到小时Comparative Ring Lives相对活塞环寿命Running-in thermoplastic piston rings a

19、nd pressure packings使用热塑活塞环和压力密封Intention is to develop transfer film on counterface目的是在相互运动表面产生转移油膜Excessive lubricant can wash transfer film from the counterface过多的润滑油可将转移油膜从接触表面冲刷走Insufficient lubricant will lead to high wear rates润滑油不足会造成高磨损率Varying lubricant rates causes highest wear rates频繁变化的

20、润滑油量将造成更高的磨损率Initial wear mechanism -establishing transfer film初始磨损件建立转移油膜Wear Behaviour磨损行为 Transfer Process Stabilised Wear Ideal Wear Profile :理想的磨损剖面Stage 1: Transfer ProcessStage 2: Wear StabilisationLiner roughness requirements缸壁粗糙度要求Life of the piston rings depends very much upon the roughnes

21、s of the counterface. Too low, transfer film not established. Too high, excessive wear rates.活塞环的寿命在很大程度上依赖于相对运动表面的粗糙度。过高将加速磨损速率Recommendations:推荐Shell 0.2 0.6 micron RaC. Lee Cook moderate pressure 4 6 micron Ra - higher pressure 2 3 micron RaCPI PEEK ring, 100 500 bar, 2 8 micron - PEEK ring, high pressures, 0.15 0.5 micronCooper 0.82 micron (?)Lubrication requirements润滑要求Values calculated for D-II-A注油量计算数值 Lower va