Abstract:
Provided is a method including routing a compressed gas from a centrifugal gas compressor through at least one of a plurality of air coolers, and directing air flow through the plurality of air coolers, wherein the plurality of air coolers are arranged adjacent to one another in a single plane that is transverse to the air flow. Further provided is a method including removing tube cores from a cooler chamber of a liquid cooler of a centrifugal gas compressor, coupling a chamber port of the cooler chamber to a first port of an air cooler, and coupling a second port of the air cooler to a compressor port of a stage of the centrifugal gas compressor.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a divisional of U.S. patent application Ser. No. 10/769,666, filed on Jan. 30, 2004, entitled “Air Cooled Packaged Multi-Stage Centrifugal Compressor System”, which is herein incorporated by reference in its entirety, and which is a continuation of U.S. patent application Ser. No. 09/918,119, filed on Jul. 30, 2001, issued as U.S. Pat. No. 6,692,235, on Feb. 17, 2004, and entitled “Air Cooled Packaged Multi-Stage Centrifugal Compressor System,” which is herein incorporated by reference in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The field of this invention is air-cooled centrifugal compressor packages including some applications for their use and the waste heat generated from them. 
       BACKGROUND OF THE INVENTION 
       [0003]    When users in a variety of industrial applications considered a compressed gas system there were many choices. These systems could serve as plant air systems to operate a wide variety of machine components and control devices. Depending on the pressure and volume requirements of a particular location different compression packages could be used for the application. Each system had its unique advantages and disadvantages. Generally speaking as power costs increased worldwide, a greater focus was placed on multi-stage centrifugal compression systems over positive displacement designs such as screw compressors. The reason for this was that the positive displacement machines became less efficient as they wore, in normal use. In general, the initial efficiency of centrifugal compressor packages was higher than the positive displacement counterparts and the centrifugal compressor efficiency would maintain a nearly constant level over long periods of operation. Centrifugal compressors also offered excellent part load efficiencies and eliminated sliding or rubbing parts, such as in screw compressors, which would cause efficiency loss over time. 
         [0004]    Other advantages of centrifugal compressors are high reliability, the availability of oil-free air and ease of maintenance. Some features that made these advantages possible were: non-contact air and oil seals; stainless steel compression elements; high quality gear design using unlimited life pinion bearings; the elimination of the need for oil removal filters; elimination of need to remove wearing parts; and an accessible horizontally split gearbox for quick inspections. 
         [0005]    In the past, multi-stage centrifugal compressor units had been sold with inter-stage water-cooling to improve efficiency of the overall system. Use of water-cooled designs involved a host of significant associated costs, especially cooling towers. It also precluded applications of water-cooled centrifugal compressor packages in locations where water was not readily available or prohibitively expensive. Some potential installations also had space constraints that made use of water-cooled centrifugal compressors impossible. Water cooled systems involving cooling towers not only had space and installation cost elements but also required substantial operating costs for things such as make up water, pumping costs, chemicals including glycol to deal with potential freezing problems. Even connection to existing closed loop chilled water systems, assuming they had the requisite capacity, involved significant piping installation expenses and some of the same incremental operating costs previously described. 
         [0006]    Multi-stage centrifugal compressor packages have, in the past, been highly engineered to be space efficient. They have been sold as a compact package with the intercoolers below a gearbox that connects all three stages to a single drive motor. The lubrication system reservoir would be provided as a separate casting from the intercoolers and mounted alongside.  FIG. 5  illustrates this layout. There the drive motor  10  is connected through a gearbox  12  to the first stage  14 , the second stage  16  and the third stage  18  centrifugal compressors. Compressed gas from the first stage  14  enters cooler  20  and passes into the second stage  16  through inlet pipe  22 . The second stage  16  has an outlet line  24  into cooler  26  and the third stage, which receives the cooled gas from cooler  26 , has its exhaust directed to an after-cooler  28 . The final discharge is through line  30  which is directed upwardly adjacent the inlet line  32  to the first stage  14 . A control panel  34 , which sometimes requires cooling, is at one end of the skid package as is a reservoir for the lubricating oil  36 , which has its own cooler (not shown). For noise control and appearance purposes, the skid further comprised a metal paneled enclosure. It should be noted that while a water-cooled system is illustrated in  FIG. 5 , that Figure is not considered or labeled prior art because one aspect of the present invention is to retrofit such units to air cooled operation with a minimum of modifications. This mode of the invention will be described in more detail below. 
         [0007]    Accordingly, with the layout of skids for multi-stage centrifugal compressor packages having gained acceptance in the industry not only for its efficient performance but also for the compactness of the package, a challenge was presented to the named inventors to create an innovative package that would be more economical to install and operate than the previous water cooled designs but would also fit a housing and have a compact size, such as a comparable footprint, for a given driver horsepower. The present invention provides air-cooling as an option on a multi-stage centrifugal compressor package with no significant performance penalty. The present invention is packaged as a unit in a comparably sized enclosure having a footprint not larger than a water-cooled unit having the same driver horsepower. It does not require the space or expense of a cooling tower. The present invention captures the exhaust heat from air-cooling in a variety of ways. The present invention permits optimization of performance and power consumption in an air-cooled environment by matching the cooling capacity to the produced output. Specialized packages can be created for particular applications such as the air separation industry where there is a need for compressed air as well as compressed nitrogen from a single package. The unit can be used to filter the room air in the environment in which it is installed. It can be a retrofit of existing water-cooled units, such as shown in  FIG. 5 , into an air-cooled system with minimal piping modifications and elimination of the previously necessary cooling tower, if it was exclusively dedicated to cooling duty for the centrifugal compressor package. 
         [0008]    In the past, exhaust gas from a second stage water-cooled unit has been used to regenerate air dryers filled with desiccant. This technique is illustrated in U.S. Pat. No. 6,221,130. There were positive displacement compressor packages offered with an air-cooling feature. However, in the realm of centrifugal multi-stage compressor packages, there have never been air-cooled commercial units available. The industry, as well as the end user customers, were convinced that an air-cooled centrifugal multi-stage package could not deliver the efficiency of the known water-cooled designs. The inventors, facing this prejudice, were forced to present technical data from testing such an air-cooled unit to potential customers. Data that is not normally part of ordinary commercial transactions in water cooled designs, such as  FIG. 7 , had to be given to potential customers to persuade them that the promised results were indeed achievable. Competitors, who offered positive displacement air-cooled units, had failed to seize upon a vast market that had gone unserved for so many years. After rollout of the air-cooled package, the customer response has been unprecedented and there is now interest from competitors to develop competing products. 
         [0009]    Part of the difficulty in accomplishing the objective of an air cooled multi-stage centrifugal compressor unit of comparable performance to a water cooled design was to be able to package the entire system in a comparable volume while getting comparable performance. Tube/fin air-to-air exchangers were tested. While such units were operative, they didn&#39;t match the cooling performance of the counterpart water-cooled systems then commercially available. They also occupied significantly more space than the water cooled counterparts. The inventors were encouraged by these results and proceeded to further optimize the performance and compactness of the assembly. What resulted was the matching up of the plate fin air cooler type to the multi-stage compressor package in a confined volume. This combination rendered comparable performance to a water cooled unit of identical size while keeping the package size comparable. This became the optimal design for commercial use. These and other features of the present invention will be more readily understood from a review of the preferred embodiment, which appears below. 
       SUMMARY OF THE INVENTION 
       [0010]    An air-cooled multi-stage compression system using centrifugal compressors is disclosed. It is packaged in a comparable volume and using the same footprint as a water-cooled unit having the same driver horsepower. The performance is comparable and opportunities for use of the waste heat are available. Existing water-cooled units can be retrofit to run in an air-cooled mode. Special applications such as combined air compression and nitrogen compression, useful in air separation applications, are presented. The circulating cooling air can make the unit into an air filter of its surrounding space. Cooling air is drawn through the enclosure before being forced through the coolers above. This air movement can cool compressor housings, the control panel and the drive motors mounted in the enclosure. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  is a perspective view of the air-cooled centrifugal compressor package; 
           [0012]      FIG. 2  is an end view of the view in  FIG. 1 ; 
           [0013]      FIG. 3  is a side view of the view in  FIG. 1 ; 
           [0014]      FIG. 4  is a top view of the view in  FIG. 1 ; 
           [0015]      FIG. 5  is a perspective view of a water-cooled centrifugal compressor package, which can be retrofitted to run in an air-cooled mode; 
           [0016]      FIG. 6  is a perspective view of a part of the air-to-air heat exchanger used in the present invention; 
           [0017]      FIG. 7  is a chart showing comparable efficiency using air or water-cooling for a centrifugal compressor package and comparing that performance to an air or water-cooled positive displacement unit of comparable size; 
           [0018]      FIG. 8  is a perspective view of the end manifolds for a two pass air-to-air tube/fin cooler. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0019]    The preferred embodiment of the present invention is illustrated in  FIG. 1 . It illustrates a multi-stage centrifugal compressor unit newly designed for air-cooled operation. The differences from the previously available water-cooled designs can be more readily appreciated by comparing  FIGS. 1 and 5 . Again, it should be kept in mind that  FIG. 5  is readily converted from water to air cooled operations with minor piping modifications, as will be described below. Comparing  FIG. 1  to  FIG. 5 , it can be seen that the water coolers  20 ,  26 , and  28  have been eliminated from their position below the three stage compressors  14 ′,  16 ′, and  18 ′. Instead, the lubricating oil reservoir  36 ′ is now below the gearbox  12 ′ and can optionally be cast as a part of it. Although not shown in  FIG. 5  the separate oil cooler and its water connections have been eliminated in the  FIG. 1  design by an air-to-air cooler  38 . Three additional air to air coolers  40 ,  42 , and  44  are mounted adjacent to each other in a horizontal plane to respectively cool the discharge from the three stages of centrifugal compressors  14 ′,  16 ′, and  18 ′. A fan b driven by electric motor  48  preferably pushes the cooling air, in parallel, through the coolers  38 ,  40 ,  42 , and  44 , although a pull through design could also be used. In the push through design, the air handled by the fan is denser and has the capability of removing more heat while the pull through design offers an improved airflow distribution through the coolers. The package shown in  FIG. 1  is preferably housed in a louvered enclosure, shown schematically as  50 . For a 350 horsepower unit the dimensions of enclosure  50  are 116″ long by 73″ wide by a height range of 70-90″ depending on the air cooler configuration selected. The cooling air flow through the enclosure  50  is such that air enters fairly low, through louvers  52  which can optionally have filters  54  and thus can pass over the reservoir  36 ′ as well as the three stages of centrifugal compressors  14 ′,  16 ′, and  18 ′ as well as the gearbox  12 ′. In this way the moving cooling air cools off these pieces of equipment as it is drawn by the fan  46 . The cooling airflow also passes over the motor  48  for the fan  46  as well as the main drive motor  10 ′. Use of the filters  54  allows the entire unit to act as an air filter in the location where it is mounted. Thus with a fan  46  delivering 18,000 SCFM and the unit mounted in a room having a height of 27 feet and 40,000 square feet of floor space, the entire space can be filtered by the unit in about 1 hour. Additionally the filters  54  pre-filter the air to be compressed. While the compressor first stage inlet has its own filter (not shown) its life is prolonged because the air has been pre-filtered by filter  54 . Another advantage of filter  54  is to keep dirt in the air sucked into the enclosure  50  from coating the compressors inside and/or fouling the cooler cores. The heated cooling air exhausted from the coolers, shown schematically as arrows  55 , can be used directly to heat a building in which the unit is mounted with a minimal amount or even no ductwork. The heated air  55  can be used in other energy saving ways such as supplying heated combustion air to boilers. 
         [0020]    While the stage temperature after cooling by air can vary, performance tests on a Cooper Turbocompressor unit TA-2000 with a 350 HP driver is shown below. The first stage  14 ′ increased the pressure from 14.03 PSIA to 26.89 PSIA with a discharge temperature of 306.6 degrees F. Prior to entry into the second stage  16 ′ the air was cooled to 81.8 degrees F. at a pressure of 25.78 PSIA. It was then compressed to 72.1 PSIA at 260.5 degrees F. and cooled by cooler  42  to 90.3 degrees F. In the third stage it was compressed up to 123.8 PSIA at 189.5 degrees F. and cooled by cooler  44  to 78.7 degrees F. The average cooling air inlet temperature was 75.7 degrees F. measured between the fan  46  and the coolers  40 ,  42  and  44 . This made the realized approach in the discharge from the three stages respectively 6.1, 14.6 and 3.0 degrees F. Oil passing through cooler  38  was cooled from 137.4 degrees F. to 88.5 degrees F. for an approach of 12.8 degrees. During the performance test the unit delivered 1500 SCFM of compressed air and consumed 386 amperes. The ambient conditions were 67.3 degrees F. dry bulb with a relative humidity of 27.9%. 
         [0021]    Those skilled in the art will recognize that the capacity of fan  46  can be altered by speed control or blade pitch control or by selective air pathway obstruction of the coolers  38 ,  40 ,  42 , and  44  so that in colder weather or at times where less output is required of the unit the level of cooling provided can match the requirements of the system. Doing this also saves operating costs for the fan motor  48 . Alternatively, in times of light load, the motor  48  may be cycled on and off. A control system to do this can be placed in the panel  64 . 
         [0022]    By mounting the coolers in a common horizontal plane or in parallel planes, instead of stacking the coolers one above the other, the cooling is done more efficiently. The coolest air is input to each cooler and the motive horsepower for the fan  46  can be reduced as the parallel flow through the various coolers from the fan  46  offers less resistance to flow. 
         [0023]      FIGS. 6 and 8  show the details of a typical cooler such as 20′. The coolers are preferably made of a modular system using vacuum brazing technology. The cooling air passes vertically through passages  56  and the compressed air makes one pass horizontally through passages  58 .  FIG. 8  shows a two-pass tube/fin arrangement in more detail. The one pass plate fin design is preferred for a reduced pressure drop and increased performance. An inlet  60  is connected to an inlet header  62  so as to accommodate a u-shaped path for the compressed air to be cooled, if using a two pass cooler. The cooled air outlet for two passes would then be on the same end of the cooler as the inlet  60 . Alternatively, one pass for the cooled air or more than two passes could be used. The more passes the larger the size of the cooler and potentially the greater the pressure drop of the compressed air through any stage cooler. Generally oversize piping and large radius elbows are preferred to minimize pressure drop and save power. This type of exchanger, which is also known as plate-fin, can give the required cooling with pressure drops per stage of less than 1 PSI, with approach temperatures of the cooled air to ambient of less than 15 degrees and as low as less than 3 degrees. The modular components for such coolers are commercially available from API Airtech Incorporated of Arcade N.Y. U.S.A. under product designations 699-0307 through 699-0310, respectively for coolers  40 ,  42 ,  44 , and  38 . 
         [0024]    Changes in the casting as between the  FIG. 5  layout and the  FIG. 1  layout can be done to further reduce pressure drop by elimination of unnecessary bends. For example the first stage outlet is rotated to look up in  FIG. 1  from looking down in  FIG. 5  so that the piping can go directly to the air cooler immediately above. To better control noise, the enclosure  50  can have sound baffles. The fan  46  also has a shroud  64  to improve performance and minimize noise. 
         [0025]    It is worth noting that the inventors&#39; experimental attempts to cool multi-stage centrifugal compressors with finned tube air-to-air exchangers were operational. However, the inventors saw a need for further optimization to enhance cooling performance while decreasing the package size. These efforts resulted in improvements including vacuum brazed plate-fin exchangers, parallel flow systems with a fan that pushed air through rather than pulled air through, and a cooling air flow path that cooled compressor components. This design was deemed an optimum which would most successfully compete with existing water cooled units. This conclusion was reached despite indications from those skilled in the art that pushing the air through the coolers would result in non-uniform flow through the coolers. The use of air cooling coupled with optimization of the package size allows, for the first time, a concept of portable and efficient multi-stage centrifugal compressor unit to be wheeled in, piped to an existing system and started (if it is engine driven). Alternatively, it can be hooked up electrically to the power grid at the location if it is driven by an electric motor. The newly designed system shown in  FIG. 1  can occupy an equal or lesser footprint than the identically outfitted unit with water-cooling, such as depicted in  FIG. 5 . The  FIG. 5  unit can be retrofitted by removing the tube cores out of coolers  20 ,  26 ,  28  and still directing the discharge from each stage through the now hollow cooler chambers. The outlet of each chamber would be redirected to an air cooler mounted above in the same configuration shown in  FIG. 1 . The cooling fan  46  is added and the operation commences on an air-cooled basis. The retrofit is fairly straightforward and, when completed, allows the disconnection of the water-cooling system equipment and the immediate savings of space and operating costs of air-cooled systems, previously described. Air-cooling affords other efficiency advantages. The airflow drawn through the enclosure  50  cools the control panel electrical components saving the installation of a panel cooler in panel  64 . The same airflow over the compressors can cool them as well as the gas in the interconnecting piping. The compressor housings and the interconnecting piping can have finned exposed areas for greater heat transfer. 
         [0026]    The use of modular sections of plate-fin air to air exchangers allows reduction of cooler approach temperatures and makes air cooling possible in high altitudes and ambient temperature applications above 105 degrees F. Water is frequently scarce in such hot environments making the present invention an economical first choice and in some cases giving an option, where no economically feasible centrifugal compression option previously existed. 
         [0027]    For special applications, such as in the air separation business, a nitrogen booster can be piped as one of the compressors on the unit. In that manner, the relatively low pressure for compressed air requirements in air separation can be met while providing a nitrogen booster in the same air-cooled package. Additional capacity for existing water-cooling systems is not required. The final layout closely resembles that shown in  FIG. 1 . 
         [0028]    Those skilled in the art will appreciate that the combination of an efficient multi-stage centrifugal compression system with air cooling opens new markets where water cooled units could not operate for reasons of lack of water, higher operating cost, or physical space requirements. Offshore platforms are a good example of applications with limit space availability. The air cooled design of the present invention uses the same or smaller foot print and requires no auxiliary space for the water cooling equipment such as circulating pumps. It should be noted that there was considerable doubt by end users that comparable performance could be obtained with an air-cooled unit. So much so that significantly more data about system parameters had to be released than compared to selling a water-cooled application in order to convince the end users of the viability of the concept. Graphs such as  FIG. 7  were part of such disclosures. 
         [0029]    The coolers are a modular design of a plate fin heat exchanger, using, in the preferred embodiment a single pass for the compressed gas to minimize pressure drop between stages and after the last stage. While a particular installation having 3 stages has been described, other installations with fewer or greater numbers of stages could be employed without departing from the invention. Although a single fan  46  is illustrated, multiple cooling fans are also within the scope of the invention. As an added benefit of the system shown in  FIG. 1 , the air drawn into the enclosure  50  cools the compressor housings and associated piping. As a result the inlet air temperature to the intercoolers, aftercooler, and oil cooler is somewhat higher than ambient. The cooling capacity can be regulated to produce a desired temperature between the stages for the compressed air. If the compressed air is being used to dry desiccant in an air dryer, the desired drying temperature can be achieved for the requisite drying time by regulation of the cooling capacity after one or more stages, which can be accomplished in the various ways previously described. The ability to package air-cooling with multi-stage centrifugal compressors opens up a previously un-served market for portable units. Custom units such as for air separation plants are possible even if existing cooling tower systems or chilled water systems have no remaining capacity. Additionally existing water cooled units can be quickly retrofitted by removing cooler cores and redirecting flow through the hollow former water cooler housings into an air cooler mounted above. The water-cooled unit of  FIG. 5  can easily run as an air cooled unit having the same footprint. Many additional savings in operating costs and space for the water-cooling equipment can be realized after the retrofit conversion. 
         [0030]    It is to be understood that this disclosure is merely illustrative of the presently preferred embodiments of the invention and that no limitations are intended other than as described in the appended claims.