Anti-surge recycle valve

Abstract

An anti-surge recycle valve system for a natural gas line using a pipeline rotary control valve for controlling gas flow through the gas line and a valve controller having a surge-programmable feature including a threshold setpoint deviation limit, which is used to control first and second control valve loops. The first solenoid valve loop drives a rotary high-pressure piston actuator when the linear position sensor determines a setpoint deviation in gas flow below the threshold deviation, and the second solenoid valve loop drives the rotary high-pressure piston actuator when the linear position sensor determines a setpoint deviation in gas flow above the threshold deviation. The system provides ultra-rapid stroking speed in tandem with highly accurate and stable positioning.

Claims

1. An anti-surge recycle valve system for a natural gas line, the anti-surge recycle valve system comprising: a pipeline rotary control valve for controlling gas flow through a gas line and movable from a completely open position through partially open positions to a completely closed position; a rotary high-pressure piston actuator for moving the pipeline rotary control valve; a linear position sensor for determining a position of the pipeline rotary control valve; a valve controller having a surge-programmable feature including a threshold setpoint deviation limit, the valve controller controlling; a first solenoid valve loop which drives the rotary high-pressure piston actuator when the linear position sensor determines a setpoint deviation in gas flow below the threshold setpoint deviation limit; and a second solenoid valve loop which drives the rotary high-pressure piston actuator when the linear position sensor determines a setpoint deviation in gas flow above the threshold setpoint deviation limit.

2. The anti-surge recycle valve system of claim 1, further comprising a valve manual override.

3. The anti-surge recycle valve system of claim 1, wherein the threshold setpoint deviation limit is adjustable.

4. The anti-surge recycle valve of claim 3, wherein the threshold setpoint deviation limit comprises a +/−20% deviation.

5. The anti-surge recycle valve system of claim 1, wherein the first solenoid valve loop comprises a pair of standard response solenoid valves and the second solenoid valve loop comprises a rapid-response solenoid valve.

6. The anti-surge recycle valve system of claim 5, wherein the rapid-response solenoid valve is configured to utilize natural gas.

7. The anti-surge recycle valve system of claim 5, wherein the rapid-response solenoid valve is configured to support elevated pressures of up to 150 psi.

8. The anti-surge recycle valve system of claim 5, wherein the rapid-response solenoid valve is configured to open in less than 500 milliseconds.

9. The anti-surge recycle valve system of claim 5, wherein the pair of standard-response solenoid valves are configured to operate during steady state.

10. The anti-surge recycle valve system of claim 5, wherein the pair of standard-response solenoid valves are configured to exhibit zero fugitive emissions during steady state.

11. The anti-surge recycle valve system of claim 10, further comprising a valve status monitor.

12. A surge control valve system for a centrifugal compressor in a fluid delivery line, the surge control valve system comprising: a first control loop; and a second control loop, wherein both the first and second control loops utilize a Red Circle Valve Controller digital positioner with a surge-programmable feature, the second control loop including a high-speed solenoid which is activated by the surge-programmable feature of the Red Circle Valve Controller digital positioner to move a control valve very rapidly until a measured difference between an input signal and an output signal falls within an acceptable value, and wherein use of a bleed gas in steady state is eliminated.

13. The surge control valve system of claim 12, wherein the first control loop operates during steady state.

14. The surge control valve system of claim 12, wherein the second control loop is utilized when the measured difference between the input signal and the output signal is above a threshold limit.

15. The surge control valve system of claim 12, wherein the threshold limit is adjustable.

16. The surge control valve system of claim 15, wherein the threshold limit comprises a +/−20% deviation in the measured difference between the input signal and the output signal.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) For the purpose of facilitating an understanding of the subject matter sought to be protected, there are illustrated in the accompanying drawings, embodiments thereof, from an inspection of which, when considered in connection with the following description, the subject matter sought to be protected, its construction and operation, and many of its advantages should be readily understood and appreciated.

(2) FIG. 1 is a schematic showing a typical centrifugal compressor station with an anti-surge assembly;

(3) FIG. 2 is a schematic illustrating a prior art single loop anti-surge valve system;

(4) FIG. 3 is a perspective view of an embodiment of a pipeline rotary control valve (PRCV) with an embodiment of the anti-surge recycle valve system of the present invention;

(5) FIG. 4 is a perspective view of the PRCV with a transparent housing for an embodiment of an attached rotary high-pressure actuator;

(6) FIG. 5 is an exploded view of an embodiment of the pipeline rotary control valve;

(7) FIG. 6A is a downstream end view of an embodiment of a rotary control valve similar to that shown in FIG. 5;

(8) FIG. 6B is a cut-away perspective view of an embodiment of a rotary control valve similar that shown in FIG. 5;

(9) FIG. 7 is a close-up view of an embodiment of the ball valve for the PRCV of the present disclosure;

(10) FIG. 8 is a left-side view of the PRCV, attached actuator and anti-surge recycle valve system of FIG. 3;

(11) FIG. 9 is a front view of the assembly of FIG. 8;

(12) FIG. 10 is a right-side view of the assembly of FIG. 8;

(13) FIG. 11 is a schematic showing the control loops of an embodiment of the presently disclosed anti-surge recycle valve assembly;

(14) FIG. 12 is a graph of the set-point deviation for the rapid response and standard response solenoids used in the disclosed anti-surge recycle valve assembly;

(15) FIG. 13 is a time-line performance graph for the anti-surge valve to open on command when the exhaust valve is open and bypass valve is closed;

(16) FIG. 14 is a time-line performance graph for the anti-surge valve to open on command when the exhaust valve and bypass valve are closed;

(17) FIG. 15 is a time-line performance graph for the anti-surge valve to open at 50% on command when the bypass valve is closed;

(18) FIG. 16 is a graph of a diagnostic test on the anti-surge recycle valve of the present disclosure; and

(19) FIG. 17 is graph showing a flow profile for an embodiment of a rotary control valve.

DETAILED DESCRIPTION OF THE INVENTION

(20) While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail at least one preferred embodiment of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to any of the specific embodiments illustrated.

(21) A centrifugal compressor system is used to move natural gas through a pipeline. As can be seen in FIG. 1, such a system 100 typically consist of a compressor 110, a scrubber 112, a cooler 114, and, due to the dynamic flow conditions of the gas line, an anti-surge valve 116. As shown in FIG. 2, current surge control valve assemblies 120 for a centrifugal compressor system 100 use a single-loop or single-mode consisting of an adjustable, electro-pneumatic positioner 122 and a series of exhaust valves 124a-c. The electro-pneumatic positioner 118 PID loop is adjusted with a rapid response in order to achieve high-speed in the event an input signal runs away from an output signal. While these systems 100 achieve fast stroking times in “surge situations,” they sacrifice precision during lower speed modes, like recycle and start-up. Further, in order to achieve high-speed ability, a heavy bleed gas is introduced in all existing digital positioners (e.g., Fisher DVC and Dresser SVI). The use of a bleed gas equals loss of product (natural gas) and lowers profitability.

(22) For details on operation of a gas line control system, reference is made to U.S. Pat. No. 9,400,060 to Garvey et al., and assigned to VRG Controls, LLC of Highland Park, Ill. The '060 patent is hereby incorporated by reference.

(23) Without intending to limit the scope of the disclosed valve system 10 to any specific embodiment, the following TABLE I is a listing of major components, and respective specifications, for a preferred embodiment of the anti-surge recycle valve assembly 12.

(24) TABLE-US-00001 TABLE I Component Model Voltage Supply Type Other Specs Standard ASCO 24 VDC 41-150 2-position, Cv 0.50. low-temp (−40° F.), Response EV8327GO52 psig 3-Way One Stainless Steel Body, Universal, Solenoid port UL CSA CE Approved, Ex Proof plugged Cl. 1 Div. 1., Buna N Elastomers, 0.250 NPT Ports, Tapped Exhauset. One (1) for CLOSE and One (1) for OPEN Rapid BIFOLDXS16- 24 VDC 29-150 2-position, Cv 14, low-temp (−20° F.), Response 16-p20SC2- psig 2-Way Stainless Steel Body, Universal, Solenoid 77U-24D-30-V High- UL CSA CE Approved Ex Proof Speed Cl. 1 Div. 1, Buna N Elastomers, 1.0 IN FNPT Exhaust Ports (2), 1.0 In FNPT Inlet Ports (1), 0.250 FNPT Ex-Pilot Port (1) Component Model Temp. Supply Type Other Specs Exhaust 289RC −20° 125 psig Exhaust Cv 22, Inlet/Outlet 1.00 IN FNPT, Booster to180° F. Max Booster Signal Port 0.250 FNPT, Body, Cover: Aluminum Die Cast, Valve, O-Rings and Gaskets: NBR Valve VMO-150 −50° to 150 psig Pneumatic Cv 0.40, 0.250 FNPT Ports Manual 200° F. Max Manual Body: Carbon Steel Override Override Bolting: 316 SS, Internals: 304 SS O-Rings: Buna-N Limit Visual Component Model Type Switches Indicator Other Specs Limit Westlock Rotary SP-DT, Beacon 90 Degree Rotary Limit Switches Switch 2007X-2- Mechanical DP-DT High with High Visibility Beacon Assembly SPDT or Visibility Travel Indicator, Area Proximity Position Classification Cl 1 Div 1 Groups Indicator C&D/T6, NAMUR Output Shaft, Various Limit Switch Configurations, Powder Coat Aluminum Housing, Available with Optional 4-20 mA Analog Feedback (Passive Use Only) Linear Balluff BTL7- Micropulse N/A Linear 4-20 mA Micropulse Transducer, Feedback E501-M0153- Linear Travel 0.250 FNPT Elec. Connections, Module J-DEXC-TA12 Position Scale (10% UL CSA CE Approved, Ex. Proof Sensor increments) Cl. 1 Div 1, Stroke Lengths Available: 4, 6, 8, 12 and “SHORT LENGTH” 2.0 IN or less adjustable, Linear Feedback Mounting Kits available
Additionally, the system 12 utilizes a Red Circle Valve Controller (RCVC) 14, as shown in FIGS. 3 and 11. The following TABLE II lists specifications for a preferred RCVC 14.

(25) TABLE-US-00002 TABLE II Model RCVC Red Circle Valve Controller Installation Valve Mount or Remote Installation Diagnostics Onboard Graphical Performance evaluation Display High-Resolution, Programmable, Multi-Color Display Command Signal 4-20 mA Analog or 24 VDC Discrete Pulse Feedback Signal 4-20 mA (Internal or External Loop Power) Remote/Local Trigger Counter Digital Feedback Deadband Adjustable 0.1% to 2.0% Travel, Typically Set 0.5% Standard Hysteresis 0.5% Full Scale (with standard Rotary Position Feedback Module) Linearity 0.5% Full Scale (with standard Rotary Position Feedback Module) Failure Mode OPEN, CLOSE, or LOCK on Loss Command Signal Consumption ZERO STEADY-STATE Bleed to Pressure System Capable Rating Explosion Proof, Class 1, Div. 1 Connections ½ FNPT Pneumatic Connections Port ¾ FNPT Electrical Connections Temperature −20° F. to 120° F. (−29° C. to 49° C.) Compatibility Dimensions, Ports, Connections 100% Compatible with Existing GE/Becker DNGP Replacement Communication HART Protocol Compliant, USB Computer Interface Manual Override Local Manual Valve Positioning Onboard Adjustment Non-Intrusive Local Thumbwheel Adjustment Area Class 1, Div. 1 EXPLOSION PROOF Classification

(26) Referring to FIGS. 3-10, there is illustrated a pipeline rotary control valve 16 (also see '060 patent) including an anti-surge recycle valve assembly 12 for a natural gas system, including embodiments of the required components. The disclosed anti-surge recycle valve assembly 12 is a dual-mode or dual-loop system (i.e., standard response loop 20 and rapid response loop 22) which provides ultra-rapid stroking speed in tandem with highly accurate and stable positioning. The first (or standard response) loop 20 is comprised of two standard response solenoid valves 24, while the second (or rapid response) loop 22 includes a rapid response solenoid valve 26.

(27) As indicated in FIGS. 11 and 12, the first loop 20 operates the standard response solenoid valves 24 when the setpoint deviation is less than an adjustable threshold value from the valve position. In a preferred embodiment, +/−20% is the preset threshold, though other threshold percentages may be suitable for specific applications. In the preferred system 10, a deviation of less than 20% is considered steady state operation but exceeding the threshold limit activates the second (i.e., rapid response) control loop 22. The first and second control loops, 20 and 22 respectively, utilizes a Red Circle Valve Controller (RCVC) with a surge-programmable feature. The surge programmable feature allows activation of the second high-speed loop via rapid response solenoid 26, which moves the rotary control valve 16 very rapidly until the difference between the input signal (e.g., setpoint pressure) and the output signal (e.g., output pressure) falls within the acceptable value—e.g., less than 20% deviation (see FIG. 11). As a result, the disclosed system eliminates the need for using a bleed gas in steady state.

(28) As shown in FIGS. 13-15, rotary valve response (line 1) to a signal command (line 2) is charted to demonstrate the rapid response and recovery of an embodiment of the disclosed system. In NG. 13, the quick exhaust valve 30 (FIG. 10) is open, while in FIG. 14 the valve 30 is closed. In both scenarios, the response time was less than 500 milliseconds to move the valve to 63% open, including response delay. This response time is related to the valve size, whereas a smaller valve will have a shorter response time and a larger valve will have a longer response time. However, in all scenarios the response time will be much less than FIG. 15 illustrates recovery of the rotary valve 16 after a 50% overshoot. FIG. 16 illustrates valve feedback in a diagnostic test of the valve controller 14.

(29) FIG. 17 illustrates a flow profile for a preferred embodiment of the pipeline rotary control valve 16 in 10° increments between 0° (fully closed position) to 90° (fully open position).

(30) The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. While particular embodiments have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made without departing from the broader aspects of applicants' contribution. The actual scope of the protection sought is intended to be defined in the following claims when viewed in their proper perspective based on the prior art.