CapCon

(Variable Capacity) Suite

Product Overview

Confidential & Proprietary

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Reciprocating Compressor
Capacity Control

Capacity control methods

By-Pass (recycle) or Suction Throttling

Step cylinder unloading systems

Stepless cylinder unloading systems

Variable speed drive

Typical Step Unloading

Full Load

75% Load

50% Load

0% Load

Manual Variable Volume Clearance

Pocket

Difficult to adjust during

operation

Sometimes requires
compressor shutdown
for adjustment

Reduces productivity

CapCon Suite

Variable Capacity control suite consists of:

Variable volume clearance pockets

HVVCP - Hydraulic Variable Volume Clr Pocket
GSP - Gas Stepless Pocket

Variable cylinder end unloading

ISC - Infinite Step Control

Hydraulic Variable Volume Clearance Pocket (HVVCP)

HVVCP Schematic

HOW IT WORKS:
Cylinder clearance volume is altered by
moving a clearance piston. The position
of the clearance piston is controlled by a
hydraulic cylinder.

HVVCP - How It Works

Solenoid valves are are
closed, pocket is locked in
position.

HVVCP - How It Works

Right solenoid valve is opened
allowing pocket to open.

HVVCP - How It Works

When cylinder pressure is
greater than balance pressure
the pocket piston moves to the
right (pocket opens)

HVVCP - How It Works

HVVCP - How It Works

HVVCP - How It Works

HVVCP - How It Works

With solenoid valves again
closed pocket is again
locked in position. Pocket
can be locked at any
intermediate point

HVVCP - How It Works

Left solenoid valve is opened
allowing pocket to close.

HVVCP - How It Works

When cylinder pressure is
lesser than balance pressure
the pocket piston moves to the
left (pocket closes)

HVVCP - How It Works

HVVCP - How It Works

HVVCP - How It Works

HVVCP - How It Works

HVVCP - How It Works

Solenoid valves are are
closed, pocket is locked in
position.

HVVCP - Lab installation

HVVCP - Lab installation

HVVCP - Cross Section View of Assembly

HVVCP - Cross Section View of Rod Packing

Gas Seals

Hydraulic Seals

Leakage
Port
(monitor
or plug)

Drain

Gas Vent

HVVCP Rod Seal

Wear Test Results
3.000

Seal Inside Diameter (inches)

2.995

2.990

1 Year @ 327 RPM = 172

Million Cycles

2.985

Rod Diameter 3.000

2.980

2.975

2.970

2.965
0
2

0
0,0

00
0 ,0

0
,0 0
00
0
,
40

0
0,0

00
0 ,0

0
,0 0
00
0
,
80

Cycles
Latest Design

0
,00
00
0
,
0
10

12

0
0,0

00
0,0

0
,00
00
0
,
0
14

Gas Stepless Clearance Pocket (GSP)

GSP
Schematic
CONTROL
PRESSURE

GSP
%
OPEN

LOAD
%

PSUCTION

100

Min

PDISCHARGE

Pressure
Transducer
4-20 mA

Max
SUCTION
VESSEL
SUCTION
PRESSURE

CYLINDER

CONTROL
PRESSURE

HOW IT
WORKS:
Cylinder clearance
volume is altered by
varying the pocket
control pressure

GSP

REG

0-100
psig

ELECTRONIC
CONTROLLER

DISCHARGE
PRESSURE
DISCHARGE
VESSEL
Pressure
Transducer
4-20 mA

4-20 mA signal
from DCS

GSP - How It Works

Control
Pressure

Clearance
Pocket

HOW IT
WORKS:
Cylinder clearance
volume is altered by
varying the pocket
control pressure

Cylinder
Pressure

GSP - How it works

Control Gas

Manual Variable Volume Pocket

GSP Installation

GSP - Valve Cap Pocket

GSP - Valve Cap Pocket

GSP - Regulator

CONTROL

DISCHARGE
VENT
INLET

GSP - Regulator

Vent
Inlet
Pressure
Control
Pressure

Discharge
Pressure

GSP Lab Testing (Full Load)

RPM

1200

GSP PV Card
1400

9/16/200 32:13.6

Run Number

2043

GSP Position

1148 CONT.

HVVCP Position

100%

ISC Position

NA

FE IHP =

406.27

1200

Control Pressure

Pressure (psia)

1000

800

600

400

200
0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

70.00%

% VOLUME
gsp_pocket_P

cyl_fe

gsp_cont_P

80.00%

90.00%

100.00%

GSP Lab Testing (87% Load)

RPM

1200

GSP PV Card
1400

9/16/200 51:24.3

FE IHP =

Run Number

2044

GSP Position

942 CONT. PRESS

HVVCP Position

100%

ISC Position

NA

352.15

1200

Pressure (psia)

1000

Control Pressure
800

600

400

200
0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

70.00%

% VOLUME
gsp_pocket_P

cyl_fe

gsp_cont_P

80.00%

90.00%

100.00%

GSP Lab Testing (30% Load)

RPM

GSP PV Card
1400

9/16/200 01:58.3

FE IHP =

Run Number

2047

GSP Position

512 CONT. PRESS

HVVCP Position

100%

ISC Position

NA

1200

121.49

1200

Pressure (psia)

1000

800

600

Control Pressure
400

200
0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

70.00%

% VOLUME
gsp_pocket_P

cyl_fe

gsp_cont_P

80.00%

90.00%

100.00%

Infinite Step Control (ISC)

Delayed Suction Valve Closing

ISC

Delayed suction valve closing

Ingersoll-Rand pioneered ISC 50 years ago

Successful with integral gas engine through the

1970s but never actively pursued in process market

ISC Schematic

HOW IT WORKS:
Cylinder capacity
is controlled by
delaying the
closing of the inlet
valves.

ISC Actuator, Valve and Plunger

DESIGN
Unloader Assembly

Standard
Actuator
Standard Gas
Seal Cartridge

ISC - Servo and Actuators

Test Lab Installation

Servo Valve

ISC Actuator Installation

Test Lab Installation

A
B

Actuator
Drain
Vent

ISC Hydraulic Power Unit (HPU)

Cooling Fan

Pump Motor
Hydraulic Pump
Fluid Reservoir
Level Sensor

ISC HMI Control Panel

ISC Controller
Electronic Controller - HMI Screens

ISC Controller
Electronic Controller - HMI Screens

ISC Controller
Electronic Controller - HMI Screens

ISC Controller
Electronic Controller - HMI Screens

ISC Controller
Electronic Controller - HMI Screens

ISC Controller
Electronic Controller - HMI Screens

ISC Controller
Electronic Controller - HMI Screens

Application

Capacity Control Suite

Market Assessment
Need for variable capacity control

Recip compressors require devices to control

(reduce) capacity to meet process needs.

Bypassing of unwanted gas wastes energy.

Capacity control devices reduce flow and save

energy.

Todays market is again focused on energy savings

(energy evaluations $600 - $1000 / hp / year)

Hydrocom established in market (approx. 300

units installed Worldwide)

Capacity Control Need Defined

Decrease operational costs

Minimize Wasted Energy

More efficient use of motor HP

Less gas to bypass

Greater Freedom of Capacity

Control of downstream pressures and flow

Capacity Control Suite

Estimated Energy Savings per Year
($0.10/Kwh or ~$653/HP/yr)

$1,400,000

$1,200,000
10%Turn Down

Operational Savings
(USD)

15%Turn Down
$1,000,000
20%Turn Down

$800,000

$600,000

$400,000

$200,000

$500

1000

5000

Compressor Power (HP)

10000

Capacity Control Suite

Typical Energy Costs

Electricity Cost $/Kwh
$/Hp/Year
Compressor
%
Power (HP) turndown
10000
10%
5000
10%
1000
10%
500
10%
10000
15%
5000
15%
1000
15%
500
15%
10000
20%
5000
20%
1000
20%
500
20%

0.05

0.1

0.15

$
327
Savings Per
Year
$ 326,617
$ 163,308
$ 32,662
$ 16,331
$ 489,925
$ 244,962
$ 48,992
$ 24,496
$ 653,233
$ 326,617
$ 65,323
$ 32,662

$
653
Savings Per
Year
$ 653,233
$ 326,617
$
65,323
$
32,662
$ 979,850
$ 489,925
$
97,985
$
48,992
$ 1,306,466
$ 653,233
$ 130,647
$
65,323

$
980
Savings Per
Year
$
979,850
$
489,925
$
97,985
$
48,992
$ 1,469,775
$
734,887
$
146,977
$
73,489
$ 1,959,700
$
979,850
$
195,970
$
97,985

CapCon Suite Turndown Chart

Product Limitations - GSP

Low Pressure Ratio

Large pocket required

High Molecular Weight

Large valve required Greater valve losses

Potential for overheating

Compressor Speed

Tested to 1,200 rpm on Natural Gas

Product Limitations - HVVCP

Low Pressure Ratio

Large pocket required

Balanced Piston Forces

Piston must be significantly larger than the rod
May require connection to discharge pressure

Only for Head End Unloading

Compressor Speed

Tested to 1,000 rpm on Natural Gas

Product Limitations - ISC

Unloader required on all suction valves

Partial load losses related to full load valve loss

Gas is forced in and out of suction valves

Depends on number, size, and gas MW

Compressor Speed

Reliable operation up to 1,000 rpm

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