Why is the minimum load for the stepless control system HycroCOM in reciprocating compressors only 20%?
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When the HydrCom system is in use, when the pressure signal is between 80% and 100%, the inter-stage return valves are fully closed; the hydraulic mechanism of the HycroCOM system delays the closing time of the intake valve in order to regulate the compressor load； When the pressure signal is between 0% and 20%, the HycroCOM system operates at a minimum load of 20%, with the bypass valve opening corresponding to 100%–0%. Why is the minimum load set at 20%, and is it required that the operating load be above 40% under normal conditions? What effects does long-term operation at low load or no load have on the compressor? Can’t the intake valve remain open for an extended period of time?
This post was last edited by 156026692 on 2017-10-15 at 08:30. Please note that reciprocating pumps are usually designed with full flow rates in mind when calculating factors such as pipeline pulsation forces, in accordance with the calculations outlined in Appendix A of API618. It is possible to refer to the situation of pumps operating at low flow rates; when a reciprocating pump operates under low load for an extended period, the pipeline vibration it causes will reach its maximum value at a certain level (the exact percentage varies depending on various conditions, and it isn’t the same in all cases). Once the pipeline vibrates excessively, you can imagine the consequences. Therefore, when the entire system, including the pipes and the compressor, is operating normally, it is reasonable to reduce the load through stepless adjustment in order to save energy. However, in cases of abnormalities such as increased pipe vibration, it is still necessary to prioritize ensuring the safe operation of the equipment. Otherwise, you might save a certain amount of electricity – say, hundreds of thousands of yuan per year – but if the vibration of the reciprocating machine is too high and it causes pipe ruptures or damage to moving parts, well, the repair costs will be enough to cover the electricity you would have saved over many years. And if an accident occurs and causes injuries or something, things will get even more complicated later on. It is estimated that the poster works in the field of production processes, so they focused too much on energy conservation and overlooked the risks associated with equipment operation under low load conditions. I was right, wasn’t I? :lol