COMPRESSOR SYSTEM WITH GROOVED EXPANSION JOINT
The disclosure includes a compressor system having a compressor for compressing and delivering a fluid to a component. First and second conduits are fluidly connected between the compressor and the component. At least one of the conduits is a thin walled conduit having an adaptor end piece connected thereto to transition from a thin wall thickness to a predetermined second wall thickness. A circumferential groove is formed in an outer surface of each of the first and second conduits at a location corresponding to at least the predetermined second wall thickness. An expansion joint clamp is adapted to engage the circumferential grooves and couple the first and second conduits together.
The present application generally relates to industrial air compressor systems and more particularly, but not exclusively, to coupling a thin walled conduit to the system with a grooved expansion joint.
BACKGROUNDLarge industrial compressor systems typically have complex design and assembly procedures. Such industrial systems can be difficult to assemble and maintain due to component weight and space claim requirements. Designing conduits with coupling members to minimize size and weight can reduce assembly time as well as enable cost effective maintenance or repair of the compressor system. Some existing systems have various shortcomings relative to certain applications. Accordingly, there remains a need for further contributions in this area of technology.
SUMMARYOne embodiment of the present invention is a unique compressor system. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for compressor systems with a unique coupling system for thin walled conduits. Further embodiments, forms, features, aspects, benefits, and advantages of the present application shall become apparent from the description and figures provided herewith.
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications in the described embodiments, and any further applications of the principles of the invention as described herein are contemplated as would normally occur to one skilled in the art to which the invention relates.
Industrial compressor systems that use external fluid to fluid heat exchangers or intercoolers can be heavy, difficult to assemble and typically require a large space claim for component connection assemblies. Fluid heat exchangers as defined herein can be of any type commonly utilized in industrial applications. It should be noted that terms such as intercooler, cooler, inter-stage cooler, aftercooler or the like can be interchanged or substituted and still fall within the broad definition of a heat exchanger as defined by the present disclosure. It should be further understood that the term “fluid” includes any gas or liquid medium used in the compressor system as disclosed herein. Typically, because of the size and weight of industrial components, each of the components are transported separately and assembled on site. It is desirable to minimize the size and weight of connection assemblies such as by use of thin walled conduits or pipes to connect various components of the compressor system. Limited options are available for coupling thin walled conduits when thermal expansion is an operational concern. The present disclosure provides means to reduce the size and complexity of the coupling mechanisms so that thin walled conduits may be used with a compressor system such as that defined herein. For purposes of this disclosure a thin walled conduit is defined as any conduit having a wall thickness that is too thin to structurally support a machined slot or groove formed in an outer surface thereof for a grooved expansion joint clamp to engage therewith. Machining a groove in a thin walled conduit deep enough to support a grooved expansion joint would result in a weakened structure or complete mechanical failure of the conduit. Typical wall thicknesses for thin wall conduits can be found in Nominal Pipe Size (NPS) tables for schedule 5 and schedule 10 conduits. Wall thickness for thin walls can range from 0.035 inches for ⅛ NPS to 0.083 inches for 3½ NPS schedule 5 conduits and from 0.049 inches to 0.120 inches for schedule 10 conduits.
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The intercooler fluid port 200 can include a wall 223 defined from an inner surface 225 to an outer surface 227. The wall 223 can be a thin wall in which case an adapter such as the adapter 207, would necessarily need to be connected thereto. Optionally the wall 223 can be formed with a wall having a thickness sufficient to receive a machined slot 222 (best seen in
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The clamp 209 can include a first o-ring groove 260 on one side and a second o-ring groove 262 on the other side to receive the o-rings 250, 252 therein so as to provide a fluid tight seal between the clamp 209 and each conduit 60, 200 respectively. It should be understood that other forms of fluid sealing arrangement can be used and remain within the teachings of the present application. For example, a single seal can be attached between the clamp and extend across the interface region of the ends of the conduit 60, 200 respectively to form a fluid tight seal therewith. In yet another embodiment the conduits can include grooves to house seals such as O-rings therein as opposed to the clamp housing the O-ring seals.
In operation the compressor system is configured to provide compressed air at a desired temperature and pressure to external systems. The compressor systems can be used in any industrial application including but not limited to automobile manufacturing, textile manufacturing, process industries, refineries, power plants, mining, material handling, etc. The controller permits user input to define parameters such as pressure, temperature and mass flow rate. The controller will send command signals to the motor to rotate at a desired operating speed in order to drive the one or more compressors and control various valving to control airflow rate and coolant flow rate. In the illustrative example, the compressor system includes a three-stage centrifugal compressor system, however, the system can operate with other types of compressors and/or with more or less stages of compressors. One or more intercoolers can be fluidly coupled to each compressor stage such that after air is compressed through the first stage the air can be transported through a first intercooler and can be cooled to a desired temperature via a heat transfer mechanism such as conduction and convection in tube type heat exchangers. The compressed air can then be transported into a second stage compressor where the air further compressed and necessarily heated to a higher temperature through a thermodynamic process. The second stage compressed air can then be routed through a second intercooler to cool the air to desired temperature while remaining at or close to the compressor outlet pressure of the second stage compressor. The cooled compressed air exiting from the second intercooler can then be transported to a third stage compressor where it is compressed to a final desired pressure and then subsequently routed to a third stage intercooler to bring the temperature of the final discharged air pressure to the desired temperature for delivery to a final subsystem. In one form the compressors can be centrifugal compressors, however, other forms of compression can include axial flow compressors, piston compressors or other positive displacement compressors can be used under the teachings of the present disclosure.
The expansion groove clamp connection with at least one thin walled conduit provides means for facilitating positional variation of components due to mechanical dimensional tolerance stack-up that occurs during assembly and/or for thermal expansion growth between various components due to temperature gradients caused by variable heating and cooling of the components of the compressor system. The expansion groove clamp used in combination with at least one thin walled conduit also provides means for coupling of fluid conduits in the compressor system in a manner that minimizes space claim and weight which can facilitate ease of assembly and maintenance of said system. As such, the conduit coupling means disclosed herein provides a system that remains structurally sound and minimizes potential for mechanical failure due to loads caused by mechanical constraints and thermal loading during operation of the compressor system.
Material selection for the fluid conduits, coupling members and other components of the compressor system can include various forms of metal, metal alloys, composites, ceramics, or plastics as desired. Metals can include, but are not limited to aluminum, steel, iron, super alloys and combinations thereof. The metal material may further be formed from cast, wrought, or sheet stock.
In one aspect the present disclosure includes a compressor system comprising: a compressor for compressing a fluid; a component in fluid communication with the compressor for receiving compressed fluid; first and second conduits fluidly connecting the compressor to the component, wherein at least one of the conduits is a thin walled conduit; an adaptor end piece connected to an end of the at least one thin walled conduit, wherein the adaptor end piece transitions from a thin wall thickness to a predetermined second wall thickness; a circumferential groove formed in an outer surface of each of the first and second conduits at a location corresponding to the predetermined second wall thickness; and an expansion joint clamp adapted to engage the circumferential grooves and couple the first and second conduits together.
Refining aspects include an adapter end piece having an angled inner wall extending from the thin wall of the thin walled conduit and the second wall thickness; wherein the expansion joint clamp permits relative movement between the first and second conduits; wherein the clamp includes a pair of circumferential leg extensions; wherein the leg extensions are positioned within the grooves of the first and second conduits; wherein the leg extensions are constructed to slide axially along a width of each groove; wherein each groove includes a pair of side walls to define opposing abutments; wherein one end of each conduit is permanently attached to a compressor component; wherein the component is an intercooler; and wherein the conduits are structured to receive relatively high temperature fluid flow therethrough.
Another aspect of the present disclosure includes an apparatus comprising: a compression system configured to compress a fluid; a first conduit fluidly connectable to the compression system; a second conduit fluidly connectable to the first conduit; wherein at least one of the first and second conduits are defined by a circumferential thin walled structure; an adaptor end connected to at least one of the first and second conduits having a thin walled structure, the adaptor having a tapered inner wall that transitions from a thin wall to a second wall thickness, wherein the second wall thickness is sufficient to support a circumferential slot formed in the outer surface thereof; a circumferential slot formed in the outer surface of each of the first and second conduits at a location having a wall thickness at least equivalent to the second wall thickness; and an expansion joint coupling engageable with the slots of the first and second conduits and operable to connect the first and second conduits together.
Refining aspects include a multi-stage centrifugal compressors driven by a motive source; further comprising: an intercooler fluidly connected to one of the first and second conduits; wherein the fluid includes air; further comprising: a fluid seal engaged with the coupling to form a fluid tight seal between the first and second conduits; wherein the expansion joint coupling permits relative movement between the first and second wherein the expansion joint coupling includes a pair of circumferential leg extensions; wherein the leg extensions are configured to engage the slots formed in the first and second conduits; wherein the leg extensions are constructed to slide between sidewall abutments along a width of each slot.
Another aspect of the present disclosure includes a method comprising: welding an adaptor to an end of a thin walled conduit, wherein the adaptor includes a portion having a second wall thickness greater than the thin walled conduit; forming an outwardly facing groove in the adaptor proximate the portion having the second wall thickness; forming an outwardly facing groove in a second conduit; connecting the first and second conduits with an expansion groove clamp positioned within the grooves of the first and second conduits; generating heated fluid with a compressor system; transporting the heated fluid through the first and second conduit; and moving the conduits relative to the clamp in response to variable thermal loading.
A refining aspect includes sliding a portion of the clamp along a width of the grooves formed in each of the conduits; wherein the compression system includes a centrifugal compressor fluidly connected to at least one intercooler with the first and second conduits; and further comprising: forming a fluid tight seal between the first and second conduits.
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the inventions are desired to be protected. It should be understood that while the use of words such as preferable, preferably, preferred or more preferred utilized in the description above indicate that the feature so described may be more desirable, it nonetheless may not be necessary and embodiments lacking the same may be contemplated as within the scope of the invention, the scope being defined by the claims that follow. In reading the claims, it is intended that when words such as “a,” “an,” “at least one,” or “at least one portion” are used there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. When the language “at least a portion” and/or “a portion” is used the item can include a portion and/or the entire item unless specifically stated to the contrary.
Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
Claims
1. A compressor system comprising:
- a compressor for compressing a fluid;
- a component in fluid communication with the compressor for receiving compressed fluid;
- first and second conduits fluidly connecting the compressor to the component, wherein at least one of the conduits is a thin walled conduit;
- an adaptor end piece connected to an end of the at least one thin walled conduit, wherein the adaptor end piece transitions from a thin wall thickness to a predetermined second wall thickness;
- a circumferential groove formed in an outer surface of each of the first and second conduits at a location corresponding to the predetermined second wall thickness; and
- an expansion joint clamp adapted to engage the circumferential grooves and couple the first and second conduits together.
2. The compressor system of claim 1, wherein the adapter end piece includes an angled inner wall extending from the thin wall of the thin walled conduit and the second wall thickness.
3. The compressor system of claim 1, wherein the expansion joint clamp permits relative movement between the first and second conduits.
4. The compressor system of claim 1, wherein the clamp includes a pair of circumferential leg extensions.
5. The compressor system of claim 4, wherein the leg extensions are positioned within the grooves of the first and second conduits.
6. The compressor system of claim 4, wherein the leg extensions are constructed to slide axially along a width of each groove.
7. The compressor system of claim 4, wherein each groove includes a pair of side walls to define opposing abutments.
8. The compressor system of claim 1, wherein one end of each conduit is permanently attached to a compressor component.
9. The compressor system of claim 1, wherein the component is an intercooler.
10. The compressor system of claim 1, wherein the conduits are structured to receive relatively high temperature fluid flow therethrough.
11. An apparatus comprising:
- a compression system configured to compress a fluid;
- a first conduit fluidly connectable to the compression system;
- a second conduit fluidly connectable to the first conduit; wherein at least one of the first and second conduits are defined by a circumferential thin walled structure;
- an adaptor end connected to at least one of the first and second conduits having a thin walled structure, the adaptor having a tapered inner wall that transitions from a thin wall to a second wall thickness, wherein the second wall thickness is sufficient to support a circumferential slot formed in the outer surface thereof;
- a circumferential slot formed in the outer surface of each of the first and second conduits at a location having a wall thickness at least equivalent to the second wall thickness; and
- an expansion joint coupling engageable with the slots of the first and second conduits and operable to connect the first and second conduits together.
12. The apparatus of claim 11, wherein the compressor system includes multi-stage centrifugal compressors driven by a motive source.
13. The apparatus of claim 11, further comprising:
- an intercooler fluidly connected to one of the first and second conduits.
14. The apparatus of claim 11, wherein the fluid includes air.
15. The apparatus of claim 11, further comprising:
- a fluid seal engaged with the coupling to form a fluid tight seal between the first and second conduits.
16. The apparatus of claim 11, wherein the expansion joint coupling permits relative movement between the first and second conduits.
17. The apparatus of claim 11, wherein the expansion joint coupling includes a pair of circumferential leg extensions.
18. The apparatus of claim 17, wherein the leg extensions are configured to engage the slots formed in the first and second conduits.
19. The apparatus of claim 17, wherein the leg extensions are constructed to slide between sidewall abutments along a width of each slot.
20. A method comprising:
- welding an adaptor to an end of a thin walled conduit, wherein the adaptor includes a portion having a second wall thickness greater than the thin walled conduit;
- forming an outwardly facing groove in the adaptor proximate the portion having the second wall thickness;
- forming an outwardly facing groove in a second conduit;
- connecting the first and second conduits with an expansion groove clamp positioned within the grooves of the first and second conduits;
- generating heated fluid with a compressor system;
- transporting the heated fluid through the first and second conduit;
- moving the conduits relative to the clamp in response to variable thermal loading.
21. The method of claim 20, wherein the moving includes sliding a portion of the clamp along a width of the grooves formed in each of the conduits.
22. The method of claim 20, wherein the compression system includes a centrifugal compressor fluidly connected to at least one intercooler with the first and second conduits.
23. The method of claim 20, further comprising:
- forming a fluid tight seal between the first and second conduits.
Type: Application
Filed: Sep 30, 2015
Publication Date: Mar 30, 2017
Inventor: Ritesh Kumar Mistry (Gandhinagar)
Application Number: 14/870,607