Systematic Engine Uprate Technology Development and Deployment for Pipeline Compressor Engines through Increased Torque

摘要

Three methods were utilized to analyze key components of slow-speed, large-bore, natural gas integral engines. These three methods included the application of computational fluid dynamics (CFD), dynamic modal analysis using finite element analysis (FEA), and a stress analysis method also using FEA. The CFD analysis focuses primarily on the fuel mixing in the combustion chamber of a TLA engine. Results indicate a significant increase in the homogeneity of the air and fuel using high-pressure fuel injection (HPFI) instead of standard low-pressure mechanical gas admission valve (MGAV). A modal analysis of three engine crankshafts (TLA-6, HBA-6, and GMV-10) is developed and presented. Results indicate that each crankshaft has a natural frequency and corresponding speed that is well away from the typical engine operating speed. A frame stress analysis method is also developed and presented. Two different crankcases are examined. A TLA-6 crankcase is modeled and a stress analysis is performed. The method of dynamic load determination, model setup, and the results from the stress analysis are discussed. Preliminary results indicate a 10%-15% maximum increase in frame stress due to a 20% increase in HP. However, the high stress regions were localized. A new hydraulically actuated mechanical fuel valve is also developed and presented. This valve provides equivalent high-energy (supersonic) fuel injection comparable to a HPFI system, at 1/5th of the natural gas fuel pressure. This valve was developed in cooperation with the Dresser-Rand Corporation.