Variable Capacity Control Suite

Capacity Control Suite

Helps you save energy and money.
Reciprocating compressors are a critical
component in producing the energy and
products we use every day.
DresserRand reciprocating compressors
and integral gas engines are found in refin
ing, petrochemical, natural gas transmission,
and in general industrial applications. For
compressor operators, maximizing efficiency
and minimizing energy costs are key.
Because of industry standards and other
unknown variables, compressors are typi
cally built oversized to run over capacity.
The positive displacement nature of process
reciprocating compressors is such that you
basically run it at full capacity or you turn it
off. Because of this, they often require devic
es to regulate (reduce) capacity and help
operators maintain process control. This is
typically done with a combination of stepped
unloading systems and a gas recycle loop,
usually referred to as a bypass. However,
the bypass thats necessary for process
control wastes energy by re-compressing
gas that has already been compressed and
sent back to suction at reduced pressure.

Thus, stepless control devices are necessary

to eliminate the need for a bypass: enter
the DresserRand suite of capacity control
options.
The beginning of stepless capacity control
dates back to the 1950s when IngersollRand developed a pneumatic hydro-mechani
cally controlled infinite step capacity control
ler (ISC) that held the suction valve open and
provided variable end unloading. (The hydrau
lically operated variable volume clearance
pockets, or HVVCP, concept was also devel
oped during this time.) The ISC technology
proved successful with integral gas engines
through the 1970s, but wasnt actively
pursued in the process market until more
recently. In the late 1990s, DresserRand
began using electronic controls on gas
engines and began adapting these products
for variable capacity control of reciprocating
compressors for process applications around
2000 (updated ISC control system).

Todays CapCon Suite

The capacity control (CapCon) suite offered
by DresserRand today comprises three vari
able control systems (1) infinite step con
trol (ISC); (2) gas-controlled stepless pockets
(GSP); and (3) hydraulic variable volume
clearance pockets (HVVCP). Each technology
allows variable output from stepped or fixed
output compressors over a wide range of
operating conditions.
This variable capacity control system gives
operators an infinite number of intermediate
steps so the compressor can run at less
than full design capacity and use less energy
when appropriate. Exerting this throttle over
the compressor allows you to save operating
energy and reduce energy costs.

The traditional process is very wasteful; it

loses time and money for clients.

ISC Infinite Step Control

(Delayed Suction Valve Closing)
Applied to all Inlet Valves 10% DVE Limit

GSP Gas-controlled Stepless Pocket

(Variable Volume Clearance Pocket)
Applied to Head End and/or Crank End
of Cylinder 10% DVE Limit

HVVCP Hydraulic Variable Volume

Clearance Pocket
Applied to Head End of Cylinder
Solid line 0% DVE Limit Dashed line
10% DVE limit

as-controlled
Stepless Pocket
(GSP)

Features

Benefits

Head-end or crank-end installation

Allows capacity control on both ends of the

compressor cylinder

Manual, automatic or remote control

Allows pocket adjustment while the compressor

is running under load
Provides infinite step control within limits set by
pocket volume
Provides maintenance and operational cost
savings

No hydraulics required

Simplifies installation and maintenance

No dynamic seals

Virtually eliminates seal maintenance and fugitive

emissions

Simple mechanical system

Requires maintenance of only two items:

A specially designed compressor valve
A special control gas regulator
Can be applied to existing pockets

Proven OEM design

Achieves optimum reliability for reduced

maintenance and downtime

Decades of experience and OEM

expertise make Dresser-Rand your

Gas-controlled Stepless
Pocket (GSP)
The DresserRand gas-controlled
stepless pocket (GSP patented
by Gas & Air Specialty Products,
Inc. #6,361,288 and licensed to
DresserRand) allows reciprocating
compressor cylinder capacity to be
continuously varied over a range set
by the pockets volume. The GSP
uses familiar, easily maintained
parts and does not require the use
of hydraulics.
A fixed volume pocket is used for
the DresserRand GSP, but the usual
plug-type valve or piston is replaced
with a specially designed compres
sor valve typically a DresserRand
Magnum valve. The valves guard
is designed so that control gas (typi
cally process gas) can be introduced
to the guard side of the elements.
The pressure of this gas controls
the load. The valve opens when the
cylinder pressure is greater than the
control pressure and closes when it
is less than the control pressure.
Thus, if the control pressure is set
partway between cylinder suction
and discharge, the pocket is open
for only part of each cycle, and part
load operation results. Different par
tial loads can be achieved by adjust
ing the control pressure. Note that
the control pressure is constant and
does not vary with compressor rota
tion. Therefore, no flywheel timing,

hydraulics, highspeed electronics,

or high-speed
solenoid valves
are required.

Control
Pressure

The GSP is ideal

for applications
where a cost
effective solution
is required to vary
capacity on both
ends of the com
pressor cylinder.
The GSP is appli
cable for gas
transmission, gas
gathering and
select process
applications.

PDischarge
Control Pressure

partner of choice.

PSuction
n

Mi

Capacity

Ma

Handwheel-operated variable
volume clearance pocket

The innovative HVVCP capacity

control technology is safer than
handwheel-operated variable volume
clearance pockets, and allows auto
matic capacity adjustments while
the compressor is running under
load.
The HVVCP hydraulic variable volume
clearance pocket manufactured by
DresserRand can be applied to
virtually any reciprocating gas com
pressor. Mounted in the outer head,
it controls capacity of the head end
of the cylinder by adjusting the clear
ance volume.

The HVVCP provides stepless

capacity control capabilities that
respond rapidly to changes in
process demand, all while the com
pressor is running under load. This
is a replacement for the handwheeloperated variable volume clearance
pocket.
HVVCPs are applicable for process
machines, gas
field machines,
100
heavy/light
90
gases, lube/
80
non-lube, clean/
dirty service,
70
and sour gas
60
applications.

ydraulic variable volume

clearance pocket (HVVCP)

CYLINDER FLOW %

Hydraulic Variable Volume

Clearance Pocket (HVVCP)

Hydraulic variable volume

clearance pocket

50
1.00

1.50

HVVCP

2.00

2.50
PRESSURE RATIO

Features

Benefits

"Bolt-on" adaptability

Allows direct replacement for any head

mounted, handwheel-operated pockets
Does not require modification to the
compressor cylinder

Manual, automatic or remote control

Provides fully adjustable capacity control on

head end within limits set by pocket volume
(~100 55 percent)
Allows safe and reliable capacity adjustment
while the compressor is running under load
Provides operational cost savings
Reduces horsepower consumption and energy
costs compared to bypass

Vent and purge capability

Reduces fugitive emissions

No compressor speed limitation

Can be applied to virtually any reciprocating

compressor

Self-contained hydraulic system

Requires no external hydraulic reservoir or

power supply
Uses standard hydraulic components

Proven OEM design

Achieves optimum reliability for reduced

maintenance and downtime

3.00

3.50

4.00

ISC Unloader

nfinite Step Control (ISC)

Infinite Step Control (ISC)

DresserRand-proprietary capacity control
technology provides a precise capacity
load step range from zero to 100 percent
within a wide range of operating condi
tions.
As a replacement for traditional port, plug
and fixed clearance pocket unloader sys
tems, the Infinite Step Control (ISC) sys
tem eliminates fixed, discrete load steps.
Compressor efficiency is optimized by
effectively controlling capacity over a wide
range of operating conditions.
When compared to other computercontrolled delayed suction valve closing
systems, the ISC provides full control over
compressor capacity with far less complex
ity and lower cost.
The ISC system is a computer-controlled,
hydraulically activated, finger unloader sys
tem that comprises three distinct subsys

ISC installed on an integral gas

engine in natural gas storage
service

tems. The electronic subsystem includes a

high-speed controller module and hydraulic
actuating components. The hydraulic
subsystem includes a hydraulic pump, res
ervoir, filtration, and related components.
The unloader subsystem includes valve
actuator covers, cages, plungers, and
DresserRand suction valves.
The ISC electronic controller provides
start/stop controls, safety shutdowns and
calculations for precise capacity control.
This includes unloading on start-up and
control of inter-stage pressure to avoid
excessive rod loading.

the inlet valve elements open for a pre

cise percentage of the discharge stroke.
The compressor capacity is reduced or
increased by accurately varying the timing
of the hydraulic signal. This precise func
tionality provides infinitely variable control
of compressor capacity.
infinite

control

step

The electronic controllers high-speed

module converts capacity set-point signals
into actual timing signals that are fed to
electric servo valves that control the pres
surization of the valve actuators. A hydrau
lic signal is then sent to each inlet valve
unloader on the compressor cylinders.
This high-pressure hydraulic signal holds

ISC installed on a process

reciprocating compressor in
refinery feed gas service

CHOOSING THE RIGHT CAPACITY CONTROL SYSTEM

Variable capacity control devices are becoming more prevalent in
the process market because of increased energy costs and the
desire to save energy and related expenses whenever possible.
Our history in the reciprocating compressor industry dates back

to the late 1800s. So our experience, backed by OEM expertise

and knowledge, makes Dresser-Rand the obvious choice to help
you select the right capacity control system for your specific oper
ating requirements.

Regional Headquarters

For more information

on Capacity Control,
contact the following location:
Dresser-Rand
Painted Post Operations
100 Chemung Street
Painted Post New York 14870 USA
Tel: (Intl +1) 607-937-2011
Fax: (Intl +1) 607-937-2905

For a complete list of

products and services, visit
www.dresser-rand.com
or contact the following:

CORPORATE Headquarters
DresserRand
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10205 Westheimer Road
Houston, Texas 77042
Tel: (Intl +1) 713-354-6100
Fax: (Intl +1) 713-354-6110

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Cedex 16
Paris 75784 France
Tel: (Intl +33) 156 26 71 71
Fax: (Intl +33) 156 26 71 72
Email: info@dresser-rand.com

The Americas
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Houston, Texas 77042
Tel: (Int'l +1) 713-354-6100
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EMEA
(Europe, Middle East, & Africa)

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Cedex 7013
Le Havre 76080, France
Tel: (Int'l +33) 2-35-25-5225
Fax: (Int'l +33) 2-35-25-5366/5367
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Fax: (Int'l +60) 3-2093-2622

2011 Dresser-Rand. DRESSER-RAND is a registered trademark of Dresser-Rand Group Inc. Printed in U.S.A.
This brochure comprises a general overview of the Dresser-Rand products described herein. It is solely for informational purposes, does not represent
a warranty or guarantee of the information contained herein, and is not to be construed as an offer to sell or solicitation to buy. Contact Dresser-Rand
for detailed design and engineering information suitable to your specific applications. Dresser-Rand reserves the right to modify its products and related
product information at any time without prior notice.
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