Cooling Function

Compressor anti-surge systems recycle discharge gas to suction when flow drops below minimum stable operation, preventing surge damage. This recycled gas carries compression heat that accumulates without cooling, raising suction temperature and reducing compressor efficiency. The spillback cooler removes this heat maintaining proper inlet temperature typically 30-50°C, protecting equipment and optimizing performance.

Design Configuration

Shell-and-tube construction with hot recycled gas on tube side and cooling medium on shell side. Compact design suits installation in recycle piping with minimal pressure drop to avoid affecting compressor operation. ERGIL sizes coolers based on recycle flow rate, compression temperature rise, and required temperature reduction with typical duties 0.5-5 MMBTU/hr.

Cooling Methods

Water-cooled units using cooling tower water provide efficient heat removal in compact footprint. Air-cooled designs employ finned tubes with fans for locations without water availability. Glycol or refrigerant cooling for applications requiring sub-ambient temperatures. Material selection accounts for gas composition including corrosive components and operating pressures to 1500 psig.

Applications

Fuel gas compressor systems, gas gathering compression stations, refrigeration compressor recycle loops, natural gas transmission compression, and process gas compression across upstream production, midstream processing, and downstream facilities. Protects centrifugal and reciprocating compressors during turndown operation.

Control Integration

Temperature monitoring on cooler outlet ensures proper cooling performance. Control integration with compressor anti-surge system optimizes recycle flow and cooling duty. Prevents overcooling that could cause condensation or hydrate formation. Simple reliable operation requiring minimal maintenance.

Construction Standards

Design per ASME Section VIII with materials suitable for gas composition and operating conditions. Carbon steel or stainless steel construction. Pressure ratings match compressor discharge conditions. Tube-side design enables cleaning when fouling occurs. Complete hydrostatic testing validates integrity.

Performance Benefits

Protects compressor from thermal damage extending equipment life. Maintains compression efficiency during low-flow operation. Prevents downstream equipment degradation from excessive temperature. Compact design minimizes installation footprint. Reliable proven technology with low maintenance requirements.

ERGIL spillback coolers deliver dependable temperature control protecting compression systems and ensuring reliable operation across varying process conditions.