Natural gas compressor unit lubricating oil intelligent comprehensive treatment device and process design

Abstract

The present application relates to a kind of natural gas compressor set lubricating oil intelligent comprehensive processing device and process design, in combination with oil and gas field station compressor set lubricating oil filling, use, monitoring analysis, cost consumption and other control mode, to market carries out depth technical exchange, and in combination with nearly 20 years of equipment production pry technology and technical maintenance management experience, realize station compressor set crankcase oil real-time circulation filtering realizes never oil change, high oil tank automatic oil supplement, overhaul old oil automatic recovery filtration detection and backfill, daily lubricating oil consumption of compressor accurate analysis, remote control and lubricating oil quality shutdown protection and other functions.For oil and gas field compressor lubricating oil product monitoring, metering, hazardous waste reduction, safety and environmental protection, maintenance cost etc., it has very important significance, can greatly improve the intelligent of equipment lubrication system, improve station equipment safe operation reliability and the improvement of equipment maintenance management level.

Description

Technical Field

[0001] This invention belongs to the field of innovative technology for the performance of lubricating oil in natural gas compressor units, specifically relating to an intelligent integrated treatment device and process design for lubricating oil in natural gas compressor units. Background Technology

[0002] Natural gas compressor units are the core production equipment for gathering, transporting, and producing gas in oil and gas fields. Each unit is equipped with a 200L elevated oil tank, installed above all lubrication points. The tank relies on gravity to supply lubrication to all parts of the compressor unit. Maintenance personnel periodically replenish the oil tank based on its level. The system primarily employs two lubrication methods: injection lubrication and splash lubrication. A fixed amount of lubricating oil is added to the crankcase. Splash lubrication of components such as main bearings, connecting rod bearings, connecting rod bushings, crosshead slides, and crossheads is achieved through the rotation and oscillation of the connecting rods and the crankshaft. However, with prolonged use, abrasive particles inevitably accumulate on the contact surfaces of the components, contaminating the lubricating oil and affecting its usability. The current compressor units at the plant lack circulating filtration devices in their crankcases, resulting in a low level of automation. Oil maintenance relies solely on the equipment production and maintenance manuals, with manual sampling and analysis of lubricating oil quality. This leads to inconsistent sampling quality and, given the diverse and extensive equipment production layout, data monitoring and analysis are not timely. Furthermore, the lack of intelligent oil consumption metering relies on rudimentary manual statistical analysis, hindering real-time and effective control of lubricating oil consumption and increasing costs. Additionally, the crankcase oil needs to be changed every 2,000 or 4,000 hours as per the manual, generating waste oil drums and hazardous waste during replacement or drainage, causing significant challenges for users in hazardous waste management.

[0003] During normal operation, the elevated oil tank needs to be replenished with lubricating oil every 5-7 days. At least three people are required to coordinate the refilling process. The filling port of the elevated oil tank is approximately 3 meters above the ground, requiring operators to stand on the equipment itself, posing a significant safety hazard. Furthermore, during routine refilling, the lubricating oil is transferred from the bulk container to a dedicated small refill container, which is then used to fill the elevated oil tank or crankcase. Because the work site is located in the heart of the Mu Us Desert, with constant sandstorms, it is difficult to avoid sand, dust, and other impurities entering the refill container and elevated oil tank, causing lubricating oil contamination. Contaminated lubricating oil will lead to lubrication failure, accelerated wear on moving parts, and ultimately, equipment malfunction and a shortened lifespan. Summary of the Invention

[0004] The purpose of this invention is to solve the above-mentioned problems by providing an intelligent integrated processing device and process design for lubricating oil in natural gas compressor units. This device enables functions such as never changing the crankcase oil in the compressor unit, real-time circulation and filtration of the crankcase oil, online monitoring and early warning of oil quality, automatic replenishment of the high-level oil tank, accurate analysis of the daily lubricating oil consumption of the compressor, remote control, and lubricating oil quality shutdown protection. This greatly improves the intelligence of the equipment lubrication system, enhances the reliability of safe operation of the equipment, and improves the level of equipment maintenance and management.

[0005] To achieve the above objectives, the present invention provides the following technical solution: an intelligent integrated processing device for lubricating oil in a natural gas compressor unit, comprising a crankcase, a PLC control cabinet, and a customized oil tank. A seventh ball valve is located below the crankcase. The seventh ball valve is connected to an oil probe via an inlet hose. A first tee is provided on the inlet hose. A pre-filtration sampling port is located at the first tee. The first tee connects to a second tee, which in turn connects to a first Y-type filter. The first Y-type filter connects to a first electric tee ball valve, which is connected to an oil pump. The oil probe and the oil pump are both connected to a coalescing filter via a fourth tee. The coalescing filter is connected to a plunger pump via a fifth tee. The plunger pump is connected to a second electric ball valve via a sixth tee. One end of the second electric ball valve is connected to a third ball valve, and the other end is connected to the sixth ball valve via an outlet hose. The third ball valve is connected to the customized oil tank, which is connected to the plunger pump via a fourth ball valve and a third Y-type filter.

[0006] Furthermore: the customized oil tank is equipped with a maintenance cover on top, a breather cap on one side of the maintenance cover, a liquid level sensor inside the oil tank, an oil temperature sensor and an oil heater on the right side of the oil tank, and a fifth ball valve at the bottom of the customized oil tank; furthermore: the intelligent integrated lubricating oil treatment device adopts a PLC control cabinet for one-button start / stop control, used for lubricating oil filter pressure differential display alarm, oil monitoring parameter display alarm, and liquid level and temperature display alarm, and is linked with the PLC of the compressor unit, enabling local or remote control, and can automatically replenish oil, drain oil during maintenance, and refuel during maintenance; furthermore: the process design of an intelligent integrated lubricating oil treatment device for a natural gas compressor unit includes the following stages;

[0007] Phase 1: Process Design

[0008] 1.1 Study the working principle and process flow of this device, design and draw a schematic diagram of the process flow of this device, and discuss and determine the schematic diagram of the process flow.

[0009] Phase Two: Material Design, Selection, and Procurement

[0010] 2.1 Research the selection of core components required for the corresponding functions of the equipment;

[0011] 2.2 Confirmation and alignment of design drawings for relevant components, and alignment of functional designs for equipment components;

[0012] 2.3 Confirm the list of parts required for the skid-mounted device and conduct market inquiries to calculate its production cost;

[0013] 2.4 Confirm the selected equipment components and procure customized execution components;

[0014] Phase 3: Production of equipment prototype skids

[0015] 3.1 The design layout diagram of the component skid is drawn from the perspectives of safety, operability, and practicality;

[0016] 3.2 Technical discussion and on-site inspection to confirm the final layout drawing;

[0017] 3.3 Design the layout of the electrical automatic control system and develop and simulate the control program;

[0018] 3.4 Produce a skid-mounted prototype according to the layout drawing, theoretically verify and analyze its functions, and then accept and ship it out of the factory;

[0019] Phase 4: On-site installation and testing

[0020] 4.1 Coordinate with users to determine installation and testing locations, selecting sites with backup machines;

[0021] 4.2 Process relevant invoices and construction test plans for approval and filing in accordance with the user's relevant management requirements;

[0022] 4.3 Implementation of on-site construction risk control measures, process construction and modification, start-up and commissioning testing, and recording of relevant functional verification data;

[0023] Phase 5: Market Application Promotion and Mass Production

[0024] 5.1 Based on the prototype testing and verification, adjust and optimize the component performance and design layout, control its production and manufacturing costs, and draw up and finalize the final set of production and manufacturing design drawings and quality control measures for the production and processing process;

[0025] 5.2 Marketing, sales, and standardized, quantified production.

[0026] Furthermore, this device can continuously monitor equipment usage and customer needs, and can provide customized system installations for users with high requirements for intelligence.

[0027] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0028] 1. The crankcase of the compressor unit is circulated and filtered for oil circulation. Through the process, the crankcase oil never needs to be changed, which solves the problem of waste lubricating oil after crankcase maintenance and achieves zero hazardous waste generation during crankcase maintenance.

[0029] 2. The compressor unit is equipped with an elevated oil tank to achieve automatic oil replenishment, which solves the safety risks of maintenance personnel and the impact of oil contamination on the safe operation and stability of the equipment, and realizes intelligent operation of lubricating oil filling in the elevated oil tank and zero hazardous waste generation;

[0030] 3. Automatic recycling, filtration, testing, and reinjection of used oil during crankcase maintenance, achieving zero hazardous waste;

[0031] 4. Accurately measure and analyze the lubricating oil consumption of the compressor unit, realize real-time online monitoring and curve analysis of lubricating oil consumption, accurately prevent and maintain, and reduce lubricating oil consumption costs;

[0032] 5. This device has local control and remote communication functions, enabling remote monitoring and early warning capabilities;

[0033] 6. Complete skid-mounted equipment enables product commercialization and generates revenue for the enterprise. Attached Figure Description

[0034] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only for more clearly illustrating the technical solutions in the embodiments of the present invention or the prior art. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0035] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0036] Figure 2 This is a three-dimensional layout diagram of the present invention;

[0037] Figure 3 This is a detailed technical roadmap of the present invention;

[0038] In the diagram: 1-Inlet flexible hose, 2-First tee, 3-Pre-filtration sampling port, 4-Second tee, 5-First Y-type filter, 6-First electric tee ball valve, 7-Suck rod, 8-Hose, 9-First ball valve, 10-Third tee, 11-Second Y-type filter, 12-Second ball valve, 13-Outlet hose, 14-Oil probe, 15-Oil pump. 16-Plunger pump, 17-Fourth three-way valve, 18-Coalescing filter, 19-Fifth three-way valve, 20-Sixth three-way valve, 21-Third Y-type filter, 22-Second electric three-way ball valve, 23-Third ball valve, 24-Fourth ball valve, 25-Seventh three-way valve, 26-Fifth ball valve, 27-Oil heater, 28-Oil temperature sensor, 29-Breathe cap, 30-Level sensor, 31-Inspection cover, 32-Customized oil tank, 33-PLC control cabinet, 34-Sixth ball valve, 35-Oil level gauge, 36-Seventh ball valve. Detailed Implementation

[0039] To enable those skilled in the art to better understand and implement the technical solutions of the present invention, the present invention will be further described below with reference to specific embodiments. However, the embodiments are only for illustration and are not intended to limit the present invention.

[0040] like Figures 1-2 The aforementioned intelligent integrated processing device for lubricating oil in a natural gas compressor unit includes a crankcase, a PLC control cabinet 33, and a customized oil tank 32. Its key feature is that a seventh ball valve 36 is located below the crankcase. The seventh ball valve 36 is connected to an oil probe 14 via an inlet hose 1. A first three-way valve 2 is provided on the inlet hose 1. A pre-filtration sampling port 3 is located at the first three-way valve 2. The first three-way valve 2 is connected to a second three-way valve 4. The second three-way valve 4 is connected to a first Y-type filter 5. The first Y-type filter 5 is connected to a first electric three-way ball valve 6. The first three-way electric ball valve 6 is connected to an oil pump 15. The oil probe 14 and the oil pump 15 are both connected to the coalescing filter 18 via the fourth three-way valve 17. The coalescing filter 18 is connected to the plunger pump 16 via the fifth three-way valve 19. The plunger pump 16 is connected to the second electric ball valve 22 via the sixth three-way valve 20. One end of the second electric ball valve 22 is connected to the third ball valve 23, and the other end is connected to the sixth ball valve 34 via the outlet hose 13. The third ball valve 23 is connected to the customized oil tank 32. The customized oil tank 32 is connected to the plunger pump 16 via the fourth ball valve 24, the third Y-type filter 21, and the plunger pump 16.

[0041] The customized oil tank 32 is provided with an inspection cover 31 on the top, a breather cap 29 on one side of the inspection cover 31, a liquid level sensor 30 inside the customized oil tank 32, an oil temperature sensor 28 and an oil heater 27 on the right side of the customized oil tank 32, and a fifth ball valve 26 at the bottom of the customized oil tank 32.

[0042] The intelligent integrated lubricating oil processing device adopts a PLC control cabinet 33 for one-button start and stop control. It is used for lubricating oil filter pressure difference display and alarm, oil probe 14 monitoring parameter display and alarm, and oil level and temperature display and alarm. It is linked with the PLC of the compressor unit and can be controlled locally or remotely. It can also automatically replenish oil, drain oil during maintenance, and add oil during maintenance.

[0043] Working principle of crankcase oil circulation filtration and monitoring

[0044] Through the one-button circulation filtration monitoring control button on the PLC control cabinet, the oil in the crankcase passes through the oil probe 14, oil pump 15, and coalescing filter 18 to filter out impurities and water in the oil before returning to the crankcase. During the process, the oil circulation filtration monitoring in the crankcase is mainly achieved through logic control of the first electric three-way ball valve 6 and the sucker rod 7.

[0045] Working principle of automatic crankcase lubrication

[0046] After the device is in operation, the oil level gauge 35 is used to detect the oil level. When the oil level is low, the plunger pump 16 is started and the oil pump 15 is stopped. The oil in the crankcase is added to the high-level oil tank through the plunger pump 16. At the same time, the plunger pump 16 adds the new oil in the customized oil tank 32 to the crankcase in the same proportion. When the oil level is detected to be full, the plunger pump 16 is turned off and the oil pump 15 is started. The process is switched to the circulation filtration monitoring process, thereby achieving the goal of never changing the oil in the crankcase.

[0047] Repairing the working principle of automatic old oil recovery filtration detection and reinjection

[0048] When the unit needs maintenance, press the compressor maintenance button on PLC control cabinet 33 to open the third ball valve 23 and close the second ball valve 12. The PLC logic controls the first electric three-way ball valve 6 and the second electric three-way ball valve 22 to discharge the engine oil in the crankcase into the customized oil tank 32 through the oil probe 14, oil pump 15, and coalescing filter device 18, thus achieving the discharge function. When refilling is completed, close the third ball valve 23 and open the second ball valve 12. The PLC logic controls the first electric three-way ball valve 6 and the second electric three-way ball valve 22 to refill the engine oil in the customized oil tank 32 back into the crankcase through the oil probe 14, oil pump 15, and coalescing filter device 18.

[0049] Precise calculation of lubricating oil consumption

[0050] When adding new oil, the amount added is accurately measured by a customized oil tank level sensor 30 (32). At the same time, the amount of oil added automatically each time the compressor is running normally is also accurately measured. Through PLC curve calculation and analysis, the daily lubricating oil consumption of the unit is monitored in real time. At the same time, upper and lower limit alarm values ​​can be set through the PLC control cabinet of this device, and it is linked with the compressor unit PLC for control. When the lubricating oil consumption of the compressor unit is very high, an alarm is triggered and the unit is shut down to prevent the equipment from malfunctioning further, thus achieving accurate measurement of lubricating oil.

[0051] Local control and remote communication functions

[0052] The intelligent integrated lubricating oil treatment device is equipped with a PLC control cabinet, which can realize the display and alarm of lubricating oil filter pressure difference, oil detection parameter display and alarm, and oil level and temperature display and alarm. It is linked with the compressor unit PLC to realize local display and control as well as remote central control room display and control. It also has one-button automatic control functions for automatic oil replenishment, maintenance oil draining and maintenance filling.

[0053] like Figure 3 The following is a detailed technical route of the device of the present invention:

[0054] User survey and exchange on lubricating oil hazardous waste and equipment management issues → Research on problem-solving strategies → Determination of solutions and plans → Discussion on equipment functions and design of process flow diagrams → Verification and discussion to determine the process flow → Development of equipment function plans and communication with customers → Design, selection and procurement of equipment components → Production of skid-mounted equipment prototypes and drawing design → Design and development of electrical control and remote transmission systems → On-site installation, testing and verification → Optimization and adjustment of finalized products → Market promotion and sales → Mass production and supply of skid-mounted units → Customized production and supply → Integration with existing compressor unit technical services to form a profit growth point.

[0055] The implementation method of the device of the present invention:

[0056] Phase 1: Process Design. This phase mainly involves studying the working principle and process flow of the equipment. It requires reviewing the skid-mounted PID process of the supporting equipment, relevant technical standards for unit lubricating oil, oil and gas field hazardous waste management requirements, discussing and determining the main functions and technologies of the equipment, conducting on-site inspections to confirm the installation method of the equipment, designing and drawing a schematic diagram of the system's process flow, discussing and determining the process diagram, and understanding customer needs and theoretical technical discussions on its safety, operability, and market positioning.

[0057] Phase Two: Material Design, Selection and Procurement. This phase mainly involves studying the design and selection of core components required to achieve the corresponding functions of the equipment, confirming the design of relevant component drawings, confirming the functional design of equipment components, confirming the list of parts required for the skid-mounted unit, conducting market inquiries to calculate its production cost, optimizing the selection of equipment components, and finalizing the procurement of components.

[0058] The third stage involves the production of a skid-mounted prototype. This stage primarily involves studying the skid components and drawing design layout diagrams based on safety, operability, and practicality. Technical discussions and on-site inspections are conducted to confirm and finalize the layout diagrams. Simultaneously, the layout of the electrical automatic control system is designed and finalized, and the control program is written and simulated for testing. Finally, a skid-mounted prototype is produced based on the layout diagrams, its functions are theoretically verified and reviewed, and the prototype is accepted before being shipped to the factory.

[0059] Phase 4: On-site installation and testing. This phase mainly studies whether the five major functions implemented by the system meet the design goals. The main workload involves coordinating with the user to determine the installation and testing location, preferably using sites with backup machines. Relevant documents and construction test plans are processed and approved according to the user's management requirements. On-site construction risk control measures are implemented, construction modifications are carried out, prototype debugging and testing are started, and relevant functional verification data is recorded. The testing and verification cycle is planned for 4000 hours, which may be adjusted according to the user's management requirements.

[0060] Phase 5: Market application and mass production. Based on the prototype testing and verification, adjust and optimize component performance and design layout, control production costs, and finalize the complete set of production and manufacturing design drawings and quality control measures for the production process. Market promotion and sales, and standardized and quantitative production are also carried out. At the same time, we continuously follow up on equipment usage and customer needs, and can carry out customized system devices. For example, for users with high intelligence, we can improve the intelligent control measures of this device, and conversely, we can optimize and control costs to meet customer needs.

[0061] This invention provides an intelligent integrated treatment device and process design for lubricating oil in natural gas compressor units, which solves the problems existing in the prior art:

[0062] 1. Address the issue of hazardous waste generated during routine oil replenishment and maintenance of compressor units;

[0063] 2. Address the safety risks associated with manually adding lubricating oil to compressors while working at heights, and resolve the secondary pollution issues related to adding lubricating oil to open containers;

[0064] 3. Solve the problem of compressor crankcases achieving zero oil change through process flow, reducing lubricating oil usage costs and achieving zero hazardous waste generation during maintenance;

[0065] 4. Solve the problem of recycling empty oil cans after the compressor unit has been filled with lubricating oil, thereby reducing maintenance costs;

[0066] 5. Solve the problem of no circulating filtration of engine oil in the crankcase of the compressor unit and the issue of online oil quality monitoring;

[0067] 6. Solve the problem of accurate metering of compressor oil and improve the stability of equipment operation.

[0068] This invention reduces the generation of hazardous lubricating oil during compressor production. The crankcase is designed to never require oil changes, reducing the workload and safety risks for workers and improving production efficiency.

[0069] By enhancing the intelligence of the compressor unit's lubrication system and making in-depth use of existing monitoring technologies, functions such as lubricating oil circulation and filtration, real-time oil monitoring and analysis, and oil metering can be achieved. Combined with remote communication monitoring, this effectively improves the reliability of equipment operation, extends the service life of moving parts, reduces material and lubricating oil usage costs, and increases economic benefits.

[0070] All content not described in detail in this invention is prior art.

[0071] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A smart integrated processing device for lubricating oil in a natural gas compressor unit, comprising a crankcase, a PLC control cabinet (33), and a customized oil tank (32), characterized in that: A seventh ball valve (36) is located below the crankcase. The seventh ball valve (36) is connected to the oil probe (14) via an inlet hose (1). A first tee (2) is provided on the inlet hose (1). A pre-filtration sampling port (3) is provided at the first tee (2). The first tee (2) is connected to a second tee (4). The second tee (4) is connected to a first Y-type filter (5). The first Y-type filter (5) is connected to a first electric three-way ball valve (6). The first electric three-way ball valve (6) is connected to an oil pump (15). Both the oil probe (14) and the oil pump (15) are connected via the first tee (36). The four-way three-way (17) is connected to the coalescing filter (18), which is connected to the plunger pump (16) via the fifth three-way (19). The plunger pump (16) is connected to the second electric ball valve (22) via the sixth three-way (20). One end of the second electric ball valve (22) is connected to the third ball valve (23), and the other end is connected to the sixth ball valve (34) via the outlet hose (13). The third ball valve (23) is connected to the custom oil tank (32), which is connected to the third Y-type filter (21) and the plunger pump (16) via the fourth ball valve (24).

2. The intelligent integrated treatment device for lubricating oil of a natural gas compressor unit according to claim 1, characterized in that: The custom oil tank (32) is provided with an inspection cover (31) on top, a breathing cap (29) is provided on one side of the inspection cover (31), a liquid level sensor (30) is provided inside the custom oil tank (32), an oil temperature sensor (28) and an oil heater (27) are provided on the right side of the custom oil tank (32), and a fifth ball valve (26) is provided at the bottom of the custom oil tank (32).

3. The intelligent integrated treatment device for lubricating oil of a natural gas compressor unit according to claim 1, characterized in that: The intelligent integrated lubricating oil processing device adopts a PLC control cabinet (33) for one-button start and stop control. It is used for lubricating oil filter pressure difference display alarm, oil probe (14) monitoring parameter display alarm, oil level temperature display alarm, and is linked with the PLC of the compressor unit. It can be controlled locally or remotely, and can automatically replenish oil, drain oil during maintenance and add oil during maintenance.

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