Natural Gas Compressor Blowdown System for Leakage Reduction
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Solution Overview
Problem
Natural gas compressors experience leakage and high pressure issues during idle periods, leading to environmental emissions and safety concerns due to incomplete valve seals and residual gas pressure.
Innovation Solution
A gas compression system incorporating a blowdown assist pump and a valve system to create a low pressure environment, either by using a blowdown tank or an engine intake manifold, to remove residual gas and reduce compressor pressure below 500 psi, thereby minimizing leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the compressor is designed with standard valves and compression cylinders, then the compression function is achieved, but gas leakage occurs during idle periods due to incomplete valve seals and residual pressure
Solution Approach 1:
The patent extracts the residual gas from the compression system by introducing a blowdown system that actively removes gas from the compression cylinders and valving system during idle periods. This extraction principle directly addresses the leakage problem by eliminating the source of harmful emissions rather than relying solely on improved sealing.
Solution Approach 2:
The control system activates the blowdown pump in advance during idle periods to reduce residual pressure before significant leakage can occur. This preliminary action prevents the accumulation of harmful pressure that would otherwise cause gas to leak through imperfect seals during the compressor's idle state.
2Object-generated harmful factors
If a blowdown system is added to remove residual gas, then gas leakage is reduced, but the device complexity increases
Solution Approach 1:
The blowdown system is designed to be self-regulating, with the control system automatically activating the blowdown pump based on sensor feedback regarding compressor state and pressure levels. This self-service capability reduces the need for complex manual control mechanisms while maintaining effective leakage prevention.
Solution Approach 2:
The patent introduces a blowdown tank as an intermediary component that temporarily stores residual gas before it is safely discharged or recompressed. This intermediary approach simplifies the overall system by providing a buffer that manages pressure transitions and reduces the complexity of direct pressure relief mechanisms.
3Productivity
If the compressor remains at high pressure during idle periods, then readiness for next cycle is maintained, but safety risks increase and restart becomes difficult
Solution Approach 1:
The control system implements periodic blowdown cycles during idle periods, actively managing pressure levels through timed activation of the blowdown pump. This periodic action maintains safety by preventing dangerous pressure accumulation while preserving restart capability through controlled pressure management rather than continuous high pressure maintenance.
Solution Approach 2:
The system dynamically changes the pressure parameter during idle periods by activating the blowdown pump to reduce pressure from high compression levels to safe storage levels. This parameter change allows the system to transition from a high-pressure state (which presents safety risks) to a controlled low-pressure state that maintains restart readiness without compromising safety.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Substantially reduces natural gas leakage into the atmosphere, decreases greenhouse gas emissions, and enhances safety by effectively managing compressor pressure during idle cycles.
Implementation Method 1
A pump system is in fluid communication with the compression system to create a low pressure to remove the residual gas
Data Source
AI summary
When a natural gas compressor completes its compression cycle, residual pressurized natural gas remains in the cylinders, valves, and conduits of the compressor. Gas leaks into the environment increasing greenhouse gas emissions and introducing safety concerns. The systems and methods herein provide ways for substantially reducing or eliminating leakage of natural gas to the atmosphere while the system sits idle between compression cycles.