Air Compressor Decompression via Inlet Valve and Isolation Path
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Solution Overview
Problem
Existing air compressor systems in drilling rigs consume unnecessary energy when not in use, as they continue to operate even during periods of low compressed air requirements, leading to inefficiencies and increased fuel consumption.
Innovation Solution
An air compressor system with an adjustable air inlet valve and an isolation valve, controlled by a controller, which takes the air compressor offline by shutting the inlet valve and opening the isolation valve, allowing the system to reduce pressure and conserve energy by using a secondary air compressor when necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the air compressor continues to operate during periods of low compressed air requirements, then the system maintains readiness for immediate use, but unnecessary energy is consumed and fuel efficiency deteriorates
Solution Approach 1:
The system segments the compressed air storage into multiple tanks (first compressed air tank and second compressed air tank) that can be independently managed. This allows the controller to selectively supply compressed air from different tanks based on demand, enabling the air compressor to be shut down or operated at reduced capacity when total demand is low, thereby reducing energy consumption while maintaining system readiness.
Solution Approach 2:
The system pre-compresses and stores air in multiple compressed air tanks before periods of high demand. The controller monitors compressed air requirements and ensures sufficient charge in the tanks in advance, allowing the air compressor to be taken offline during low-demand periods without compromising the ability to meet future demand.
2Use of energy by moving object
If the air compressor is shut down during periods of low demand, then energy consumption is reduced, but the system may not be ready to meet sudden increases in compressed air requirements
Solution Approach 1:
By dividing compressed air storage into multiple independent tanks with individual control valves and charge indicators, the system can maintain sufficient compressed air reserves in the tanks even when the air compressor is shut down. This segmented architecture ensures that sudden increases in demand can be met from stored reserves while the air compressor restarts, balancing energy savings with system readiness.
Solution Approach 2:
The controller continuously monitors compressed air charge levels in the tanks and compressed air requirements. Based on this feedback, the controller intelligently determines when to shut down or start the air compressor, ensuring that sufficient reserves are maintained to meet sudden demand increases while maximizing energy savings during low-demand periods.
3Use of energy by moving object
If multiple valves and control systems are added to manage compressed air distribution, then energy efficiency and system control are improved, but device complexity increases
Solution Approach 1:
The controller serves multiple functions: it monitors compressed air charge levels in both tanks, determines compressed air requirements, controls the discharge valves of both tanks, and manages the air compressor operation. This multi-functionality consolidates control logic into a single device, reducing overall system complexity despite the addition of multiple valves and tanks.
Solution Approach 2:
The system merges the control of multiple compressed air tanks and the air compressor into a single integrated control system. The controller coordinates the operation of first discharge valve, second discharge valve, and air compressor based on unified logic that considers total compressed air requirements, simplifying the control architecture compared to having independent control systems for each component.
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
This solution efficiently manages energy usage by reducing the load on the driving engine, minimizing fuel consumption, and maintaining system pressure during periods of low demand, thereby enhancing operational efficiency.
Implementation Method 1
a first non-return valve disposed in the main air discharge passage between the air outlet of the air compressor and the air inlet of the first receiver
Implementation Method 2
an oil separator disposed in the first receiver
Implementation Method 3
an adjustable air inlet valve connected to the air inlet of the air compressor, wherein the adjustable air inlet valve is configured to be adjustable to regulate how much air can flow into the air inlet of the air compressor
Implementation Method 4
an isolation valve disposed in the air flow between the main air discharge passage and the air inlet of the second receiver, wherein the isolation valve is configured to have an open position where air from the main air discharge passage can flow through the secondary discharge passage and a closed position where air from the main air discharge passage cannot flow through the secondary discharge passage
Implementation Method 5
an air compressor having an air inlet and an air outlet, the air compressor configured to compress air from the air inlet and to deliver a volume of compressed air to the air outlet
Data Source
AI summary
Methods, computer readable media, and apparatus are disclosed for decompressing an air compressor. The methods including compressing air, the compressed air flowing through a first path through a first non-return valve to a first receiver; and in response to determining to take the air compressor off-load, closing an air inlet valve of the air compressor to stop air from entering the air compressor, opening a second path from the air outlet of the air compressor to approximately atmospheric pressure to lower the air pressure at the air inlet of the air compressor, stopping a first flow of oil from the first receiver to the air compressor, wherein the first flow of oil is for cooling the compressor, stopping a second flow of oil from a separator for a working air to the air compressor, and flowing oil from the first receiver to the air compressor for lubrication.