Dynamic Gas Routing for Multistage Compressors
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Solution Overview
Problem
Existing natural gas compressors require external pressure regulators and are inefficient when dealing with supply gas pressures higher than their maximum inlet pressure, limiting their design flexibility and efficiency.
Innovation Solution
A gas compressor design with multiple compression stages and valves that route the supply gas directly to the appropriate stage based on its inlet pressure, allowing for a wider range of inlet pressures without reducing the supply gas pressure, using a system of valves and sensors to manage gas flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an external pressure regulator is installed to reduce supply gas pressure to match the compressor's maximum inlet pressure, then the compressor can operate within its designed pressure limits, but the system complexity increases and energy is lost due to pressure reduction
Solution Approach 1:
The compressor system is designed to perform multiple functions by accepting supply gas at various pressure levels. Multiple compression stages with different maximum inlet pressures allow the same compressor to handle both high-pressure and low-pressure supply gas without requiring external pressure regulators, making the system universally adaptable to different supply conditions
Solution Approach 2:
The system dynamically selects which compression stage to activate based on the incoming supply gas pressure. Valves automatically route the supply gas to the appropriate compression stage that can accommodate the current pressure level, allowing the system to adapt its configuration in real-time to maintain efficient operation across varying pressure conditions
2Reliability
If supply gas pressure is reduced using an external pressure regulator, then the compressor can accept the gas, but energy efficiency decreases due to loss of the higher pressure and subsequent work required to compress the gas back
Solution Approach 1:
The system performs preliminary routing of the supply gas to the appropriate compression stage before compression begins. By pre-selecting the correct stage based on supply pressure, the system avoids the energy-wasting cycle of reducing pressure and then recompressing, thereby preserving the energy value of the incoming high-pressure gas
Solution Approach 2:
The system changes its operational parameters by activating different compression stages based on the supply gas pressure. Instead of forcing all supply gas through a fixed single-stage configuration, the system adjusts which stage is active to match the supply pressure, thereby maintaining energy efficiency across different operating conditions
3Productivity
If the compressor is designed for a specific location with a specific inlet pressure, then it can operate efficiently at that location, but the design becomes limited and cannot be used in other locations with different inlet pressures
Solution Approach 1:
The compressor is designed as a multi-functional system that can operate efficiently at multiple locations with different inlet pressures. By incorporating multiple compression stages with different maximum inlet pressure capabilities and implementing automatic routing logic, the single compressor design can adapt to various regional pressure conditions without requiring location-specific customization
Solution Approach 2:
The compressor dynamically adjusts its operational configuration based on the supply gas pressure conditions at any given location. The valve system automatically routes supply gas to the appropriate compression stage that can handle the local pressure conditions, enabling the same compressor design to maintain optimal efficiency across diverse geographic locations with varying inlet pressures
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
Enables efficient operation across a broader range of inlet pressures, reducing the need for external regulators and minimizing energy loss, while maintaining compressor loads within specified limits, effectively accommodating high supply pressures by dynamically routing gas to the appropriate compression stage.
Implementation Method 1
providing a supply gas having an inlet pressure at the gas inlet; and opening the valve corresponding to the compression cylinder that has a maximum inlet pressure greater than or equal to the inlet pressure of the supply gas to route the supply gas from the inlet to that compression cylinder
Implementation Method 2
a plurality of compression cylinders in fluid communication with each other, configured to compress a gas in at least two gas compression stages
Data Source
AI summary
Most multistage compressors specify a maximum inlet pressure that may be supplied to the compressor to stay within designed limits. If the supply gas to be compressed is at a higher pressure than the specified maximum inlet pressure, then its pressure must be reduced before connecting it to the compressor. This pressure reduction is inefficient. The present invention avoids reducing the inlet pressure by routing the supply gas directly to the appropriate compression stage depending on its inlet pressure such that the compressor loads are still within the specified limits of the equipment.