Flexible Pre-Cambered Frame for Mobile Gas Compressor Wear Reduction
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Solution Overview
Problem
Mobile natural gas compressors with high horsepower ratings face reliability issues and high maintenance costs due to excessive wear and tear, particularly in remote locations, limiting their effectiveness and profitability in oil and gas production.
Innovation Solution
A mobile unitary high horsepower rated natural gas compression package featuring a pre-cambered trailer frame that flexes during transport and operation, an inflexible sub-skid for the compressor, ancillary components with break flanges for flexibility, a horizontal gas scrubber, adjustable cooler support, pullout arrangement for maintenance access, and a disk style muffler for sound deadening, all designed to reduce wear and enhance reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If mobile compressors with high horsepower ratings are used, then compression power is improved, but reliability deteriorates due to excessive wear and tear
Solution Approach 1:
The compressor system is divided into modular components (compressor unit, engine, ancillary equipment) that can be independently supported and maintained. The flexible frame segments the structural support system, allowing different parts to move independently and reduce stress transmission between components.
Solution Approach 2:
The flexible pre-cambered frame is designed to absorb and dissipate vibration energy before it can cause damage to the compressor components. The pre-cambered configuration creates built-in stress relief mechanisms that protect the compressor from excessive wear during operation and transport.
2Adaptability or versatility
If mobile compressors are used in remote locations, then operational flexibility is improved, but maintenance complexity increases
Solution Approach 1:
The modular design allows the compressor system to be broken down into discrete, easily replaceable units. Ancillary equipment is separately mounted and can be serviced independently, reducing maintenance complexity in remote locations where comprehensive repair facilities are unavailable.
Solution Approach 2:
The flexible frame with break flanges allows the structure to adapt to different operational conditions and transport configurations. This dynamic design simplifies maintenance by allowing quick reconfiguration and access to different components without requiring complex disassembly procedures.
3Reliability
If the frame is made flexible to reduce wear, then reliability is improved, but structural strength deteriorates
Solution Approach 1:
The frame system employs different structural properties in different locations: the pre-cambered flexible portions provide vibration absorption, while the sub-skid and break flange regions provide rigid support and controlled articulation points. This localized differentiation of structural qualities maintains overall strength while providing flexibility where needed.
Solution Approach 2:
The frame system combines different structural elements (flexible pre-cambered sections, rigid sub-skid, articulated break flanges) to create a composite structure that exhibits both flexibility and strength. Each component is optimized for its specific function, and their combination provides the desired balance of properties.
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
The solution significantly reduces downtime and operating costs by improving the reliability and longevity of mobile compressors, addressing the challenges of wear and tear and maintenance complexities in remote locations.
Implementation Method 1
a pre-cambered frame configured to flex during transport and in response to vibration during operation
Implementation Method 2
a horizontal gas scrubber affixed to the sub-skid
Implementation Method 3
a cooler and an adjustable cooler support
Data Source
Figure 1~6
Figure 3
Figure 4~5
AI summary
A mobile high horsepower rating natural gas compression package is presented. The apparatus includes a trailer having a flexible pre-cambered frame (100) configured to absorb shock during transport and dissipate vibration during operation, and an inflexible sub-skid (130) attached to the flexible frame (100) A high horsepower rating engine (132) driven compressor (134) is attached to the sub-skid (130) while ancillary compression package components (142, 144) are attached to the flexible frame (100) An arrangement of break flanges (140) is employed to permit relative motion between the compressor (134) and the ancillary compression package components (142, 144) during transport and operation.