Hydraulic Gas Compressor Buffer Chamber and Adaptive Control
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Solution Overview
Problem
Hydraulic gas compressors in oil and gas field applications face issues with contamination of hydraulic fluid, inefficient operation, and increased costs due to the presence of natural gas components, which affect the functioning and efficiency of the compressors.
Innovation Solution
An adaptive control system for hydraulic gas compressors that monitors piston speed, temperature, and load pressure to adjust the reversal timing of the driving force, using proximity sensors and a controller to optimize the operation and prevent contamination by maintaining a buffer chamber to inhibit non-driving fluid components from entering the hydraulic fluid chamber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a hydraulic gas compressor is used to compress natural gas, then gas compression efficiency is improved, but contamination of hydraulic fluid by natural gas components occurs
Solution Approach 1:
The compressor is divided into separate functional zones: a gas compression chamber and a hydraulic fluid chamber, physically separated by a piston and cylinder wall. This segmentation prevents direct contact between natural gas components and hydraulic fluid, eliminating contamination while maintaining compression efficiency.
Solution Approach 2:
The piston acts as an intermediary element between the natural gas and hydraulic fluid. It transmits mechanical force from the hydraulic side to compress gas on the other side without allowing the two fluids to mix, thus preventing contamination while enabling efficient gas compression.
2Productivity
If natural gas is removed from the well shaft to reduce back pressure, then oil flow to the well pump is improved, but additional equipment and operational costs increase
Solution Approach 1:
The hydraulic gas compressor serves multiple functions: it compresses natural gas to remove it from the well shaft (reducing back pressure), simultaneously generates useful compressed gas for site utilization or transportation, and operates using hydraulic fluid already present in the system. This multi-functionality reduces the need for separate gas removal equipment.
Solution Approach 2:
The system uses the hydraulic fluid required for pump operation to also drive the gas compressor. The hydraulic motor utilizes the hydraulic fluid flow to generate mechanical power for gas compression, making the gas removal process self-sufficient without requiring additional external power sources or complex equipment.
3Productivity
If the driving force reversal timing is fixed, then the control system is simple, but compression efficiency is reduced due to varying operating conditions
Solution Approach 1:
The control system continuously monitors operating parameters such as gas pressure, temperature, and flow rate, and uses this feedback to dynamically adjust the driving force reversal timing. This ensures optimal compression efficiency across varying operating conditions while maintaining a relatively simple control architecture.
Solution Approach 2:
The reversal timing of the driving force is made dynamic rather than fixed. The system adapts the timing based on real-time operating conditions, allowing the compressor to maintain high efficiency whether operating at high or low gas flow rates, pressures, or temperatures.
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 adaptive control system enhances the efficiency of gas compression, reduces wear, and extends equipment life by ensuring smooth transitions and maximum compression efficiency, while minimizing contamination and operational costs.
Implementation Method 1
a driving force is applied to a piston in a gas compressor by a hydraulic fluid
Implementation Method 2
maintain a buffer chamber to inhibit non-driving fluid components from entering the hydraulic fluid chamber
Data Source
AI summary
Systems are provided comprising at least one driving cylinder comprising a driving chamber and a driving piston within the driving chamber. The driving piston separates the driving chamber into a driving fluid zone for receiving a driving fluid and a buffer zone for receiving a buffer fluid. The driving piston is movable in the driving chamber by the driving fluid. The systems may also comprise a driven cylinder comprising a driven chamber and a driven piston moveable in the driven chamber. The driven piston is connected to and driven by the driving piston to move within the driven chamber. The driven chamber comprises an input port configured to receive a driven fluid at a first, lower pressure into the driven chamber and an output port configured to expel the driven fluid at a second, higher pressure from the driven chamber when the driven fluid is pressurized by the driven piston. The buffer fluid is different from the driving fluid and the driven fluid, and the buffer fluid in the buffer zone separates the driving fluid from the driven fluid.