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US 12,385,480 B2Granted
Active oil injection system for a diaphragm compressor
AssigneePDC Machines Inc.
InventorsGuy Babbitt, Chris Turner, Bryce Whitehill, Michael Sprengel, Kareem Afzal
Life of this patent
Estimating the term…
Abstract
Devices and methods for operating a diaphragm compressor. Embodiments of the present disclosure comprise an oil piston being driven to pressurize work oil against the diaphragm of the compressor. In embodiments, an injection pump provides a supplemental flow of work oil in the region of pressurized fluid, and such pump may be part of an actively controlled system. In embodiments, a pressure relief valve vents an overpump flow of work oil, and such valve may be variable. Embodiments provide feedback and control mechanisms, including control of the injection pump and the relief valve.
Claims24
An active oil injection system in a diaphragm compressor, comprising:
- a diaphragm compressor comprising:
- a compressor head comprising:
- a work oil head support plate and a process gas head support plate defining a diaphragm cavity therebetween, the work oil head support plate comprising a piston cavity, an inlet, and an outlet, and
- a metallic diaphragm mounted between the work oil head support plate and the process gas head support plate, the metallic diaphragm dividing the diaphragm cavity into a work oil region and a process gas region, the work oil region being in separate communication with each of the piston cavity, the inlet, and the outlet, wherein the metallic diaphragm is configured to actuate from a first position proximate the work oil head support plate to a second position proximate the process gas head support plate to pressurize process gas in the process gas region to a process gas discharge pressure,
- a drive configured to intensify and supply primary work oil to the compressor head, the drive comprising:
- a drive cavity extending from the compressor head and in communication with the work oil region via the piston cavity,
- a piston mounted in the drive cavity and defining the volume of the work oil region, and
- an actuator configured to power the piston,
- wherein, during a discharge cycle, the drive is configured to power the piston to move toward the compressor head to intensify primary work oil in the work oil region from a first pressure to an intensified pressure and thereby actuate the metallic diaphragm to the second position;
- a hydraulic circuit connecting the outlet of the work oil head support plate to the inlet of the work oil head support plate, the hydraulic circuit comprising:
- an oil reservoir configured to collect overpumped work oil from the work oil region via the outlet of the work oil head support plate,
- a hydraulic accumulator configured to provide a supply of supplemental work oil to the inlet of the work oil head support plate,
- an injector pump in communication with the hydraulic accumulator, the injector pump configured to produce a variable volumetric displacement of the supplemental work oil from the oil reservoir to the hydraulic accumulator, the injector pump comprising:
- a pump operatively coupled to the hydraulic accumulator, and
- a pressure relief mechanism operatively coupled to the work oil region of the diaphragm cavity, the pressure relief mechanism comprising:
- a pressure relief valve in communication with the outlet of the work oil head support plate and configured to relieve the pressurized work oil from the work oil region, the pressure relief valve comprising a hydraulic relief setting corresponding to a target pressure condition of the pressurized work oil relative to the process gas discharge pressure, and
- a control valve configured to actively adjust the hydraulic relief setting of the pressure relief valve based on a current condition of the process gas;
- and
- a feedback mechanism configured to control the injector pump, the feedback mechanism comprising:
- a first measurement device operatively coupled to one or more of the outlet and the pressure relief valve, the first measurement device configured to detect a current condition of the pressurized work oil flowing through the pressure relief valve from the work oil region, the first measurement device of the feedback mechanism comprising one or more of a flow meter downstream of the outlet, a position sensor in the pressure relief valve, and a pressure transducer located downstream of the pressure relief valve, and
- wherein the feedback mechanism is configured to adjust the volumetric displacement of the injector pump to the hydraulic accumulator in response to the detected current condition.
18 more elements
An active oil injection system in a diaphragm compressor, comprising:
- a diaphragm compressor comprising:
- a first compressor head comprising:
- an inlet, an outlet, a first head cavity, and
- a first diaphragm dividing the first head cavity into a first work oil region and a process gas region, the first diaphragm configured to actuate to pressurize process gas in the process gas region,
- a second compressor head comprising:
- an inlet, an outlet, a second head cavity, and
- a second diaphragm dividing the second head cavity into a second work oil region and a process gas region, the second diaphragm configured to actuate to pressurize process gas in the process gas region,
- a drive configured to intensify work oil and alternatingly provide intensified work oil to the first and second compressor heads, the drive comprising:
- a first diaphragm piston configured to intensify work oil against the first diaphragm,
- a second diaphragm piston configured to intensify work oil against the second diaphragm, and
- an actuator configured to power the first and second diaphragm pistons,
- wherein the first diaphragm piston and the second diaphragm piston are configured to alternatingly intensify the work oil in the respective first or second work oil region to an intensified pressure and thereby actuate the respective first or second diaphragm;
- a hydraulic circuit connecting the outlet of the first compressor head to the inlet of the first compressor head and connecting the outlet of the second compressor head to the inlet of the second compressor head, the hydraulic circuit comprising:
- an oil reservoir configured to collect overpumped work oil via the outlets of the first and second compressor heads,
- a hydraulic accumulator configured to provide a supplemental supply of work oil to the inlets of the first and second compressor heads,
- an injector pump in communication with the hydraulic accumulator, the injector pump configured to produce a variable volumetric displacement of supplemental work oil from the oil reservoir to the hydraulic accumulator, the injector pump comprising:
- a pump operatively coupled to the hydraulic accumulator,
- a pressure relief mechanism comprising:
- a first pressure relief valve in communication with the outlet of the first compressor head and configured to relieve an overpump of the pressurized work oil from the work oil region, the first pressure relief valve comprising a hydraulic relief setting corresponding to a first target pressure condition of the pressurized work oil relative to the process gas discharge pressure,
- a first control valve configured to actively adjust the hydraulic relief setting of the first pressure relief valve based on the current condition of the discharged process gas,
- a second pressure relief valve in communication with the outlet of the second compressor head and configured to relieve an overpump of the pressurized work oil from the work oil region, the second pressure relief valve comprising a hydraulic relief setting corresponding to a second target pressure condition of the pressurized work oil relative to the process gas discharge pressure,
- a second control valve configured to actively adjust the hydraulic relief setting of the second pressure relief valve based on the current condition of the discharged process gas;
- and
- a feedback mechanism configured to control the injector pump, the feedback mechanism comprising:
- one or more measurement devices configured to measure the current condition of the pressurized work oil flowing through one or more of the first and second pressure relief valves from the one or more first work oil region and the second work oil region, the one or more measurement devices of the feedback mechanism comprising one or more of a flow meter downstream of the outlet of one or more of the first compressor head and the second compressor head, a position sensor in the pressure relief valve, and a pressure transducer located downstream of the pressure relief valve, and
- wherein the feedback mechanism is configured to adjust the volumetric displacement of the injector pump in response to the current condition of the pressurized work oil flowing through the pressure relief valve from the first work oil region and the second work oil region.
23 more elements
An active oil injection system in a hydraulically powered diaphragm compressor, comprising:
- a hydraulically powered diaphragm compressor comprising:
- a first compressor head comprising:
- an inlet, an outlet, a first head cavity, and
- a first diaphragm dividing the first head cavity into a first work oil region and a process gas region, the first diaphragm configured to actuate to pressurize process gas in the process gas region,
- a second compressor head comprising:
- an inlet, an outlet, a second head cavity, and
- a second diaphragm dividing the second head cavity into a second work oil region and a process gas region, the second diaphragm configured to actuate to pressurize process gas in the process gas region,
- a hydraulic drive configured to intensify work oil and alternatingly provide intensified work oil to the first and second compressor heads, the hydraulic drive comprising:
- a first diaphragm piston configured to intensify work oil against the first diaphragm,
- a second diaphragm piston configured to intensify work oil against the second diaphragm, and
- a hydraulic actuator configured to power the first and second diaphragm pistons,
- wherein the first diaphragm piston and the second diaphragm piston are configured to alternatingly intensify the work oil in the respective first or second work oil region to an intensified pressure and thereby actuate the respective first or second diaphragm;
- a hydraulic circuit connecting the outlet of the first compressor head to the inlet of the first compressor head and connecting the outlet of the second compressor head to the inlet of the second compressor head, the hydraulic circuit comprising:
- an oil reservoir configured to collect overpumped work oil via the outlets of the first and second compressor heads,
- a hydraulic accumulator configured to provide a supplemental supply of work oil to the inlets of the first and second compressor heads,
- an injector pump in communication with the hydraulic accumulator, the injector pump configured to produce a variable volumetric displacement of supplemental work oil from the oil reservoir to the hydraulic accumulator, the injector pump comprising:
- a pump operatively coupled to the hydraulic accumulator,
- a pressure relief mechanism comprising:
- a first pressure relief valve in communication with the outlet of the first compressor head and configured to relieve the pressurized work oil from the work oil region, the first pressure relief valve comprising a hydraulic relief setting corresponding to a first target pressure condition of the pressurized work oil relative to the process gas discharge pressure, and
- a second pressure relief valve in communication with the outlet of the second compressor head and configured to relieve the pressurized work oil from the work oil region, the pressure relief valve comprising a hydraulic relief setting corresponding to a second target pressure condition of the pressurized work oil relative to the process gas discharge pressure;
- and
- a feedback mechanism configured to control the injector pump, the feedback mechanism comprising:
- one or more measurement devices configured to sense or measure a current condition of the intensified work oil flowing out one or more of the first compressor head and the second compressor head, the one or more measurement devices of the feedback mechanism comprising one or more of a flow meter downstream of the outlet of one or more of the first compressor head and the second compressor head, a position sensor in the pressure relief valve, and a pressure transducer located downstream of the pressure relief valve, and
- wherein the feedback mechanism is configured to adjust the volumetric displacement of the injector pump in response to the current condition.
21 more elements
An active oil injection system in a diaphragm compressor, comprising:
- a diaphragm compressor comprising:
- a compressor head comprising:
- a work oil head support plate and a process gas head support plate defining a diaphragm cavity therebetween, the work oil head support plate comprising a piston cavity, an inlet, and an outlet, and
- a metallic diaphragm mounted between the work oil head support plate and the process gas head support plate, the metallic diaphragm dividing the diaphragm cavity into a work oil region and a process gas region, the work oil region being in separate communication with each of the piston cavity, the inlet, and the outlet, wherein the metallic diaphragm is configured to actuate from a first position proximate the work oil head support plate to a second position proximate the process gas head support plate to pressurize process gas in the process gas region to a process gas discharge pressure,
- a drive configured to intensify and supply primary work oil to the compressor head, the drive comprising:
- a drive cavity extending from the compressor head and in communication with the work oil region via the piston cavity,
- a piston mounted in the drive cavity and defining the volume of the work oil region, and
- an actuator configured to power the piston,
- wherein, during a discharge cycle, the drive is configured to power the piston to move toward the compressor head to intensify primary work oil in the work oil region from a first pressure to an intensified pressure and thereby actuate the metallic diaphragm to the second position;
- a hydraulic circuit connecting the outlet of the work oil head support plate to the inlet of the work oil head support plate, the hydraulic circuit comprising:
- an oil reservoir configured to collect overpumped work oil from the work oil region via the outlet of the work oil head support plate,
- an injector pump in communication with the oil reservoir, the injector pump configured to produce supplemental work oil from the oil reservoir to the inlet of the work oil head support plate;
- and
- a pressure relief mechanism operatively coupled to the work oil region of the diaphragm cavity, the pressure relief mechanism comprising:
- a pressure relief valve in communication with the outlet of the work oil head support plate and configured to relieve the pressurized work oil from the work oil region, the pressure relief valve comprising a hydraulic relief setting corresponding to a target pressure condition of the pressurized work oil relative to the process gas discharge pressure, and
- a control valve configured to actively adjust the hydraulic relief setting of the pressure relief valve based on a current condition of the process gas;
- and
- a feedback mechanism configured to control the injector pump, the feedback mechanism comprising:
- a first measurement device operatively coupled to one or more of the outlet and the pressure relief valve, the first measurement device configured to detect a current condition of the pressurized work oil flowing through the pressure relief valve from the work oil region, the first measurement device of the feedback mechanism comprising one or more of a flow meter downstream of the outlet, a position sensor in the pressure relief valve, and a pressure transducer located downstream of the pressure relief valve.
16 more elements
Dependencies are inferred from the claim text.