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US 12,540,631 B2Granted
Intensification system and method
AssigneeKraft Werks Group, LLC
InventorEdward A Dray
Life of this patent
Estimating the term…
Abstract
An intensifier system comprising at least two intensifiers configured in series, wherein each intensifier in the series is configured to generate a greater pressure in a process medium than the preceding intensifier. A process medium pilot-operated check valve is configured between each intensifier to operate normally as a check valve (e.g., closed) and to operate in a bypass mode when piloted (e.g., open), allowing for both full bypass and enhanced control over a smoother depressurization of the intensifier system without the need for assistance from external devices.
Claims20
An intensifier system, comprising:
- at least two intensifiers configured to fluidly couple in series, each intensifier configured to increase a pressure of a process medium and comprising:
- a control medium chamber configured to fluidly couple to a control medium inlet and a process medium chamber configured to fluidly couple to both a process medium intensifier inlet and a process medium intensifier outlet,
- wherein an orientation of the process medium intensifier inlet represents an upstream direction relative to the intensifier and
- wherein an orientation of the process medium intensifier outlet represents a downstream direction relative to the intensifier;
- a process medium inlet check valve configured to fluidly couple between a process medium system inlet and the process medium intensifier inlet of a first intensifier in the series;
- at least one process medium pilot-operated check valve, wherein each process medium pilot-operated check valve is configured to fluidly couple between the process medium intensifier outlet of each upstream intensifier and the process medium intensifier inlet of each downstream intensifier;
- a process medium pilot-operated two-way valve configured to fluidly couple between a process medium system outlet and the process medium intensifier outlet of a last intensifier in the series;
- and
- a control system, comprising:
- at least one control medium power unit configured to fluidly couple to at least one control medium proportional control valve,
- wherein each of the intensifiers is configured to fluidly couple to one of the control medium proportional control valves;
- at least one proportional integration regulator,
- wherein each of the proportional integration regulators is configured to electronically couple to one control medium proportional control valve;
- and
- at least one process medium pressure sensor configured to detect a process medium pressure at the process medium system outlet;
- and
- a programmable logic controller configured to execute a control system logic comprising a sequence of commands, comprising:
- during a pressurization phase, pressurizing each of the intensifiers in sequence from the first intensifier in the series to the last intensifier in the series,
- wherein each intensifier is pressurized until the process medium pressure reaches the lesser of a process medium test pressure and a process medium transition pressure,
- wherein the at least one process medium pilot-operated check valve that is configured to fluidly couple to a respective process medium intensifier inlet of a respective downstream intensifier being pressurized is operated in a closed position when the respective downstream intensifier is being pressurized;
- during a depressurization phase, depressurizing each of the intensifiers in sequence from the last intensifier in the series to the first intensifier in the series,
- wherein each intensifier is depressurized until the process medium pressure nears, but does not reach, the process medium transition pressure of a respective upstream intensifier in the series,
- wherein the at least one process medium pilot-operated check valve that is configured to fluidly couple to the respective process medium intensifier inlet of the respective downstream intensifier being depressurized is operated in a closed position during the depressurization phase of each intensifier and is operated in an open position after the respective downstream intensifier has been depressurized;
- and
- depressurizing all the intensifiers until the process medium pressure reaches zero.
22 more elements
A method for operating an intensifier system for a process medium, comprising:
- controlling a control medium of the intensifier system with a programmable logic controller,
- wherein the programmable logic controller is configured to control a pressurization phase and a depressurization phase;
- during the pressurization phase, pressurizing a first, upstream intensifier until a process medium pressure nears a process medium transition pressure,
- wherein the process medium transition pressure is the maximum process medium pressure generated by the first, upstream intensifier;
- and
- pressurizing a second downstream intensifier until the process medium pressure reaches a process medium test pressure,
- wherein process medium pilot-operated check valve is configured to fluidly couple in series between the first, upstream intensifier and the second, downstream intensifier,
- wherein the process medium pilot-operated check valve is operated by the programmable logic controller in a closed position during the pressurization of the downstream intensifier;
- during the depressurization phase, depressurizing the downstream intensifier;
- opening the process medium pilot-operated check valve with the programmable logic controller when the process medium pressure nears, but does not reach, the process medium transition pressure of the first upstream intensifier;
- and
- depressurizing both of the intensifiers until the process medium pressure reaches zero.
9 more elements
A method for testing a pressure vessel with an intensifier system, comprising:
- fluidly coupling the pressure vessel to the intensifier system,
- wherein the intensifier system comprises at least one upstream intensifier, at least one downstream intensifier, and a process medium pilot-operated check valve fluidly coupled between each intensifier,
- wherein the process medium pilot-operated check valve comprises a bypass cylinder, and
- wherein the bypass cylinder is configured to be controlled by a programmable logic controller and bypass the process medium pilot-operated check valve when the process medium pilot-operated check valve is in the open position;
- controlling operation of the intensifier system with the programmable logic controller,
- wherein the programmable logic controller is configured to control a fill method, an intensification method, and a replacement method;
- the fill method comprising:
- opening a process medium purge valve;
- opening a process medium fill valve;
- opening a process medium pilot-operated two-way valve;
- and
- filling the pressure vessel to a desired level with a process medium;
- the intensification method comprising:
- a pressurization phase, a maintenance phase, and a depressurization phase,
- wherein the depressurization phase comprises:
- depressurizing the at least one downstream intensifier;
- opening the process medium pilot-operated check valve when the pressure of the at least one downstream intensifier nears, but does not reach, a process medium transition pressure of the at least one upstream intensifier;
- and
- depressurizing both the at least one downstream intensifier and the at least one upstream intensifier together until a process medium pressure reaches zero;
- and
- the replacement method comprising:
- fluidly decoupling the pressure vessel from the intensifier system, and either:
- replacing the pressure vessel with an additional pressure vessel and repeating the method for testing on the additional pressure vessel, or
- completing the method for testing and draining the process medium from the intensifier system.
21 more elements
Dependencies are inferred from the claim text.