Displacement intensifier, system, and method

An intensifier system comprising:

• an intensifier comprising:
• an intensifier cylinder comprising:
• a control medium chamber configured to contain a pressurized control medium and to fluidly couple to at least one control medium inlet, and
• an intensifier piston configured to mechanically couple to an intensifier rod which extends from a first face of the intensifier piston;
• a system manifold comprising:
• a process medium chamber configured to contain a pressurized process medium and to fluidly couple to at least one process medium intensifier inlet, and
• at least one process medium inlet check valve configured to fluidly couple to the respective process medium intensifier inlet;
• and
• a coupler configured to:
• mechanically couple the system manifold to a pressure vessel, and
• fluidly couple the process medium chamber to the pressure vessel;
• wherein the intensifier rod is configured to extend axially from the intensifier cylinder, through the system manifold, and into the process medium chamber, and
• wherein the pressure of the process medium within the process medium chamber changes in proportion to the length of the intensifier rod extending into the process medium chamber;
• and
• a control system configured to operate the intensifier, the control system comprising:
• at least one control medium power unit;
• at least one control medium proportional control valve configured to fluidly couple between the respective control medium power unit and the respective control medium inlet;
• at least one proportional integration regulator configured to electronically couple to the respective control medium proportional control valve;
• at least one process medium pressure sensor configured to measure the process medium pressure;
• at least one control medium drain valve configured to fluidly couple to the respective control medium inlet, and
• a programmable logic controller configured to execute a control system logic comprising a sequence of commands and to electrically couple to at least one of:
• the at least one control medium power unit,
• the at least one control medium proportional control valve,
• the at least one proportional integration regulator,
• the at least one process medium pressure sensor, and
• the at least one control medium drain valve.

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 intensifier system comprises a primary intensifier configured to fluidly couple in series to a secondary intensifier, and
• wherein the primary intensifier is configured to increase a pressure of the process medium within a pressure vessel by partially displacing the process medium contained within the pressure vessel;
• wherein the programmable logic controller is configured to control a pressurization phase and a depressurization phase;
• during the pressurization phase, pressurizing the primary intensifier until the process medium pressure nears a process medium transition pressure,
• wherein the process medium transition pressure is the maximum process medium pressure generated by the primary intensifier;
• and
• pressurizing the secondary intensifier until the process medium pressure reaches a process medium test pressure,
• wherein a process medium pilot-operated check valve is configured to fluidly couple between the primary intensifier and the secondary intensifier,
• wherein the process medium pilot-operated check valve is operated by the programmable logic controller in a closed position;
• during the depressurization phase, opening the process medium pilot-operated check valve with the programmable logic controller;
• and
• depressurizing the primary intensifier and the secondary intensifier until the process medium pressure nears or reaches zero.

The method ofclaim 13, wherein the process medium pilot-operated check valve comprises a bypass cylinder, and

• wherein the bypass cylinder is configured to be controlled by the 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;
• wherein at least one intensifier comprises at least one of a rod, a plunger, and a piston;
• and
• wherein at least one of the rod, the plunger, and the piston are configured to transmit a pressure between the control medium and the process medium;
• and
• the method further comprising in the depressurization phase:
• controlling a return of at least one of the respective rod, the respective plunger, and the respective piston to a zero-displacement starting position with the respective control medium proportional control valve.