Note: Descriptions are shown in the official language in which they were submitted.
0008088-17/87389636
COMPRESSER FOR PUMPING FLUID HAVING CHECK VALVES ALIGNED WITH
FLUID PORTS
FIELD
[0001] The present disclosure relates generally to fluid compression or
pumping
devices and systems, and specifically to fluid compressors having fluid ports
and
check valves connected to the ports.
BACKGROUND
[0002] Fluid compressors are useful for pumping fluids. A fluid compressor
typically has a fluid chamber and a pair of fluid ports serving as an inlet or
outlet of
the fluid chamber. Check valves may be connected to the fluid ports for
controlling
fluid flow through the inlet or outlet ports.
[0003] For example, United States patent publication no. US20210270257,
published on September 02, 2021, disclosed fluid compressors for pumping
multiphase fluids. A representative view of a compressor 100 disclosed therein
is
shown in FIG.1. Compressor 100 includes a compression cylinder 102 having
opposite ends 112a, 112b. The compression cylinder 100 has a double-acting
compression piston for compressing a fluid towards one or the other of the two
ends
112a, 112b. The compression piston is driven by two hydraulic cylinders each
coupled to the compression cylinder at one of the ends 112a, 112b through a
central
port. Each end 112a, 112b also has two fluid ports 104a, 104b spaced from the
central port, one of which is an inlet port and the other of which is an
outlet port. The
fluid to be pumped can flow in and out of compression cylinder 102 through
ports
104a and ports 104b. Each port 104a,104b is connected to a check valve 108a,
108b by an elbow connector 106a, 106b. The elbow connectors 106a,106b are used
and have sufficient size so that the check valves 108a, 108b are offset from
the
hydraulic cylinders at each end 112a, 112b of the compression cylinder 100.
The
1
Date Recue/Date Received 2021-09-23
0008088-17/87389636
check valves 108a,108b are connected by flanges and pipes to the fluid input
source
and the output destination. The check valves 108a, 108b are configured and
oriented
to control the fluid flow at the ports 104a, 104b.
[0004] It is desirable to improve the efficiency or performance of such
fluid
compressors.
SUMMARY
[0005] In an embodiment, the present disclosure relates to a compressor
that
comprises a first cylinder for compressing a fluid. The first cylinder
comprises a
chamber configured to receive a fluid and having a first end and a second end,
a
piston reciprocally movable in the chamber for alternately compressing the
fluid
towards the first or second end, three or more first ports at the first end of
the
chamber, the first ports comprising at least one first inlet port and at least
one first
outlet port, and three or more second ports at the second end of the chamber,
the
second ports comprising at least one second inlet port and at least one second
outlet
port. Each one of the first and second ports defines a fluid flow path
extending along
an axial direction of the port. The compressor also comprises at least one
second
cylinder each connected and configured to drive movement of the piston in the
first
cylinder through one of the first and second ends and a plurality of check
valves,
each associated with one of the first and second ports and connected inline
with the
associated port along the axial direction of the associated port. The piston
is
reciprocally movable in the chamber along an axial direction of the chamber,
and the
axial directions of the first and second ports are parallel to the axial
direction of the
chamber.
[0006] In some embodiments the check valves connected to the inlet ports
are
oriented to allow the fluid to flow into the compression chamber through the
inlet ports
and the check valves connected to the outlet ports are oriented to allow fluid
to flow
out of the compression chamber through the outlet ports.
2
Date Recue/Date Received 2021-09-23
0008088-17/87389636
[0007] In some embodiments, the first ports comprise at least two inlet
ports,
and the second ports comprise at least two inlet ports. In some embodiments,
the first
ports comprise at least two outlet ports, and the second ports comprise at
least two
outlet ports.
[0008] In at least some of the embodiments presented herein, the
compressor
further comprises a plurality of first conduits each connecting one of the
check valves
to its associated port. In some embodiments, each one of the first conduits
defines a
straight fluid path between the check valve and the port connected by the
respective
first conduit.
[0009] In some embodiments, the check valves connected to the inlet
ports are
first check valves and the check valves connected to the outlet ports are
second
check valves and the compressor further comprises a second conduit connected
to
the first check valves for connecting a fluid source to the inlet ports to
supply the fluid
from the fluid source to the compression chamber though the inlet ports, and a
third
conduit connected to the second check valves for receiving compressed fluid
from
the compression chamber through the outlet ports.
[0010] In some embodiments, each of the second and third conduits
comprises
a first end comprising a first flange, a plurality of second ends each
comprising a
second flange for connecting the respective second end to one of the check
valves
and at least one third end comprising a third flange and a removable blanking
plate
coupled to the third flange.
[0011] In some embodiments, the first ports comprise two first inlet
ports and
two first outlet ports, and the second ports comprise two second inlet ports
and two
second outlet ports.
[0012] In some embodiments, the at least one first inlet port is
positioned
above the at least one first outlet port, and the at least one second inlet
port is
positioned above the at least one second outlet port.
[0013] In some embodiments, the check valves are in-line check valves.
3
Date Recue/Date Received 2021-09-23
[0013a] In some embodiments, at least one of the plurality of check
valves is
mounted in its associated port.
[0013b] In some embodiments, each one of the first and second ends of the
chamber comprises a head plate, and each one of the check valves is secured to
a
respective one of the head plates in the respective associated port. In some
embodiments, each check valve is partially inserted into the respective
associated
port.
[0014] In another embodiment, the present disclosure relates to a
compressor
that comprises a first cylinder for compressing a fluid. The first cylinder
comprises a
chamber configured to receive a fluid and having a first end and a second end,
a
piston reciprocally movable in the chamber along an axial direction of the
chamber for
alternately compressing the fluid towards the first or second end, a plurality
of first
inlet ports and a plurality of first outlet ports at the first end of the
chamber and a
plurality of second inlet ports and a plurality of second outlet ports at the
second end
of the chamber. Each one of the inlet and outlet ports defines a fluid flow
path
extending along an axial direction of the port, the axial directions of the
inlet and
outlet ports being perpendicular to the axial direction of the chamber. The
compressor also comprises at least one second cylinder each connected and
configured to drive movement of the piston in the first cylinder through one
of the first
and second ends and a plurality of check valves, each associated with one of
the
inlet and outlet ports and connected inline with the associated port along the
axial
direction of the associated port.
[0015] In some embodiments, the first inlet ports are positioned above
the first
outlet ports at the first end of the chamber and the second inlet ports are
positioned
above the second outlet ports at the second end of the chamber.
[0016] In some embodiments, the plurality of check valves are in-line
check
valves.
[0017] In some embodiments, the compressor further comprises a plurality
of
first conduits each connecting one of the check valves to its associated port.
In some
4
Date recue / Date received 2021-11-26
0008088-17/87389636
embodiments, each one of the first conduits defines a straight fluid path
between the
check valve and the port connected by the respective first conduit.
[0017a] In some embodiments, the check valves connected to the inlet
ports are
first check valves and the check valves connected to the outlet ports are
second
check valves and the compressor further comprises a first conduit connected to
the
first check valves for connecting a fluid source to the inlet ports to supply
the fluid
from the fluid source to the compression chamber though the inlet ports, and a
second conduit connected to the second check valves for receiving compressed
fluid
from the compression chamber through the outlet ports.
[0017b] In some embodiments, each of the first and second conduits
comprises
a first end comprising a first flange, a plurality of second ends each
comprising a
second flange for connecting the respective second end to one of the check
valves
and at least one third end comprising a third flange and a removable blanking
plate
coupled to the third flange.
[0017c] In some embodiments, the first ports comprise two first inlet
ports and
two first outlet ports, and the second ports comprise two second inlet ports
and two
second outlet ports.
[0017d] In some embodiments, at least one of the plurality of check
valves is
mounted in its associated port.
[0017e] In some embodiments, each one of the first and second ends of the
chamber comprises a head plate, and each one of the check valves is secured to
a
respective one of the head plates in the respective associated port. In some
embodiments, each check valve is partially inserted into the respective
associated
port.
[0018] In another embodiment, the present disclosure relates to a system
for
compressing a fluid, comprising first and second compressors each as defined
herein. The first and second compressors are connected such that the
compressed
4a
Date recue / Date received 2021-11-26
0008088-17/87389636
fluid from the outlet ports of the first compressor is fed into the inlet
ports of the
second compressor for further compression.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] In the figures, which illustrate example embodiments:
[0020] FIG.1 is a front perspective view of a comparison compressor;
[0021] FIG. 2A is a schematic cross-sectional view of a simplified
compressor,
according to an example embodiment;
[0022] FIG. 2B is a schematic view of the compressor of FIG. 2A in
operation at a
first state;
[0023] FIG. 2C is a schematic view of the compressor of FIG. 2A in
operation at a
second state;
[0024] FIG. 2D is a schematic view of the compressor of FIG. 2A in
operation at a
third state;
[0025] FIG. 2E is a schematic view of the compressor of FIG. 2A in
operation at a
fourth state;
[0026] FIG. 3A is a line graph illustrating schematically the changes in
the fluid
volume and pressure between an end of the compression chamber and the piston
during a piston stroke in the compressor of FIG. 2A;
[0027] FIG. 3B is a line graph illustrating schematically the changes in
the fluid
volume and pressure between another end of the compression chamber and the
piston during a piston stroke in the compressor of FIG. 2A;
[0028] FIG. 4 is a schematic cross-sectional view of a simplified
compressor,
according to another example embodiment;
Date Recue/Date Received 2021-09-23
0008088-17/87389636
[0029] FIG. 5A is a cross-sectional rear perspective view of a compressor
according to a further example embodiment;
[0030] FIGS. 5B and 5C are partially transparent, front perspective views
of the
compressor of FIG. 5A;
[0031] FIG. 5D is a partially transparent, rear perspective view of the
compressor
of FIG.5A;
[0032] FIGS. 5E and 5F are front perspective and top plan views of the
compressor of FIG. 5A;
[0033] FIG. 5G is a partially transparent front view of the compressor of
FIG. 5A;
[0034] FIG. 5H is a cross sectional end view of the compressor of FIG. 5A,
along
the line A-A in FIG. 5G;
[0035] FIG. 51 is an end view of the compressor of FIG. 5A;
[0036] FIG. 5J is a cross-sectional rear perspective view of the compressor
of
FIG. 5A, with some check valves in an open configuration;
[0037] FIG. 5K is a cross-sectional rear perspective view of the compressor
of
FIG. 5A, with some check valves in an open configuration;
[0038] FIG. 6A is a partially transparent, cross-sectional rear perspective
view of a
compressor according to a further embodiment;
[0039] FIGS. 6B and 6C are front perspective views of the compressor of
FIG. 6A;
[0040] FIGS. 6D and 6E are top plan and front views of the compressor of
FIG.
6A;
[0041] FIG. 6F is a cross sectional end view of the compressor of FIG.6A,
along
the line A-A in FIG. 6E;
6
Date Recue/Date Received 2021-09-23
0008088-17/87389636
[0042] FIG. 6G is an end view of the compressor of FIG. 6A;
[0043] FIG. 7A is a partially transparent, cross-sectional top perspective
view of a
compressor according to a further embodiment;
[0044] FIGS. 7B and 7C are front perspective views of the compressor of
FIG. 7A;
[0045] FIGS. 7D and 7E are top plan and front views of the compressor of
FIG.
7A;
[0046] FIG. 7F is a cross sectional end view of the compressor of FIG. 7A,
along
the line B-B in FIG. 7E;
[0047] FIG. 7G is an end view of the compressor of FIG. 7A; and
[0048] FIG. 8 is a schematic view of an oil and gas producing well system.
DETAILED DESCRIPTION
[0049] It has been recognized that when the compression piston within the
compression chamber of the compressor 100 as shown in FIG.1 reaches an end of
stroke position, a relatively large dead volume (or minimal chamber volume)
still
undesirably remains within the space between the piston face and the check
valves
108a or 108b, particularly in the ports 104a or 104b and the elbow connectors
106a
or 106b. This large dead volume leads to decreased pumping efficiency and
performance. This problem would be exaggerated when the sizes of the elbow
connectors 106a, 106b and the check valves 108a, 108b are increased to provide
increased throughput or to pump certain liquids such as liquids produced from
a well
in oil and gas applications. It is thus desirable to provide a fluid
compressor with
reduced dead volume to increase the compression ratio of the compressor
without
reducing or limiting the pumping throughput.
[0050] The present inventor has discovered a number of solutions to address
the
above problem. First, connecting a check valve to an inlet/outlet port without
an
7
Date Recue/Date Received 2021-09-23
0008088-17/87389636
elbow connector therebetween can provide a straight, shortened fluid flow path
between the port and the check valve, thus reducing the dead volume. The
straight
flow path will also improve the flow characteristics in the flow path, thereby
increasing
pumping efficiency.
[0051] As can be appreciated, when the elbow connector between the check valve
and the port is eliminated or replaced with a straight connector, the check
valve can
be positioned closer to the port, reducing the path volume between the end of
the
piston and the check valve. This will beneficially reduce the dead volume
(i.e., the
volume of compressed fluid retained within the compressor at the end of each
stroke)
of the compressor. With a smaller dead volume, the compressor will be able to
draw
in, compress and expel a larger volume of liquid on each stroke, and provide a
higher
compression ratio on each stroke.
[0052] Due to the limited room at each end of the compression cylinder in
the
presence of the hydraulic cylinder coupled to the compression cylinder, the
sizes of
the inlet and outlet ports and the check valves are constrained, which in turn
limits the
fluid throughput. However, the present inventor realized that three or more
fluid
communication ports may be provided at each end of the compressor to increase
the
fluid throughput. For example, at least two of the end ports may be inlet
ports, or at
least two of the end ports may be outlet ports. In some embodiments, two inlet
ports
and two outlet ports may be provided at each end of the compressor. The
multiple
inlet or outlet ports can be sized and arranged so they are offset from the
hydraulic
cylinder at the same end.
[0053] Accordingly, an example embodiment herein relates to a compressor for
receiving a fluid supply, compressing the fluid and then moving the fluid to
another
location. The fluid may be a gas, a liquid or a multiphase fluid that
comprises 100%
gas, 100% liquid, or any proportion of gas/liquid therebetween. The compressor
may
include a compression chamber configured to receive a fluid which is
compressed
towards a first end or a second end of the compression chamber by a piston
that is
8
Date Recue/Date Received 2021-09-23
0008088-17/87389636
reciprocally moveable along an axial direction. The first and second ends of
the
chamber may each include three or more ports for fluid communication. At least
one
first inlet port at the first end of the compression chamber and at least one
second
inlet port at the second end of the compression chamber are configured to
allow fluid
to enter the compression chamber. The compressor may also include at least one
first outlet port at the first end of the compression chamber and at least one
second
outlet port at the second end of the compression chamber, both configured to
allow
fluid to exit the compression chamber. Movement of the piston may be driven by
at
least one second cylinder connected to the piston within the first cylinder.
The
compressor may also include a plurality of check valves, each connected to one
of
the inlet and outlet ports, inline with the respective port along the axial
direction. The
position and alignment of the check valves relative to their respective port
reduces
dead volume and provides a straight flow path for fluid in and out of the
compression
chamber.
[0054] In an embodiment the check valves are oriented to be aligned with
the
axial direction of movement of the piston within the compression chamber. In a
further embodiment, the check valves are perpendicular to the axial direction
of
movement of the piston within the compression chamber.
[0055] In an embodiment, the compressor may have two first inlet ports at
the first
end of the compression chamber and two second inlet ports at the second end of
the
compression chamber. The compressor may also include two first outlet ports at
the
first end of the compression chamber and two second outlet ports at the second
end
of the compression chamber. These ports may advantageously increase space at
each end of the compressor for additional components to be accommodated such
as
for example, different sizes of hydraulic cylinders to drive movement of the
piston.
[0056] In an embodiment, a first compressor may be configured to be
connected
to a second compressor. The first compressor may compress a fluid to a first
9
Date Recue/Date Received 2021-09-23
0008088-17/87389636
pressure P1 and the second compressor may further compress the fluid to a
second
higher pressure P2.
[0057] The compressors may be configured to be operable to transfer multiphase
mixtures of substances that comprise 100% gas, 100% liquid, or any proportion
of
gas/liquid therebetween, wherein during operation, the ratio of gas/liquid is
changing,
either intermittently, periodically, or substantially continuously. The
compressors can
also handle fluids that may also carry abrasive solid materials such as sand
without
damaging important components of the compressor system such as the surfaces of
various cylinders and pistons.
[0058] An example compressor 200 is schematically illustrated in FIG. 2A.
As
depicted, compressor 200 may include first cylinder 202 for compressing a
fluid. First
cylinder 202 may include tubular wall 226 with first and second end plates
228a, 228b
at either end. The inner surface of tubular wall 226 and the inner surfaces of
end
plates 228a, 228b define compression chamber 204, which has first end 205a and
second end 205b. Piston 206 may be reciprocally moveable within compression
chamber 204 in an axial direction towards first end 205a or second end 205b as
indicated by the arrows in FIG. 2A. Piston 206 divides compression chamber 204
into two adjacent first and second compression chamber sections 208a, 208b. At
first
end 205a of compression chamber 204 there may be two ports 210a, 212a
configured to allow fluid to flow into and out of compression chamber section
208a.
As shown in FIG. 2A, ports 210a, 212a may be cylindrical linear channels
extending
from the outer vertical side to the inner vertical side of plate 228a. At
second end
205b there may be two ports 210b, 212b configured to allow fluid to flow into
and out
of compression chamber section 208b. As shown in FIG. 2A, ports 210b, 212b may
be cylindrical linear channels extending from the outer vertical side to the
inner
vertical side of plate 228b. To each of ports 210a, 210b, 212a, 212b,
respective
check valves 216a, 216b, 218a, 218b may be connected. Check valves 216a, 216b,
218a, 218b, may be any suitable check valve, also known as a non-return valve,
reflux valve, foot valve or one way valve, and are configured to move between
an
Date Recue/Date Received 2021-09-23
0008088-17/87389636
open configuration and a closed configuration. When in a closed configuration
fluid
flow is not permitted in either direction through the check valve. When in an
open
configuration, the check valves allow fluid to flow through in one direction
only from
an inlet side to an outlet side of the check valve. The check valve may switch
from a
closed configuration to an open configuration when the pressure is greater on
the
inlet side of the port than the outlet side, creating a pressure differential
across the
check valve. Once the pressure differential reaches a pre-determined value,
known
as the threshold pressure (also known as the cracking pressure), the check
valves
are configured to open, permitting fluid flow from the inlet side to the
outlet side only.
The check valves may be operable to be adjustable such that the threshold
pressure
that causes the check valve to open may be set at a desired value. The check
valves
are configured to switch from the open configuration back to the closed
configuration,
preventing fluid flow therethrough once the pressure differential drops to a
lower
pressure, known as the reseal pressure.
[0059] Check valves 216a, 216b, 218a, 218b may be any suitable type as is
known in the art. For example, the check valves may be ball check valves,
diaphragm check valves, swing check valves, lift check valves, in-line check
valves or
reed valves. In a specific embodiment, check valves 216a, 216b, 218a, 218b may
be
a threaded in-line check valve such as a 3" SCV Check Valve made by DFT Inc.
[0060] Check valves 216a, 216b, 218a, 218b may be connected to their
respective ports 210a, 210b, 212a, 212b by any suitable method. For example,
check valves 216a, 216b, 218a, 218b may have threaded fittings at either end
configured to engage with corresponding threaded fittings at the outer end of
ports
210a, 210b, 212a, 212b. In other embodiments, check valves 216a, 216b, 218a,
218b may be configured to be partially inserted into their respective ports
210a, 210b,
212a, 212b and secured by a suitable method such as welding.
[0061] The orientation of check valves 216a, 216b, 218a, 218b relative to
ports
210a, 210b, 212a, 212b will determine if each port functions as an inlet port
or an
11
Date Recue/Date Received 2021-09-23
0008088-17/87389636
outlet port. As depicted in FIG. 2A, check valves 216a, 216b may be oriented
such
that ports 210a, 210b operate as inlet ports to supply fluid to compression
chamber
204. This is achieved by connecting the outlet side of check valve 216a to the
outer
end of port 210a such that, when check valve 216a is in an open configuration,
fluid
is only permitted to flow into chamber section 208a through port 210a. Fluid
is
prevented from flowing out of chamber section 208a through check valve 216a at
all
times by the orientation of check valve 216a.
[0062] Similarly, the outlet side of check valve 216b may be connected to
the
outer end of port 210b such that, when check valve 216b is in an open
configuration,
fluid is only permitted to flow into chamber section 208b through port 210b.
Fluid is
prevented from flowing out of chamber section 208b through check valve 216b at
all
times by the orientation of check valve 216b.
[0063] Check valves 218a, 218b may be oriented such that ports 212a, 212b
operate as outlet ports to remove fluid from compression chamber 204. The
inlet
side of check valve 218a may be connected to the outer end of port 212a such
that,
when check valve 218a is in an open configuration, fluid is only permitted to
flow from
chamber section 208a through port 212a. Fluid is prevented from flowing into
chamber section 208a through check valve 218a at all times by the orientation
of
check valve 218a.
[0064] Similarly, the inlet end of check valve 218b may be connected to the
outer
end of port 212b such that, when check valve 218b is in an open configuration,
fluid
is only permitted to flow from chamber section 208b through port 212b. Fluid
is
prevented from flowing into chamber section 208b through check valve 218b at
all
times.
[0065] A pair of inlet conduits 220a, 220b may be connected to respective
check
valves 216a, 216b to supply fluid from a fluid source and a pair of outlet
conduits
222a, 222b may be connected to respective check valves 218a, 218b, to receive
compressed fluid from check valves 218a, 218b. In the embodiment shown in FIG.
12
Date Recue/Date Received 2021-09-23
0008088-17/87389636
2A, check valves 216a, 216b, 218a, 218b may be positioned inline with their
respective ports 210a, 210b, 212a, 212b in the axial direction, which are in
turn
positioned inline with the axial direction of movement of piston 206.
[0066] With reference to FIGS. 2B to 2E, piston 206 may reciprocally move
between first end of stroke position 224a at first end 205a of compression
chamber
204 (shown in FIG. 2B) and second end of stroke position 224b at second end
205b
of compression chamber 204 (shown in FIG. 2D). FIGS. 3A and 3B depict the
change in volume of compression chamber sections 208a, 208b with the position
of
piston 206. With reference to FIG. 3A, when piston 206 is at position 224a,
the
volume of first compression chamber 208a is at a minimum volume (also referred
to
as the dead volume) and increases to a maximum volume once piston 206 reaches
second end of stroke position 224b. As piston 206 returns to first end of
stroke
position 224a, the volume of first compression chamber will decease back to
the
minimum volume.
[0067] Similarly, as shown in FIG. 3B, the volume of second compression
chamber 208b will increase from a minimum volume at the second end of stroke
position 224b to a maximum volume at the first end of stroke position 224a.
[0068] As check valves 216a, 216b, 218a, 218b are positioned inline with
their
respective ports 210a, 210b, 212a, 212b, they may be positioned closer to
their
respective port. This will beneficially reduce the path volume between check
valves
216a, 218a and piston 206 when piston 206 is first end of stroke position 224a
and
between check valves 216b, 218b and piston 206 when piston 206 is second end
of
stroke position 224b. As such, the dead volumes in the compressors shown in
FIGS
3A and 3B are less than that of the comparative compressor shown in FIG. 1.
[0069] As will be explained below, as piston 206 reciprocates within
compression
chamber 204, fluid may alternately enter, and exit each of the compression
chamber
sections 208a, 208b. Flow of fluid in and out of each compression chamber
section
208a, 208b is controlled by the state of each of the check valves attached to
the
13
Date Recue/Date Received 2021-09-23
0008088-17/87389636
ports. One complete cycle of compressor 200 is illustrated in FIGS. 28 to 2D,
with
direction of fluid flow at each stage indicated. Piston 206 may start at first
end of
stroke position 224a shown in FIG. 2B and move, via the intermediate position
shown
in FIG. 2C to second stroke position 224b shown in FIG. 2D. Piston 206 may
then
reverse direction from second end of stroke position 224b and return to first
end of
stroke position shown in FIG. 2B, via the intermediate position shown in FIG.
2E.
The change in volume and representative examples for the variation in pressure
of
first and second compression chambers 208a, 208b are shown in FIGS. 3A and 3B
respectively.
[0070] Turning first to FIG. 2B, piston 206 is shown at first end of stroke
position
224a. Check valves 216a, 216b, 218a, 218b are all closed such that fluid
cannot flow
into or out of first or second compression chamber sections 208a, 208b. Fluid
will
already be located in first and second compression chamber sections 208a, 208b
having previously been drawn in during previous strokes.
[0071] As piston 206 moves in direction indicated by the arrow in FIG. 2B,
the
pressure in first compression chamber section 208a will drop as the volume
increases (as shown between (i) and (ii) of FIG. 3A), causing a pressure
differential to
develop between the outer and inner sides of inlet check valve 216a. Once the
differential pressure reaches the threshold pressure of valve 216a, valve 216a
will
open and fluid will flow from conduit 220a into first compression chamber
section
208a, via inlet port 210a as shown in FIG. 2C. Once valve 216a is open, the
pressure within first compression chamber section 208a will remain generally
constant until piston 206 reaches the second end of stroke position 224b, (as
shown
between (ii) and (iii) of FIG. 3A). Once piston 206 reaches second end of
stroke
position 224b (FIG. 2D), valve 216a will close when the pressure differential
between
the outer and inner sides of valve 216a drops and reaches the reseal pressure
of
valve 216a.
14
Date Recue/Date Received 2021-09-23
0008088-17/87389636
[0072] At the same time, movement of piston 206 decreases the volume of
second compression chamber 208b and increases the pressure within chamber
section 208b as the fluid within chamber section 208b is compressed (as shown
between (vi) to (vii) of FIG. 3B). This will cause a pressure differential to
develop
between the inner and outer side of outlet check valve 218b. Once the pressure
differential reaches the threshold pressure of valve 218b, valve 218b will
open and
will flow out of second compression chamber section 208b and into conduit
222b, via
outlet port 212b. Once valve 218b is open, the pressure within second
compression
chamber section 208b will remain generally constant (as shown between (vii) to
(viii)
of FIG. 3B) until piston 206 reaches second end of stroke position 224b. Once
piston
206 reaches second end of stroke position 224b (FIG. 2D), valve 218b will
close due
to the pressure differential between the outer and inner sides of valve 218b
dropping
and reaching the reseal pressure of valve 218b.
[0073] Next, compressor 300 is configured for the return drive stroke. At
second
end of stroke position 224b shown in FIG. 2D, all check valves will be closed
and with
reference to (iii) of FIG. 3A, first compression chamber 208a will be at a
maximum
volume and contain fluid drawn in during the previous stroke. At the same
time, with
reference to (viii) of FIG. 3B, second compression chamber 208b will have its
minimum volume and contain a volume of pressurised fluid (i.e. fluid at a
higher
pressure than the fluid in first compression chamber 208a).
[0074] As piston 206 moves in the direction indicated by the arrow in FIG.
2D, the
pressure in second compression chamber section 208b will drop as the volume
increases (as shown between (viii) and (ix) of FIG. 3B), causing a pressure
differential to develop between the outer and inner sides of inlet check valve
216b.
Once the differential pressure reaches the threshold pressure of valve 216b,
valve
216b will open and fluid will flow from conduit 220b into first compression
chamber
section 208b, via inlet port 210b (FIG. 2E). Once valve 216b is open, the
pressure
within second compression chamber will remain generally constant until piston
206
reaches the first end of stroke position 224a, (as shown between (ix) and (x)
of FIG.
Date Recue/Date Received 2021-09-23
0008088-17/87389636
3B). Once piston 206 reaches first end of stroke position 224a (FIG. 2B),
valve 216b
will close when the pressure differential between the outer and inner sides of
valve
216b drops and reaches the reseal pressure of valve 216b.
(0075] At the same time, movement of piston 206 decreases the volume of first
compression chamber 208a and increases the pressure in chamber section 208a as
the fluid within is compressed (as shown between (iii) to (iv) of FIG. 3A).
This will
cause a pressure differential to develop between the inner and outer side of
outlet
check valve 218a. Once the pressure differential reaches the threshold
pressure of
valve 218a, valve 218a will open and will flow out of first compression
chamber
section 208a and into conduit 222a, via outlet port 212a. Once valve 218a is
open,
the pressure within first compression chamber section 208a will remain
generally
constant (as shown between (iv) to (v) of FIG. 3A) until piston 206 reaches
first end of
stroke position 224a. Once piston 206 reaches first end of stroke position
224a (FIG.
2B), valve 218a will close due to the pressure differential between the outer
and inner
sides of valve 218a dropping, reaching the reseal pressure of valve 218a.
[0076] The foregoing movement and compression of fluid within compression
chamber 204 will continue as piston 206 continues to move between the first
and
second end of stroke positions 224a, 224b.
[0077] Turning to FIG. 4, an example compressor 200' according to another
embodiment is shown schematically. Compressor 200' may be generally similar to
compressor 200 as described above but in this embodiment, at either end of
tubular
wall 226 are first and second end plates 228a', 228b'. At first end 205a there
may be
two ports 210a', 212a' configured to allow fluid to flow into and out of first
compression chamber section 208a. Ports 210a', 212a' may be cylindrical
channels
within plate 228a' extending from an outer side to an inner side of second end
plate
228a'. Port 210a' may extend from the upper horizontal face to the inner
vertical face
of first end plate 228a'. Port 212a' may extend from the lower horizontal face
to the
inner vertical face of first end plate 228a'.
16
Date Recue/Date Received 2021-09-23
0008088-17/87389636
[0078] Similarly, at second end 205b there may be two ports 210b', 212b'
configured to allow fluid to flow into and out of second compression chamber
section
208b. Ports 210b', 212b' may be cylindrical channels within plate 228b'
extending
from an outer side to an inner side of second end plate 228b'. Port 210b' may
extend
from the upper horizontal face to the inner vertical face of first end plate
228b'. Port
212b' may extend from the lower vertical face to the inner vertical face of
second end
plate 2281)'.
[0079] Similar to compressor 200, to each of ports 210a', 210b', 212a',
212b'
respective check valves 216a, 216b, 218a, 218b may be connected. As the outer
ends of ports 210a', 212a' are on the respective upper and lower faces of
first end
plate 228a' and the outer ends of ports 210b', 212b' are on the respective
upper and
lower faces of second end plate 228b', check valves 216a, 216b, 218a, 218b are
positioned perpendicular to the axial direction of movement of piston 206.
[0080] As shown in FIG. 4, ports 210a', 210b', 212a', 212b' extend
vertically
though the respective end plate, before turning at 90 degrees inwards. In
other
embodiments, ports 210a', 210b', 212a', 212b' may follow any other suitable
path,
such as a curved path.
[0081] FIGS. 5A to 51 illustrate a compressor 300, which is an example
embodiment of compressor 200. Compressor 300 may include first cylinder 302
for
compressing a fluid within compression chamber 304 having first end 305a and
second end 305b (FIG. 5A). First cylinder 302 may include cylinder
barrel/tubular
wall 326 positioned between first and second cylinder head plates 328a, 328b
at
respective first and second ends 305a, 305b of compression chamber 304. First
cylinder 302 may also include piston 306, reciprocally moveable within
compression
chamber 304 in an axial direction towards first end 305a or second end 305b.
Piston
306 may divide compression chamber 302 into two adjacent compression chamber
sections 308a (FIG. 5C), 308b (FIG. 5B). First compression chamber section
308a
may be defined by the interior surface of tubular wall 326, a surface of
piston 306 and
17
Date Recue/Date Received 2021-09-23
0008088-17/87389636
the inner face 336a of first head plate 328a (FIG. 5C). Second compression
chamber
section 308b may be formed on the opposite side of piston 306 to first
compression
chamber section 308a and may be defined by the interior surface of tubular
wall 326,
a surface of piston 306 and the inner face 336h of second head plate 328b
(FIG. 5B).
[0082] Piston 306 may be reciprocally moveable within first cylinder 302
between
a first end of stroke position 324a (FIGS. 5A and 5B) and second end of stroke
position 324b (FIG. 5C). The end of stroke positions may be a physical end of
stroke
positions whereby for a physical first end of stroke position, the surface of
piston 306
will contact the inner face 336a of first head plate 328a. Likewise, for a
physical
second end of stroke position, the surface of piston 306 will contact the
inner face
336b of second head plate 328b. More desirably, for example to reduce noise
and
wear on components of compressor 300 during operation, the end of stroke
positions
are pre-defined end of stroke positions selected such that when piston 306 is
almost
at the physical end of stroke position, but not yet in contact with first or
second head
plates 328a, 328b. For example, in an embodiment, a pre-defined end of stroke
position may be 0.5" away from first or second head plates 328a, 328b.
[0083] Compressor 300 may also include first and second, one way acting,
hydraulic cylinders 330a, 330b (FIG. 56) positioned at opposite ends of
compressor
300. Hydraulic cylinders 330a, 330b may each include a hydraulic piston
therewithin,
each connected to opposite ends of piston rod 307 and each configured to
provide a
driving force that acts in an opposite direction to each other, both acting
inwardly
towards each other and towards first cylinder 302, thus driving reciprocal
movement
of piston 306.
[0084] First cylinder 302 and hydraulic cylinders 330a, 330b may have
generally
circular cross-sections although alternately shaped cross sections are
possible in
some embodiments.
[0085] With reference to FIG. 5C, first head plate 328a may have a
generally
square or rectangular shape with a pair of upper first inlet ports 310a, a
pair of lower
18
Date Recue/Date Received 2021-09-23
0008088-17/87389636
first outlet ports 312a and centrally located piston rod opening 332a. First
inlet ports
310a and first outlet ports 312a may be circular openings that extend through
first
head plate 328a from outer face 334a to inner face 336a of first head plate
328a.
Similarly, with reference to FIGS. 5B and 5H, second head plate 328h may have
a
generally square or rectangular shape with a pair of upper second inlet ports
310b, a
pair of lower second outlet ports 312b and centrally located piston rod
opening 332b.
Second inlet ports 310b and second outlet ports 312b may be circular openings
that
extend through first head plate 328b from outer face 334b to inner face 336b
of first
head plate 328b.
[0086] First inlet ports 310a are configured to receive fluid at outer
first end 338a
and communicate fluid to inner second end 340a inside first chamber section
308a
(FIG. 5A). Similarly, second inlet ports 310b are configured to receive fluid
at outer
first end 338b and communicate fluid to an inner, second end 340b inside
second
chamber section 308b (FIG. 5A).
[0087] First outlet ports 312a are configured to receive fluid from first
chamber
section 308a at inner first end 342a and communicate fluid to outer second end
344a.
Similarly, second outlet ports 312b are configured to receive fluid from
second
chamber section 308b at inner first end 342b and communicate fluid to outer
second
end 344h.
[0088] Connected to each of first ends 338a, 338b of inlet ports 310a, 310b
may
be respective inlet check valves 316a, 316b configured to ensure that fluid
may flow
into compression chamber 304 from inlet ports 310a, 310b (i.e., fluid only
travels from
first ends 338a, 338h to second ends 340a, 340b). In some embodiments, inlet
check valves 316a, 316b may be connected directly to first ends 338a, 338b of
inlet
ports 310a, 310b. In the embodiment shown in FIG. 5A, short conduits 346a,
sized to
be partially received within first ends 338a of inlet ports 310a, may be
disposed
between inlet check valve 316a and first inlet ports 310a to facilitate
connection of
check valves 316a. Similarly, short conduits 346b, sized to be partially
received
19
Date Recue/Date Received 2021-09-23
0008088-17/87389636
within first ends 338b of inlet ports 310b, may be disposed between inlet
check valve
316b and second inlet port 310b to facilitate connection of check valve 316b.
[0089] Similarly, connected to each of the second ends 344a, 344b of outlet
ports
312a, 312b may be respective outlet check valves 318a, 318b configured to
ensure
that fluid may only flow from compression chamber 304 into outlet ports 312a,
312b,
(i.e., fluid only travels in the direction from first ends 342a, 342b to
second ends
344a, 344b). In some embodiments, outlet check valves 318a, 318b may be
connected directly to second ends 344a, 344b of outlet ports 312a, 312b. In
the
embodiment shown in FIG. 5A, short conduits 348a, sized to be partially
received
within second ends 344a of outlet ports 312a, may be disposed between outlet
check
valve 318a and first outlet port 312a to facilitate connection of check valve
318a.
Similarly, short conduits 348b, sized to be partially received within second
ends 344b
of outlet ports 312b, may be disposed between outlet check valve 318b and
second
outlet port 312b to facilitate connection of check valve 318b.
[0090] Connections between ports 310a, 310b, 312a, 312b, conduits 346a,
346b,
348a, 348 and check valves 316a, 316b, 318a, 318b may be facilitated by any
suitable method, such as welding or by providing complementary threaded ends
between adjoining components.
[0091] In operation, compressor 300 may operate in a similar manner to as
previously described for compressor 200. Similar to as described above for
compressor 200, check valves 316a, 316b, 318a, 318b are operable to move
between open and closed configurations depending on the pressure differential
across each check valve. When in a closed configuration, fluid is not
permitted to
flow in either direction through the check valve. When in an open
configuration, fluid
is permitted to flow in one direction only through the check valve. As shown
in FIG.
2A, check valves 316a, 316b, 318a, 318b are all in a closed configuration and
fluid
may not enter or leave compression chamber 304.
Date Recue/Date Received 2021-09-23
0008088-17/87389636
[0092] With reference to FIG. 5J, inlet check valve 316a and outlet check
valve
318b are shown in the open configuration. This configuration is similar to as
shown
in FIG. 2C for compressor 200 and may occur when piston 306 is moving from
first
end of stroke position 324a to second end of stroke position 324b and the
pressure
differential across check valves 316a, 318b has reached the threshold pressure
of
the valves. With inlet check valves 316a in an open configuration, fluid can
flow as
indicated through secondary conduits 360a, inlet check valve connectors 364a,
inlet
check valves 316a, conduits 346a and into first compression chamber section
308a
through first inlet ports 310a. With outlet check valves 318b in an open
configuration,
fluid can flow as indicated from second compression chamber section 308b,
through
second outlet ports 312b, conduits 348b, outlet check valves 318b, and into
outlet
check valve connectors 378b.
[0093] With reference to FIG. 5K, inlet check valve 316b and outlet check
valve
318a are shown in the open configuration. This configuration is similar to as
shown
in FIG. 2E for compressor 200 and may occur when piston 306 is moving from
second end of stroke position 324b to first end of stroke position 324a and
the
pressure differential across check valves 316b, 318a has reached the threshold
pressure of the valves. With inlet check valves 316b in an open configuration,
fluid
can flow as indicated through secondary conduits 360b, inlet check valve
connectors
364b, inlet check valves 316b, conduits 346b and into second compression
chamber
section 308b through first inlet ports 310b. With outlet check valves 318a in
an open
configuration, fluid can flow as indicated from first compression chamber
section
308a, through first outlet ports 312a, conduits 348a, outlet check valves
318a, and
into outlet check valve connectors 378a.
[0094] By providing multiple, smaller inlet and outlet ports on each of
first and
second head plates 328a, 328b (and corresponding smaller check valves and
connectors) as opposed to single larger ports on each head plate, larger
hydraulic
cylinders may be used with compressor 300, which may be desirable in some
applications such as when compressing a fluid with a high proportion of
liquid.
21
Date Recue/Date Received 2021-09-23
0008088-17/87389636
[0095] With reference to FIGS. 5B-D in particular, the fluid communication
system
is shown, which provides fluid to compressor 300 to be compressed within
compression chamber 304, may include suction intake manifold 350 and pressure
discharge manifold 352.
[0096] On the fluid intake side of compressor 300, suction intake manifold
350
may have two manifold outlets 351a and 351b and a single manifold inlet 351c.
A
flange associated with outlet 351a is connected to first flange 354a of inlet
connector
356a. Inlet connector 356a may include primary conduit 358a, which may have
the
same interior channel diameter as manifold 350, and a pair of smaller, spaced
apart
secondary conduits 360a extending orthogonally from primary conduit 358a (FIG.
5B). Flanges 361a associated with secondary conduits 360a are each connected
to
flanges 365a associated with inlet check valve connectors 364a which are in
turn
configured to connect to input check valves 316a. As such, inlet connector
356a and
inlet check valve connectors 364a may provide fluid communication from outlet
351a
of suction intake manifold 350 to inlet check valves 316a.
[0097] Similarly, a flange associated with outlet 351b is connected to
first flange
354b of inlet connector 356b. Inlet connector 356b may include a primary
conduit
358b, which may have the same interior channel diameter as manifold 350, and a
pair of smaller, spaced apart secondary conduits 360b extending orthogonally
from
primary conduit 358b (FIGS. 5B, 5D). Flanges 361b associated with secondary
conduits 360b are connected to flanges 365b associated with check valve
connectors
364b, configured to connect to input check valves 316b. As such, inlet
connector
356b and inlet check valve connectors 364b may provide fluid communication
from
outlet 351b of suction intake manifold 350 to inlet check valves 316b.
[0098] With reference to FIG. 5C, on the fluid pressure discharge side of
compressor 300, pressure discharge manifold 352 may have two manifold inlets
353a
and 353b and a single manifold outlet 353c. A flange associated with inlet
353a is
connected to first flange 368a of outlet connector 370a. Outlet connector 370a
may
22
Date Recue/Date Received 2021-09-23
0008088-17/87389636
include primary conduit 372a, which may have the same interior channel
diameter as
manifold 352 and a pair of smaller, spaced apart secondary conduits 374a
extending
orthogonally from primary conduit 372a. Flanges 375a associated with secondary
conduits 374a are connected to flanges 379a associated with outlet check valve
connectors 378a, which are configured to connect to outlet check valves 318a.
As
such, outlet connector 370a and outlet check valve connectors 378a may provide
fluid communication from outlet check valves 318a to manifold inlet 353a of
pressure
discharge manifold 352.
[0099] Similarly, a flange associated with inlet 353b is connected to a
first flange
368b of outlet connector 370b. Outlet connector 370a may include a primary
conduit
372b, which may have the same interior channel diameter as manifold 352 and a
pair
of smaller, spaced apart secondary conduits 374b extending orthogonally from
primary conduit 372b. Flanges 375b associated with secondary conduits 374b are
connected to flanges 379b associated with outlet check valve connectors 378b,
which
are configured to connect to outlet check valves 318b. As such, outlet
connector
370b and outlet check valve connectors 378b may provide fluid communication
from
outlet check valves 318b to manifold inlet 353b of pressure discharge manifold
352.
[00100] Inlet connector 356a may also include second flange 382a at the
opposite end of conduit 358a to first flange 354a and inlet connector 356b may
also
include second flange 382b at the opposite end of conduit 358b to first flange
354b
(FIG. 5B). Blanking plates 384a, 384b may be secured to second flanges 382a,
382b
respectively.
[00101] Outlet connector 370a may also include second flange 386a at the
opposite end of conduit 372a to first flange 368a and outlet connector 370b
may also
include a second flange 386b at the opposite end of conduit 372b to first
flange 368b
(FIG. 5C). Blanking plates 388a, 388b may be secured to second flanges 386a,
388b
respectively.
23
Date Recue/Date Received 2021-09-23
0008088-17/87389636
[00102] Second flanges 382a, 382b, 386a, 386b, may be operable to
facilitate
connections between multiple compressors, a representative example of which
will
be discussed later.
[00103] The manifolds, conduits and connectors described above may be
sized
dependent upon the required output/discharge pressures and output flow rates
to be
produced by compressor 300 and may be sized in order to achieve a desired
maximum required flow velocity through compressor 300. In an embodiment the
maximum flow velocity is 23 feet per second. For example, in some embodiments,
suction intake manifold 350, pressure discharge manifold 352 and primary
conduits
358a, 358b, 372a, 372b may all have approximately the same interior channel
diameter, such as in the range of 4-6 inches or even greater. Secondary
conduits
360a, 360b, 374a, 374b, check valve connectors 364a, 364b, 378a, 378b and
conduits 346a, 346b, 348a, 346b may all have approximately the same interior
channel diameter, such as in the range of 2-4 inches or even greater.
Connections
between the manifolds, check valves and conduits described above may be
secured
by any suitable method, such as by welding or by using threaded connections.
[00104] As shown in FIGS. 5A to 51, compressor 300 is configured with
inlet
ports 310a, 310b at the top and outlet ports 312a, 312b at the bottom of
cylinder
heads 328a, 328b. This configuration may be beneficial, for example when
compressor 300 is handling a fluid that contains a significant proportion of
solids
and/or debris which will migrate to the bottom of compression chamber 304 due
to
gravity and will be pumped out of chamber 304 during reciprocal movement of
piston
306. This may increase the reliability of compressor 300 as the accumulation
of
solids and/or debris within compression chamber 304 is reduced.
[00105] However, the configuration of inlet and outlet ports may be
selected
according to the particular application of compressor 300 and may depend on a
number of factors such as the desired inlet (suction) pressure, outlet
pressure, gas
24
Date Recue/Date Received 2021-09-23
0008088-17/87389636
and liquid volume fraction of the fluid and the proportion of solids and other
debris in
the fluid.
[00106] In other embodiments, the upper two ports on each of cylinder
heads
328a, 328b may be outlet ports whilst the lower two ports may be inlet ports.
This
configuration may be beneficial, for example, when handling a fluid with a
higher gas
volume fraction and when a lower inlet pressure is desired.
[00107] Compressor 300 may be in hydraulic fluid communication with a
hydraulic fluid supply system which may provide an open loop or closed loop
hydraulic fluid supply circuit. The hydraulic fluid supply system may be
configured to
supply a driving fluid to drive the hydraulic pistons in hydraulic cylinders
330a, 330b.
[00108] Compressor 300 may also include a controller to control the
operation
of compressor 300, such as by changing the operational mode of the hydraulic
fluid
supply system. The control system may include a number of sensors such as
proximity sensors in order to detect the position of components such as piston
306
within first cylinder 302 or pistons within hydraulic cylinders 330a, 330b in
order to
determine when piston 306 is approaching or has reached either of the end of
stroke
positions 324a, 324b. The controller may use information from the sensors to
control
the hydraulic fluid system in order to control and adjust the reversal of
piston 306 in
either direction. Examples of hydraulic cylinders, hydraulic fluid supply
system and a
control system suitable for use with compressor 300 are disclosed in US
10,544,783,
and US 20210270257, the entire contents of each of which are incorporated
herein
by reference.
[00109] Turning to FIGS. 6A to 6G, another embodiment of a compressor 400
is
shown, which is an example embodiment of the compressor 200' shown in FIG. 4.
First cylinder 302 of compressor 400 may include cylinder barrel/tubular wall
326
positioned between first and second cylinder head plates 428a, 428b at
respective
first and second ends 305a, 305b of compression chamber 304. First head plate
428a may have a generally square or rectangular shape with a pair of upper
first inlet
Date Recue/Date Received 2021-09-23
0008088-17/87389636
ports 410a, a pair of lower first outlet ports 412a and a centrally located
piston rod
opening 432a (not shown). As shown in FIG. 6A, first inlet ports 410a may
extend
within first head plate 428a in a downwards direction from first ends 438a in
top face
435a before turning at 90 degrees inwards to second ends 440a in inner face
436a of
first head plate 428a. First outlet ports 412a may extend in an outwards
direction
from first ends 442a in inner face 436a of first head plate 428a before
turning at 90
degrees downwards to second ends 444a in bottom face 437a of first head plate
428a.
[00110] Similarly, second head plate 428b may have a generally square or
rectangular shape with a pair of upper second inlet ports 410b, a pair of
lower second
outlet ports 412b and a centrally located piston rod opening 432b (FIG. 6F).
Second
inlet ports 410b may extend within second head plate 428b in a downwards
direction
from first ends 438b in top face 435b before turning at 90 degrees inwards to
second
ends 440b in inner face 436a of second head plate 428a. Second outlet ports
412a
may extend in an outwards direction from first ends 442b in inner face 436a of
second head plate 428b before turning at 90 degrees downwards to second ends
444b in bottom face 437b of second head plate 428b.
[00111] Connected to each of the first ends 438a, 438b of inlet ports
410a, 410b
may be respective inlet check valves 316a, 316b configured to ensure that
fluid may
flow into compression chamber 304 from inlet ports 410a, 410b (i.e., fluid
only travels
in the direction from first ends 438a, 438b to second ends 440a, 440b of inlet
ports
410a, 410b). In some embodiments, inlet check valves 316a, 316b may be
connected directly to first ends 438a, 438b of inlet ports 410a, 410b. In the
embodiment shown in FIG. 6A, short conduits 346a, sized to be partially
received
within first ends 438a of inlet ports 410a, may be disposed between inlet
check
valves 316a and first inlet ports 410a. Similarly, short conduits 346b, sized
to be
partially received within first ends 438b of inlet ports 410b, may be disposed
between
inlet check valves 316b and second inlet ports 410b.
26
Date Recue/Date Received 2021-09-23
0008088-17/87389636
[00112] Similarly, connected to each of the second ends 444a, 444b of
outlet
ports 412a, 412b may be respective outlet check valves 318a, 318b configured
to
ensure that fluid may flow into outlet ports 412a, 412b, from compression
chamber
304 (i.e., fluid only travels in the direction from first ends 442a, 442b to
second ends
444a, 444b of outlet ports 412a, 412b). In some embodiments, outlet check
valves
318a, 318b may be connected directly to second ends 444a, 444b of outlet ports
412a, 412b. In the embodiment shown in FIG. 6A, short conduits 348a, sized to
be
partially received within second ends 444a of outlet ports 412a, may be
disposed
between outlet check valves 318a and first outlet ports 412a. Similarly, short
conduits 348h, sized to be partially received within second ends 444b of
outlet ports
412b, may be disposed between outlet check valves 318b and second outlet ports
412b.
[00113] Configuring compressor 400 such that the inlet and outlet ports
are on
the upper and lower faces of cylinder heads 428a, 428b provides additional
space on
the outer faces 434a, 434b of cylinder heads 428a, 428b. This may provide
space for
accommodating larger diameter hydraulic cylinders on compressor 400 as
desired.
[00114] In other embodiments of compressor 400, the upper ports on each
of
cylinder heads 428a, 428b may be outlet ports whilst the lower ports may be
inlet
ports.
[00115] Referring to FIGS. 6B to 6E, the fluid communication system that
provides fluid to compressor 400 may be generally similar to the fluid
communication
system of compressor 300, but is sized to connect to the differently
positioned check
valves 316a, 316b, 318a, 318b on compressor 400. The fluid communication
system
may include suction intake manifold 450 and pressure discharge manifold 452.
Suction intake manifold 450 may have two manifold outlets 451a and 451b and a
single manifold inlet 451c. A flange associated with outlet 451a is connected
to a
first flange 354a of inlet connector 356a, which is in turn connected to first
inlet check
valves 316a through inlet check valve connectors 364a. A flange associated
with
27
Date Recue/Date Received 2021-09-23
0008088-17/87389636
outlet 451b is connected to a first flange of inlet connector 356h which is in
turn
connected to second inlet check valves 316b through check valve connectors
364b.
[00116] On the fluid pressure discharge side of compressor 400, pressure
discharge manifold 452 may have two manifold inlets 453a and 453b and a single
manifold outlet 453c. A flange associated with inlet 453a is connected to
first flange
368a of outlet connector 370a which is in turn connected to first outlet check
valves
318a through outlet check valve connectors 378a. A flange associated with
inlet
453b is connected to a first flange 368b of outlet connector 370b which is in
turn
connected to second outlet check valves 318a through outlet check valve
connectors
378b.
[00117] Providing first and second inlet and first and second outlet
ports through
each of first and second head plates 428a, 428b as opposed to a larger single
inlet
and single outlet port in each head plate may be desirable in order to reduce
the
thickness of head plates 428a, 428b. For example, the pair of first inlet
ports 410a
may each have a diameter of around 2 inches. In order to achieve a similar
flow
velocity of fluid, a single inlet port to replace ports 410a would be required
to have a
larger diameter, for example about 4 inches. This would undesirably
significantly
increase the thickness of head plate 428a in order to accommodate the larger
port
within, increasing the size, weight and cost (through the extra material
required for
the thicker cylinder head) of the compressor.
[00118] Turning to FIGS. 7A to 7G, another embodiment of a compressor 500
is
shown, which is another example embodiment of compressor 200 shown in FIG. 2A.
[00119] In comparison to compressor 300 described above, first head plate
528a, whilst generally similar to first head plate 328a, may be configured
with a pair
of first inlet ports 510a vertically spaced from each other on a first side of
first head
plate 528a. Similar to first inlet ports 310a, first inlet ports 510a may
extend through
first head plate 528a and are configured to receive fluid at an outer, first
end 538a
and communicate fluid to an inner, second end 540a inside first chamber
section
28
Date Recue/Date Received 2021-09-23
0008088-17/87389636
308a (FIG. 7A). First head plate 528a may also be configured with a pair of
first
outlet ports 512a, vertically spaced from each other on the opposite side of
first head
plate 528a to first inlet ports 510a. Similar to first outlet ports 312b,
first outlet ports
512b may extend through first head plate 528a and are configured to receive
fluid at
an inner, first end 542a inside first chamber section 308a and communicate
fluid to
an outer, second end 544a.
[00120] Second head plate 528b may be generally similar to first head
plate
328b and may be configured with a pair of second inlet ports 510b vertically
spaced
from each other on a first side of second head plate 528b. Similar to second
inlet
ports 310b, second inlet ports 510b may extend through second head plate 528b
and
are configured to receive fluid at an outer, first end 538b and communicate
fluid to an
inner, second end 540b inside second chamber section 308b (FIG. 7A). Second
head plate 528b may also be configured with a pair of first outlet ports 512b,
vertically
spaced from each other on the opposite side of second head plate 528b to first
inlet
ports 510a. Similar to second outlet ports 312b, second outlet ports 512b may
extend through second head plate 528b and are configured to receive fluid at
an
inner, first end 542b inside second chamber section 308b and communicate fluid
to
an outer, second end 544b.
[00121] First and second inlet ports 510a, 510b may be connected to
suction
intake manifold 350 in a similar manner to as described above for compressor
300
through inlet connectors 356a, 356b, inlet check valve connectors 364a, 364b
and
inlet check valves 316a, 316b for supplying fluid to compression chamber 304,
with
inlet connectors 356a, 356b and intake manifold 350 oriented to accommodate
the
different inlet port configuration of compressor 500.
[00122] First and second outlet ports 512a, 512b may be connected to
pressure
discharge manifold 352 in a similar manner to as described above for
compressor
300 through outlet check valves 318a, 318b, outlet check valve connectors
378a,
378b and outlet connectors 370a, 370b for receiving fluid from compression
chamber
29
Date Recue/Date Received 2021-09-23
0008088-17/87389636
304, with outlet connectors 370a, 370b and pressure discharge manifold 352
oriented
to accommodate the different outlet port configuration of compressor 500.
[00123] With reference to FIG. 8 an example oil and gas producing well
system
1100 is illustrated, which utilises a compressor 1106, which may be any
compressors
described above. Oil and gas producing well system 1100 is illustrated
schematically
and may be installed at, and in, a well shaft (also referred to as a well
bore) 1108 and
may be used for extracting liquid and/or gases (e.g., oil and/or natural gas)
from an
oil and gas bearing reservoir 1104.
[00124] Extraction of liquids including oil as well as other liquids such
as water
from reservoir 1104 may be achieved by methods such as the use of a down-well
pump, which operates to bring a volume of oil toward the surface to a well
head 1102.
An example of a suitable down-well pump is disclosed in United States Patent
Application Serial No. 16/147,188, filed September 28, 2018 (now United States
Patent Serial No. 10,544,783, issued January 28, 2020), the entire contents of
which
is hereby incorporated herein by reference.
[00125] Well shaft 1108 may have along its length, one or more generally
hollow cylindrical tubular, concentrically positioned, well casings 1120a,
1120b,
1120c, including an inner-most production casing 1120a that may extend for
substantially the entire length of the well shaft 1108. Intermediate casing
1120b may
extend concentrically outside of production casing 1120a for a substantial
length of
the well shaft 1108, but not to the same depth as production casing 1120a.
Surface
casing 1120c may extend concentrically around both production casing 1120a and
intermediate casing 1120b, but may only extend from proximate the surface of
the
ground level, down a relatively short distance of the well shaft 1108.
[00126] Natural gas may exit well shaft 1108 into piping 1124 whilst
liquid may
exit well shaft 1108 through a well head 1102 to an oil flow line 1133. Oil
flow line
1133 may carry the liquid to piping 1124, which in turn carries the combined
gas and
oil to inlet manifold 351c of compressor 1106. Compressor 1106 may operate
Date Recue/Date Received 2021-09-23
0008088-17/87389636
substantially as described above to compress gas and liquid supplied by piping
1124.
Compressed fluid that has been compressed by compressor 1106 may exit though
outlet manifold 353c and flow via piping 1130 to interconnect to pipeline
1132.
[00127] In another embodiment, a plurality of compressors may be
connected in
series in order to provide a pressure boost to a fluid. An advantage to this
approach
is that less energy is required to compress fluid, such as gas, in multiple
stages.
[00128] In an example embodiment, a first compressor may be connected to
a
second compressor such that fluid flows through the first compressor to the
second
compressor. Fluid at a first pressure P1 may have its pressure boosted to a
second
pressure P2 (that is greater than P1) by the first compressor. Fluid may then
flow to
the second compressor, where the pressure of the fluid will be boosted to a
third
pressure P3 (that is greater than P2).
[00129] The first and second compressors may be interconnected in a
number
of suitable configurations in order for fluid that has been compressed in
compression
chamber sections 308a, 308b of the first compressor to flow to the second
compressor. For example, when the first and second compressors are both
similar to
compressor 300, second flanges 386a, 386b (with blanking plates 388a, 388b
removed) on the first compressor may be interconnected to manifold inlet 351c
or
second flanges 382a, 382b of the second compressor.
[00130] In one embodiment, the first and second compressors may have
different specifications. For example, the second compressor may be configured
to
handle fluid at a higher pressure and have hydraulic cylinders and a piston
with a
larger diameter than the first compressor.
[00131] For example, in an embodiment, the first compressor may have an
inlet
pressure of 50 psi and an outlet pressure of 250 psi and the second compressor
may
have an inlet pressure of 250 psi and an outlet pressure of 500 psi.
31
Date Recue/Date Received 2021-09-23
0008088-17/87389636
[00132] The compressors may also be employed in other oilfield and other
non-
oilfield environments to transfer gas and multi-phase fluids efficiently and
quietly.
[00133] Whilst the illustrated embodiments depict compressors with two
inlet
ports and two outlet ports on each cylinder head, other variations are
contemplated
with different numbers of inlet and/or outlet ports on each cylinder head.
[00134] When introducing elements of the present invention or the
embodiments thereof, the articles "a," "an," "the," and "said" are intended to
mean
that there are one or more of the elements. The terms "comprising,"
"including," and
"having" are intended to be inclusive and mean that there may be additional
elements
other than the listed elements.
[00135] Of course, the above described embodiments are intended to be
illustrative only and in no way limiting. The described embodiments of
carrying out
the invention are susceptible to many modifications of form, arrangement of
parts,
details, and order of operation. The invention, therefore, is intended to
encompass all
such modifications within its scope.
32
Date Recue/Date Received 2021-09-23
