SYSTEMS AND METHODS FOR A GAS-DRIVEN COMPRESSOR

Abstract

A gas-driven compressor system includes a compressor body with first and second piston cavities and a shuttle valve cavity. The system has a low pressure outlet and high pressure inlet communicating with the first piston cavity via the shuttle valve cavity, and compressor inlet/outlet ports communicating with the second piston cavity. A shuttle valve moves between first and second positions within its cavity. The piston has a first head portion movable by pressurized inlet flow and a second head portion that compresses fluid in the second cavity. The piston selectively directs flow from the high pressure inlet to either side of the shuttle valve cavity based on piston position, thereby directing pressurized flow to either side of the first head portion. This arrangement powers the reciprocating movement of the piston.

Claims

1. A gas-driven compressor system comprising: a compressor body defining a first piston cavity, a second piston cavity, and a shuttle valve cavity; a low pressure port in fluid communication with the first piston cavity, via the shuttle valve cavity, to vent the first piston cavity; a high pressure port in fluid communication with the first piston cavity, via the shuttle valve cavity, to provide pressurized inlet flow to the first piston cavity; a compressor inlet in fluid communication with the second piston cavity; a compressor outlet in fluid communication with the second piston cavity; a shuttle valve movable between a first position and a second position within the shuttle valve cavity; and a piston having: a first head portion movable within the first piston cavity by the pressurized inlet flow; and a second head portion movable within the second piston cavity by the movement of the first head portion within the first piston cavity to compress a fluid in the second piston cavity; the piston fluidly coupling a signal flow from the high pressure inlet selectively to a first side or a second side of the shuttle valve cavity, depending on a position of the piston, to selectively direct the pressurized inlet flow to the first piston cavity on, respectively, a first side or a second side of the first head portion of the piston to power reciprocating movement of the piston.

2. The gas-driven compressor system of claim 1, wherein the piston is configured to move in a first direction to draw the fluid into the second piston cavity and in a second direction to compress fluid within the second piston cavity.

3. The gas-driven compressor system of claim 1, wherein the piston defines a first groove and a second groove arranged to fluidly couple the signal flow from the high pressure port selectively to the first side or the second side of the shuttle valve cavity.

4. The gas-driven compressor system of claim 3, wherein the first groove is aligned with a first shuttle valve signal line when the first head portion of the piston is in a first position in the first piston cavity, and wherein the second groove is aligned with a second shuttle valve signal line when the first head portion of the piston is in a second position in the first piston cavity.

5. The gas-driven compressor system of claim 3, wherein the first groove is spaced axially from the second groove along the piston and the high pressure port is in communication with the piston along: a first inlet signal line arranged to pressurize the first groove when the first head portion of the piston is at a first end of the first piston cavity; and a second inlet signal line arranged to pressurize the second groove when the first head portion of the piston is at a second end of the first piston cavity.

6. The gas-driven compressor system of claim 3, wherein the first and second grooves are included on the second head portion of the piston.

7. The gas-driven compressor system of claim 1, further comprising: a lever that couples the first head portion to the second head portion.

8. The gas-driven compressor system of claim 1, wherein the first head portion of the piston separates the first piston cavity into a first volume and a second volume; wherein the shuttle valve in the first position provides the pressurized inlet flow to the first volume and vents the second volume to the low pressure port, to move the piston in a first direction; and wherein the shuttle valve in the second position provides the pressurized inlet flow to the second volume and vents the first volume to the low pressure port, to move the piston in a second, opposite direction.

9. A method of compressing a fluid using a process gas driven compressor, comprising: providing a high pressure port of a compressor body in communication with a first pressure; providing a low pressure port of the compressor body in communication with a second pressure; and moving a first piston with reciprocating movement within a first piston cavity, by moving a shuttle valve in response to a pressure differential between the high pressure port and the low pressure port, the movement of the shuttle valve selectively directing pressurized fluid from the high pressure port to opposite sides of the first piston within the first piston cavity, dependent on a position of a piston assembly that includes the first piston; the movement of the first piston moving a second piston of the piston assembly with reciprocating movement in a second piston cavity to compress a fluid within the second piston cavity.

10. The method of claim 9, further comprising: aligning a first circumferential groove of the piston assembly with a first shuttle valve signal line when the piston assembly is in a first position, to direct the pressurized fluid from the high pressure port to a first side of the shuttle valve, to move the shuttle valve from a first position to a second position; and aligning a second circumferential groove of the piston assembly with a second shuttle valve signal line when the piston assembly is in the second position, to direct high pressure fluid to a second side of the shuttle valve to move the shuttle valve from the second position back to the first position.

11. The method of claim 9, further comprising: discharging the compressed fluid from the second piston cavity, through a compressor outlet port, when the compressed fluid reaches a predetermined threshold pressure.

12. The method of claim 9, further comprising: selectively blocking, with the piston assembly, fluid connection between the high pressure port and shuttle valve signal lines during the reciprocating movement of the first and second pistons.

13. The method of claim 9, wherein drawing fluid into the second piston cavity includes: drawing fluid through an inlet port and a first check valve into the second piston cavity during movement of the piston from the first position to the second position.

14. The method of claim 9, wherein the fluid compressed in the second piston cavity is further compressed in a second stage compression by the reciprocating movement of the piston assembly.

15. The method of claim 14, wherein the reciprocating movement of the piston assembly directs the compressed fluid from the second piston cavity to a third piston cavity to be compressed by the reciprocating movement of the piston assembly.

16. A gas-driven compressor system, comprising: a high pressure port; a low pressure port; a piston assembly, including: a first piston movable within a first piston cavity in response to a pressure differential between the high pressure port and the lower pressure port; and a second piston moveable within a second piston cavity by movement of the first piston, to compress a fluid in the second piston cavity; and a shuttle valve movable between a first position and a second position in response to the pressure differential between the high pressure port and the low pressure port to cause reciprocating movement of the piston assembly by selectively directing pressurized fluid from the high pressure port to opposite sides of the first piston, dependent on a position of the piston assembly.

17. The gas-driven compressor system of claim 16, further comprising: a lever mechanically coupled between the first piston and the second position to multiply a force applied by the first piston to the second piston.

18. (canceled)

19. The gas-driven compressor system of claim 16, wherein the second piston includes a first diaphragm, and a second diaphragm secured together by a piston rod.

20. The gas-driven compressor system of claim 19, wherein the first diaphragm forms a first chamber including an inlet port and an outlet port, and wherein the second diaphragm forms a second chamber including a port open to the atmosphere.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] FIG. 1 is a diagrammatic view of an example of a process gas driven compressor system with a piston and a shuttle valve arranged in a first position, according to aspects of the present disclosure.

[0024] FIG. 2 is a diagrammatic view of the process gas driven compressor system of FIG. 1 with the piston in the first position and the shuttle valve arranged in a second position.

[0025] FIG. 3 is a diagrammatic view of the process gas driven compressor system of FIG. 2, with the piston arranged in an intermediary position and the shuttle valve arranged in the second position.

[0026] FIG. 4 is a diagrammatic view of the process gas driven compressor system of FIG. 3 with the piston arranged in a second position and the shuttle valve arranged in the second position.

[0027] FIG. 5 is a diagrammatic view of the process gas driven compressor system of FIG. 4 with the piston arranged in the second position and the shuttle valve arranged in the first position.

[0028] FIG. 6 is an axonometric partial view of an example implementation of the process gas driven compressor system of FIG. 1 with the piston and the shuttle valve arranged in the first position.

[0029] FIG. 7 is an axonometric partial view of an example implementation of the process gas driven compressor system of FIG. 1 with the piston in the first position and the shuttle valve arranged in the second position.

[0030] FIG. 8 is an axonometric partial view of an example implementation of the process gas driven compressor system of FIG. 1 with the piston arranged in the intermediary position and the shuttle valve arranged in the second position.

[0031] FIG. 9 is an axonometric partial view of an example implementation of the process gas driven compressor system of FIG. 1 with the piston arranged in the second position and the shuttle valve arranged in the second position.

[0032] FIG. 10 is an axonometric partial view of an example implementation of the process gas driven compressor system of FIG. 1 with the piston arranged in the second position and the shuttle valve arranged in the first position.

[0033] FIG. 11 is a diagrammatic view of another example of a process gas driven compressor system according to aspects of the present disclosure.

[0034] FIG. 12 is a diagrammatic view of yet another example of a process gas driven compressor system according to aspects of the present disclosure.

[0035] FIG. 13 is an axonometric view of a piston of the process gas driven compressor system of FIG. 12.

[0036] FIG. 14 is an axonometric view of the piston of FIG. 13.

[0037] FIG. 15 is a cross-sectional axonometric view of the piston of FIG. 13.

[0038] FIG. 16 is a diagrammatic view of the process gas driven compressor system of FIG. 12 including the piston of FIG. 13.

[0039] FIG. 17 is a diagrammatic view of the process gas driven compressor system of FIG. 12 including another example of a shuttle valve.

DETAILED DESCRIPTION

[0040] The following discussion is presented to enable a person skilled in the art to make and use embodiments of the invention. Given the benefit of this disclosure, various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the principles herein can be applied to other embodiments and applications without departing from embodiments of the invention. Thus, embodiments of the invention are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein.

[0041] The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of embodiments of the invention. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of embodiments of the invention.

[0042] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of including, comprising, or having and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms mounted, connected, supported, and coupled and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, connected and coupled are not restricted to physical or mechanical connections or couplings.

[0043] As briefly described above, some natural gas products, such as valves and electronic regulators, use low pressure gas to operate. In use, some applications of valves and regulators require venting to atmosphere (e.g., auto resetting spring open regulators). With conventional valves and regulators, one challenge is the required low-pressure gas is at a lower pressure than the lowest pressure in the system and cannot be re-injected into the line. One method is to use low pressure, compressed air to operate these products. This requires some amount of gas compression infrastructure. In remote locations, this can be a challenge. Alternatively, process media can be reduced to the appropriate level then exhausted once it has been utilized. Venting process media to the atmosphere can be unfavorable for a variety of reasons, including negative environmental factors.

[0044] Aspects of the present disclosure can address these and other drawbacks of conventional operations of valves and regulators. For example, some implementations of the present disclosure provide a process gas driven compressor. The compressor can repressurize low pressure process gas and inject it back into the system (e.g., pipeline) after use. In particular, examples of the present disclosure can provide a compressor that uses process media to drive a piston of the compressor and generate pressurized fluid that can be reinjected back into the system. For example, the compressor may pressurize process fluid by moving the piston linearly back and forth to compress fluid within a piston cylinder. In some examples, incorporation of a second stage in the compression system can increase output pressure compared to a single-stage compression system.

[0045] In some examples, the compressor system includes a compressor body with first and second piston cavities that receive portions of a piston. The head of the piston separates the first cavity into first and second volumes. The system includes high and low pressure inlets connected to respective pressure lines, with transfer lines directing pressurized fluid to the first or second volumes based on shuttle valve orientation and correspondingly venting the other volume to the low pressure inlet. In some examples, the shuttle valve controls fluid flow direction. The shuttle valve moves via high pressure fluid supplied through shuttle valve signal lines, which direct fluid to either side of the shuttle valve depending on a current state of the compressor to control movement of the shuttle valve.

[0046] In some examples, a second piston cavity includes an inlet port with a first check valve permitting one-way fluid flow in, and an outlet port with a second check valve permitting one-way fluid flow out. This arrangement permits fluid compression as the piston moves.

[0047] In some examples, during use, the piston moves through a series of stages. For example, in a first stage, the piston and shuttle valve are in first positions. High pressure fluid enters the first volume through the first transfer line, while the second volume is vented to lower pressure through the second transfer line. When the piston is in the first position, a first circumferential groove in the piston shaft (or other feature) aligns with the high pressure line and first shuttle valve signal line, allowing high pressure fluid to flow to the first side of the shuttle valve to move the shuttle valve.

[0048] In a second stage, the shuttle valve moves to a second position (e.g., moved by pressure, as above), redirecting high pressure fluid to the second volume and venting the first volume to lower pressure. This initiates piston movement (e.g., a third stage), which begins drawing fluid into the second piston cavity through the inlet port.

[0049] In a fourth stage, a second circumferential groove of the piston shaft (or other feature) aligns with the high pressure line and second shuttle valve signal line, directing high pressure fluid to the second side of the shuttle valve to move the shuttle valve towards the first position.

[0050] In a fifth stage, the shuttle valve returns to the first position, redirecting high pressure fluid to the first volume and venting the second volume to lower pressure. This causes the piston to move towards the first position, compressing fluid in the second piston cavity until it reaches sufficient pressure to exit through the second check valve and outlet port.

[0051] In some examples, the system may utilize a lever to connect a first piston to a second piston in order to provide a mechanical advantage to generate higher output pressure from low differential input pressure. In other examples, other systems for mechanical advantage can also or alternatively be used (e.g., providing a larger acting surface areas on the first piston than on the second piston, etc.).

[0052] In some examples, the compressor system may be a two-stage compressor system. For example, movement of a piston in a first direction can cause a first stage compression (e.g., in the second piston cavity, as described above). This first-stage compressed fluid can be routed to another piston cavity (e.g., similar to the second piston cavity, as described above) and then further compressed by movement of the piston (e.g., in a second direction). In some examples, the shuttle valve may include extensions with radial passageways to control fluid flow while preventing pressure bleed.

[0053] FIGS. 1-5 illustrate an example of a compressor system 100 (e.g., a process fluid driven compressor system). The compressor system 100 may be in the form of a process fluid driven compressor including a compressor body 102 defining a first piston cavity 126 and a second piston cavity 155. In some example, the first and second piston cavities 126, 155 may each receive a portion of a piston 108 (e.g., a main piston). For example, a first head 145 of the piston 108 may translate within the first piston cavity 126, while a second head (e.g., narrower shaft) 165 of the piston may translate within the second piston cavity 155. In some examples, the head 145 of the piston 108 may have a larger diameter than the shaft 165 of the piston 108, or other differently sized pistons or piston heads can be provided. Correspondingly, the first piston cavity 126 may have a larger diameter than the second piston cavity 155.

[0054] In some examples, the head 145 of the piston 108 may separate the first piston cavity 126 into a first volume 125 and a second volume 135. Correspondingly, to actuate (e.g., move) the piston 108 within the first and second piston cavities 126, 155, varying pressures may be applied to the head 145 of the piston 108 (e.g., via the influx of high pressure fluid into the first or second piston cavities, and corresponding venting of the other). In some examples, in order to provide high/low pressure fluid to the system 100, the body 102 may include a high pressure port (e.g., inlet) 104 and a low pressure port (e.g., inlet) 106. In some examples, one or more high pressure lines 120 (or other inlet flow paths) can be in communication with the high pressure inlet 104. Correspondingly, one or more low pressure lines 124 (or other inlet flow paths) can be in communication with the low pressure inlet 106.

[0055] In some examples, depending on an orientation of a shuttle valve, fluid from the high pressure lines 120 may pass into either the first volume 125 or the second volume 135 via either a first transfer line 114 or a second transfer line 116, and likewise for fluid vented from the volumes 125, 135 to the low pressure lines 124. Thus, in some examples, based on the orientation of the shuttle valve, the direction of travel of the piston 108 may be controlled (e.g., via alternating flow of high pressure fluid into either the first volume 125 or the second volume 135).

[0056] In some examples, in addition to the piston 108, the system 100 may include a shuttle valve 110, which may be housed within a shuttle cavity 132, separate from the first and second piston cavities 126, 155. In some examples, the shuttle valve 110 may be moveable within the shuttle cavity 132 via high pressure fluid from the high pressure inlet 104. For example, the shuttle cavity 132 may receive high pressure fluid from the high pressure inlet 104 via one or more shuttle valve signal lines 134. For example, a first shuttle valve signal line 134 may apply high pressure fluid signal to a first side of the shuttle valve 110 (e.g. to move the shuttle valve 110 in a first direction), while a second shuttle valve signal line 136 may apply high pressure fluid signal to a second side of the shuttle valve 110 (e.g., to move the shuttle valve 110 in a second, opposite direction). As further detailed below, depending on the position of the shuttle valve 100, lands and grooves (or other features) on the shuttle valve 100 can cause selective pressurization and venting of the first piston cavity 126 to drive reciprocating movement of the piston 108.

[0057] In some examples, in order to facilitate fluid flow into and out of the second piston cavity 155, the compressor system 100 may include an inlet port 148 (or other compressor inlet) and an outlet port 115 (or other compressor outlet). In some examples, the inlet port 148 may include a first check valve 140 (e.g., a suction valve), which may permit one-way flow of fluid into the second piston cavity 155. Correspondingly, the outlet port 115 may include a second check valve 142 (e.g., a discharge valve), which may permit one-way flow of fluid out of the second piston cavity 155. For example, the inlet port 148 and corresponding check valve 140 may permit the inflow of low pressure fluid into the second piston cavity 155 during movement of the piston 108 in a first direction. Correspondingly, the outlet port 115 and corresponding check valve 142 may permit the outflow of high pressure fluid out of the second piston cavity 155 as the fluid is compressed due to movement of the piston 108 in a second, opposite direction. In general, the check valve 142 may be configured to permit the outlet of compressed fluid (e.g., to the outlet port 115) once the compressed fluid reaches a predetermined threshold pressure.

[0058] With continued reference to FIGS. 1-5, an example process for compressing fluid (e.g., process fluid from a pipeline, air, etc.) using the compressor system 100 will be described. For example, FIG. 1 illustrates a first stage of a fluid compression process. In the first stage, each of the piston 108 and the shuttle valve 110 are arranged in respective first positions 175, 185. That is, with respect to the orientation shown in FIG. 1, each of the piston 108 and the shuttle valve 110 are arranged the right side of their respective cavities 126, 132. In some examples, for the piston 108 to reach the first position 175, the high pressure inlet 104 may supply high pressure fluid from the high pressure line 120 through the first transfer line 114 to the first volume 125. Correspondingly, the low pressure inlet 106 may vent the second volume 135 to low pressure via the low pressure line 124 and the second transfer line 116.

[0059] In some examples, due to the orientation of the shuttle valve 110 in the first position 185, the first transfer line 114 is configured as a high pressure line (e.g., is fluidically connected to the high pressure line 120). However, as the shuttle valve moves 110 to a second position, the first transfer line 114 may transition to a low pressure line (e.g., fluidically connected to the low pressure line 124).

[0060] Generally, features on the piston 108 or the body 102 can cooperate to selectively route signal pressure to opposite sides of the shuttle valve 110, depending on a position of the piston 108. In some examples, when the piston 108 is in the first position 175, a first circumferential groove 152 formed in the shaft 165 of the piston 108 may be aligned with the high pressure line 120 and a first shuttle valve signal line 134. Thus, high pressure fluid from the high pressure line 120 may flow through the first shuttle valve signal line 134 and to a first side of the shuttle valve 110. Correspondingly, the shuttle valve 110 may begin to actuate within the shuttle valve cavity 132 in the direction shown by arrow 167.

[0061] Turning now to FIG. 2, a second stage of the fluid compression process is shown. In the second stage, the piston 108 remains in the first position 175, while the shuttle valve 110 has moved to a second position 187. With the shuttle valve 110 in the second position 187, high pressure fluid from the high pressure line 120 is now in fluid communication with the second volume 135 via the second transfer line 116. Correspondingly, the low pressure inlet 106 may vent the first volume 125 to low pressure via the low pressure line 124 and the first transfer line 114. As a result, the piston 108 may begin to move in the direction shown by arrow 169 (sec, e.g., FIG. 3), which may begin to draw fluid into the second piston cavity 155 via the inlet port 148 (e.g., through the first check valve 140). Further, during movement of the piston in the direction shown by arrow 169, the fluid connection between the high pressure line 120 and the shuttle valve signal lines 134, 136 may be blocked by the shaft 165 of the piston 108.

[0062] As shown in FIG. 4, at a third stage of the fluid compression process, the piston 108 may be in a second position 177, while the shuttle valve 110 remains in the second position 187. When the piston 108 is in the second position 177, a second circumferential groove 154 formed in the shaft 165 of the piston 108 may be aligned with the high pressure line 120 and the second shuttle valve signal line 136. Thus, high pressure fluid from the high pressure line 120 may flow through the second shuttle valve signal line 136 and to a second side of the shuttle valve 110. Correspondingly, the shuttle valve 110 may begin to actuate within the shuttle valve cavity 132 in the direction shown by arrow 163 (e.g., towards the first position 185).

[0063] As shown in FIG. 5, at a fourth stage of the fluid compression process, the piston 108 may be in the second position 177, while the shuttle valve 110 has returned to the first position 185. As mentioned previously, when the shuttle valve 110 is in the first position 185, the high pressure inlet 104 may supply high pressure fluid from the high pressure line 120 through the first transfer line 114 to the first volume 125. Correspondingly, the low pressure inlet 106 may vent the second volume 135 to low pressure via the low pressure line 124 and the second transfer line 116 to the second volume 135. As a result, the piston 108 may begin to move in the direction shown by arrow 191 (e.g., towards the first position 175, see, e.g., FIG. 1). In some examples, as the piston 108 moves in the direction shown by arrow 191, the fluid within the second piston cavity 155 may be compressed, which may pressurize the fluid. In some examples, once the fluid reaches a predetermined pressure, the fluid may pass out of the second check valve 142 and out of the outlet port 115.

[0064] In some examples, a discharge flange 158 can direct pressure back into the body 102. In general, the discharge flange 158 can be used to build up a steady pressure for release, rather than an oscillating pressure. However, in some examples, the discharge flange 158 may not be included.

[0065] FIGS. 6-10 illustrate an example of a process gas driven compressor system 600, which is an example implementation of the process gas driven compressor system 100 as described in FIGS. 1-5. As will be recognized, the system 600 shares a number of components in common with and operates in a similar fashion to the examples illustrated and described previously (e.g., the system 100 in FIGS. 1-5). For the sake of brevity, these common features will not be again described in detail. Rather, previous discussion of commonly named or numbered features, unless otherwise indicated, also applies to example configurations of the system 600.

[0066] Similar to FIG. 1, FIG. 6 shows an example of the system 600 in a first stage, with the piston 108 in a first position 175 and the shuttle valve 110 in a first position 185. Similar to FIG. 2, FIG. 7 shows an example of the system 600 in a second stage, with the piston 108 in the first position 175 and the shuttle valve 110 in a second position 187. Similar to FIG. 3, FIG. 8 shows an example of the system 600 with the piston 108 moving between the first position 175 and the second position 177 (e.g., drawing fluid into the second piston cavity 155 through the inlet port 148) and the shuttle valve 110 in the second position 187. Similar to FIG. 4, FIG. 9 shows an example of the system 600 with the piston 108 in the second position 177 and the shuttle valve 110 in the second position 187. Similar to FIG. 5, FIG. 10 shows an example of the system 600 with the piston 108 in the second position 177 and the shuttle valve 110 in the first position 185. Correspondingly, as mentioned above, the piston 108 may begin to move between the second position 177 and the first position 175. As a result, fluid within the second piston cavity 155 may be compressed, which may pressurize the fluid. In some examples, once the fluid reaches a predetermined pressure, the fluid may pass out of the second check valve 142 and out of the outlet port 115.

[0067] FIG. 11 shows another example of a process gas driven compressor system 1100. As will be recognized, the system 1100 shares a number of components in common with and operates in a similar fashion to the examples illustrated and described previously (e.g., the system 100). For the sake of brevity, these common features will not be again described below in detail. Rather, previous discussion of commonly named or numbered features, unless otherwise indicated, also applies to example configurations of the system 1100.

[0068] In some examples, the system 1100 may be particularly suitable for applications in which only a small pressure differential is available (e.g., where no control valve is available). For example, in order to generate a relatively small pressure drop, a first pitot-tube (or similar) may be oriented towards (e.g., facing upstream) fluid flow in a pipeline, while a second pitot-tube (or similar) may be oriented away from (e.g., facing downstream) fluid flow in a pipeline. As a result, a small pressure differential may exist between the first and second pitot-tubes, which may be combined with a mechanical advantage (e.g., a lever) in order to pressurize a fluid (e.g., atmospheric air, process fluid, etc.).

[0069] In some examples, similar to the system 100, the system 1100 may generate movement in the piston 108 based on a position of the shuttle valve 110. For example, when high pressure fluid is routed into the first volume 125 and the second volume 135 is vented to low pressure, the piston 108 may move in the direction shown by arrow 1140. In some examples, the piston 108 may be mechanically connected to a second piston 1145 via a lever 1125. In some examples, the second piston 1145 may include a first diaphragm 1105 and a second diaphragm 1110 secured together via a second piston rod 1135. Further, in some examples, the lever 1125 may be connected at a first end to a first piston rod 1130 extending from the piston 108 and at a second end to the second piston rod 1135. Thus, as the piston 108 moves in the direction shown by arrow 1140, the second piston 1145 may move in the direction shown by arrow 1150. As a result, fluid may be expelled from a second chamber 1115 formed by the second diaphragm 1110 (e.g., out of a port 1120 in fluid communication with the atmosphere). Correspondingly, fluid may be drawn into a first chamber 1155 formed by the first diaphragm 1105 through the inlet port 148 (e.g., including the first check valve 140).

[0070] In some examples, the shuttle valve 110 may then switch positions (e.g., from the first position 185 to the second position 187), which may route high pressure fluid into the second volume 135 and vent the first volume 125 to low pressure. As a result, the piston 108 may move in the direction shown by arrow 1150. In some examples, as the piston 108 moves in the direction shown by arrow 1150, the second piston 1145 may move in the direction shown by arrow 1140. As a result, fluid may be sucked into the second chamber 1115 (e.g., from the atmosphere via the port 1120). Correspondingly, fluid may be pressurized within the first chamber 1155. In some examples, once the fluid within the first chamber 1155 reaches a predetermined pressure, the pressurized fluid may pass out of the outlet port 115 (e.g., including the second check valve 142).

[0071] As should be appreciated, the above described system 1100 may utilize a relatively low differential pressure and the mechanical advantage provided by the lever 1125 to pressurize a fluid. In one particular example, a pressure drop of about 3 PSI across the piston 108 may be able to generate a pressure of about 100 PSI at the outlet port 115.

[0072] FIGS. 12-17 illustrate another example of a process gas driven compressor system 200. In some examples, the system 200 may function similarly to the system 100. However, the system 200 may be in the form of a two-stage compressor system. In some examples, the system 200 may include a compressor body 202 with a generally irregular geometry. It should be appreciated that other body geometries are possible such that the compressor body 202 may be optimized and reshaped with regular or irregular geometry depending on size, pressurization, and other system requirements. Furthermore, the compressor body 202 can be formed from a variety of materials and manufacturing methods, including additive manufacturing (e.g., 3D printing), which can be used to further optimize the geometry of the body 202.

[0073] In some examples, the compressor body 202 may include a high pressure inlet 204, a low pressure inlet 206, a first piston cavity 210, and a shuttle valve cavity 212. The high pressure inlet 204 is in communication with a high pressure line 216 and the low pressure inlet 206 is in communication with a low pressure line 218. In some examples, one or more shuttle valve signal lines (e.g., a first shuttle valve signal line 222 and a second shuttle valve signal line 225) are used to communicate pressure from the first piston cavity 210 to the shuttle valve cavity 212 during operation. As will be described below, first and second transfer lines 224, 226 can transfer high and low pressure fluid from the high and low pressure inlets 204, 206 depending on the positions of a piston 230 in the piston cavity 210 and a shuttle valve 254 in the shuttle valve cavity 212.

[0074] FIGS. 13-15 illustrate an example of the piston 230 that can be included in the compressor system 200. In some examples, the piston 230 includes a piston body 232 with a first piston stem 234 and a second piston stem 238 extending away from opposing sides of the piston body 232. In some examples, as the system 200 is a two-stage compressor system, the first stem 234 may include a first pressurization surface 236 and the second stem 238 may include a second pressurization surface 240. The pressurization surfaces 236, 240 may be disposed on opposite axial ends of the piston body 232 and generally provide first and second stages of compression, respectively, within the compressor system 200. The piston body 232 also includes first and second piston heads 242, 244 separated by a piston core 246.

[0075] In some examples, the first piston head 242 includes a first circumferential groove 243 and the second piston head 244 includes a second circumferential groove 245. In some examples, each of the first and second heads 242, 244 include respective first and second communication ports 248, 250 extending therethrough. In some examples, the first communication port 248 can extend from an exterior surface of the second head 244, through the core 246, and into the first circumferential groove 243 of the first head 242. Correspondingly, the second communication port 250 can extend from an exterior surface of the first head 242, through the core 246, and into the second circumferential groove 245 of the second head 244. In some examples, the ports 248, 250 can permit fluid communication between the piston cavity 210 and the shuttle valve cavity 212 via the shuttle valve signal lines 222, 225.

[0076] During use of the system 200, the piston 230 may move axially back and forth within the piston cavity 210 in order to pressurize a fluid. In general, in the two-stage system, discharged pressure from the first stage goes into the inlet of the second stage to thereby increase the outlet pressure. Thus, the compressor system 200 can be used to reinject relatively high pressure fluid into a fluid system without having to vent residual fluid to the atmosphere or other vessel. For example, the first pressurization surface 236 can pressurize fluid within the compressor body 202 in a first compression chamber 305 at a first stage of compression. The pressurized fluid can then travel, via a pressure passageway 260 to a second compression chamber 310, where the second pressurization surface 236 can further increase the pressure at a second stage of compression. Following pressurization of the fluid within the second compression chamber 310, the fluid may travel out of an outlet port 315 (e.g., once at a predetermined pressure set by a check valve, etc.).

[0077] In use, the piston 230 can receive pressurized fluid on the right side of the first head 242 via the first transfer line 224 or on the left side of the second head 244 via the second transfer line 226 (with respect to the orientation shown in FIG. 16). Additionally, the second communication port 250 (see FIG. 15) can communicate pressure applied at the right side of the first head 242 to the second circumferential groove 245. Accordingly, when the piston 230 has traveled leftward sufficiently under pressure on the first head 242, so that the second circumferential groove 245 is aligned with the shuttle valve signal line 222, the higher the pressure applied at the right side of the first head 242 can be transmitted to left side of the shuttle valve cavity 212. This higher pressure can thus move the shuttle valve 254 to the right (in the orientation shown) based on the position of the piston 230. Moving the shuttle valve 254 to the right then routes higher pressure to the left side of the second head 244 to drive the piston 230 back to the right (as similarly discussed above).

[0078] In this regard, similarly, the first communication port 248 (see FIG. 15) can communicate pressure applied at the left surface of the second head 244 to the first circumferential groove 243. When the first circumferential groove 243 is aligned with the shuttle valve signal line 225 (see also FIG. 17), the pressure applied at the left surface of the second head 244 can be transmitted to the shuttle valve cavity 212 to move the shuttle valve 254 in the opposite direction and, with reference to preceding discussion, to thus continue reciprocating operation of the piston 230.

[0079] In some examples, based on the position of the shuttle valve 254 (e.g., as discussed above), high pressure fluid from the high pressure inlet 204 can move the piston 230 to the right (with directional reference to FIG. 16), which may compress fluid within the first compression chamber 305 and then vent the compressed fluid from the first compression chamber 305. Similarly, based on the position of the shuttle valve 254, high pressure fluid from the high pressure inlet 204 can also move the piston 230 to the left (with directional reference to FIG. 16), which may compress fluid within the second compression chamber 310 (e.g., as received from the first compression chamber 305) and push the further compressed fluid out of the outlet 315. Correspondingly, motion of the piston 230 to the right may push fluid from the first compression chamber 305 to the second compression chamber 310, and motion of the piston 230 to the left may push pressurized fluid out of the second compression chamber 310 while also drawing new fluid into the first compression chamber 305 via an inlet 320.

[0080] With reference to FIG. 17, in some examples, the compressor body 202 can include auxiliary chambers 268 in communication with the shuttle valve cavity 212. Relatedly, in some examples, a shuttle valve, such as the shuttle valve 254 can include extensions 270 that extend into the auxiliary chambers 268 to block flow from the high pressure inlet 204. As a result, the extensions 270 may mitigate the risk of pressure bleeding into the system. In some examples, to facilitate movement of the shuttle valve (e.g., due to the flow of fluid), the extensions 270 can each include a radial passageway 272 that can fluidly couple the auxiliary chamber 268 to the shuttle valve cavity 212. However, in some examples, the radial passageway 272 may be blocked when the shuttle valve 254 is disposed in the first position 185 or the second position 187 (e.g., as shown in FIG. 17).

[0081] Advantages of the present disclosure provide a fluid pressurization system that uses process fluid that can be reinjected into a pressurized fluid line without requiring venting to the atmosphere. Thus, examples of the disclosed technology can provide an improvement over conventional systems and methods for pressurizing and conserving fluid within a fluid system, such as a system with parallel regulators that may need to be switched during maintenance or other uses where it may be useful to reinject residual fluid into a system rather than vent it to the atmosphere.

[0082] In some implementations, devices or systems disclosed herein can be utilized, manufactured, or installed using methods embodying aspects of the invention. Correspondingly, any description herein of particular features, capabilities, or intended purposes of a device or system is generally intended to include disclosure of a method of using such devices for the intended purposes, a method of otherwise implementing such capabilities, a method of manufacturing relevant components of such a device or system (or the device or system as a whole), and a method of installing disclosed (or otherwise known) components to support such purposes or capabilities. Similarly, unless otherwise indicated or limited, discussion herein of any method of manufacturing or using for a particular device or system, including installing the device or system, is intended to inherently include disclosure, as embodiments of the invention, of the utilized features and implemented capabilities of such device or system.

FURTHER EXAMPLES

[0083] Example 1. A gas-driven compressor system comprising: a compressor body defining a first piston cavity, a second piston cavity, and a shuttle valve cavity; a low pressure port in fluid communication with the first piston cavity, via the shuttle valve cavity, to vent the first piston cavity; a high pressure port in fluid communication with the first piston cavity, via the shuttle valve cavity, to provide pressurized inlet flow to the first piston cavity; a compressor inlet in fluid communication with the second piston cavity; a compressor outlet in fluid communication with the second piston cavity; a shuttle valve movable between a first position and a second position within the shuttle valve cavity; and a piston having: a first head portion movable within the first piston cavity by the pressurized inlet flow; and a second head portion movable within the second piston cavity by the movement of the first head portion within the first piston cavity to compress a fluid in the second piston cavity; the piston fluidly coupling a signal flow from the high pressure port selectively to a first side or a second side of the shuttle valve cavity, depending on a position of the piston, to selectively direct the pressurized inlet flow to the first piston cavity on, respectively, a first side or a second side of the first head portion of the piston to power reciprocating movement of the piston.

[0084] Example 2. The gas-driven compressor system of Example 1, wherein the piston is configured to move in a first direction to draw the fluid into the second piston cavity and in a second direction to compress fluid within the second piston cavity.

[0085] Example 3. The gas-driven compressor system of any one of Examples 1 to 2, wherein the piston defines a first groove and a second groove arranged to fluidly couple the signal flow from the high pressure port selectively to the first side or the second side of the shuttle valve cavity.

[0086] Example 4. The gas-driven compressor system of Example 3, wherein the first groove is aligned with a first shuttle valve signal line when the first head portion of the piston is in a first position in the first piston cavity, and wherein the second groove is aligned with a second shuttle valve signal line when the first head portion of the piston is in a second position in the first piston cavity.

[0087] Example 5. The gas-driven compressor system of any one of Examples 3 to 4, wherein the first groove is spaced axially from the second groove along the piston and the high pressure port is in communication with the piston along: a first inlet signal line arranged to pressurize the first groove when the first head portion of the piston is at a first end of the first piston cavity; and a second inlet signal line arranged to pressurize the second groove when the first head portion of the piston is at a second end of the first piston cavity.

[0088] Example 6. The gas-driven compressor system of any one of Examples 3 to 5, wherein the first and second grooves are included on the second head portion of the piston.

[0089] Example 7. The gas-driven compressor system of any one of Examples 1 to 6, further comprising: a lever that couples the first head portion to the second head portion.

[0090] Example 8. The gas-driven compressor system of any one of Examples 1 to 7, wherein the first head portion of the piston separates the first piston cavity into a first volume and a second volume; wherein the shuttle valve in the first position provides the pressurized inlet flow to the first volume and vents the second volume to the low pressure port, to move the piston in a first direction; and wherein the shuttle valve in the second position provides the pressurized inlet flow to the second volume and vents the first volume to the low pressure port, to move the piston in a second, opposite direction.

[0091] Example 9. A method of compressing a fluid using a process gas driven compressor, comprising: providing a high pressure port of a compressor body in communication with a first pressure; providing a low pressure port of the compressor body in communication with a second pressure; and moving a first piston with reciprocating movement within a first piston cavity, by moving a shuttle valve in response to a pressure differential between the high pressure port and the low pressure port, the movement of the shuttle valve selectively directing pressurized fluid from the high pressure port to opposite sides of the first piston within the first piston cavity, dependent on a position of a piston assembly that includes the first piston; the movement of the first piston moving a second piston of the piston assembly with reciprocating movement in a second piston cavity to compress a fluid within the second piston cavity.

[0092] Example 10. The method of Example 9, further comprising: aligning a first circumferential groove of the piston assembly with a first shuttle valve signal line when the piston assembly is in a first position, to direct the pressurized fluid from the high pressure port to a first side of the shuttle valve, to move the shuttle valve from a first position to a second position; and aligning a second circumferential groove of the piston assembly with a second shuttle valve signal line when the piston assembly is in the second position, to direct high pressure fluid to a second side of the shuttle valve to move the shuttle valve from the second position back to the first position.

[0093] Example 11. The method of any one of Examples 9 to 10, further comprising: discharging the compressed fluid from the second piston cavity, through a compressor outlet port, when the compressed fluid reaches a predetermined threshold pressure.

[0094] Example 12. The method of any one of Examples 9 to 11, further comprising: selectively blocking, with the piston assembly, fluid connection between the high pressure port and shuttle valve signal lines during the reciprocating movement of the first and second pistons.

[0095] Example 13. The method of any one of Examples 9 to 12, wherein drawing fluid into the second piston cavity includes: drawing fluid through an inlet port and a first check valve into the second piston cavity during movement of the piston from the first position to the second position.

[0096] Example 14. The method of any one of Examples 9 to 13, wherein the fluid compressed in the second piston cavity is further compressed in a second stage compression by the reciprocating movement of the piston assembly.

[0097] Example 15. The method of Example 14, wherein the reciprocating movement of the piston assembly directs the compressed fluid from the second piston cavity to a third piston cavity to be compressed by the reciprocating movement of the piston assembly.

[0098] Example 16. A gas-driven compressor system, comprising: a high pressure port; a low pressure port; a piston assembly, including: a first piston movable within a first piston cavity in response to a pressure differential between the high pressure port and the lower pressure port; and a second piston moveable within a second piston cavity by movement of the first piston, to compress a fluid in the second piston cavity; and a shuttle valve movable between a first position and a second position in response to the pressure differential between the high pressure port and the low pressure port to cause reciprocating movement of the piston assembly by selectively directing pressurized fluid from the high pressure port to opposite sides of the first piston, dependent on a position of the piston assembly.

[0099] Example 17. The gas-driven compressor system of Example 16, further comprising: a lever mechanically coupled between the first piston and the second position to multiply a force applied by the first piston to the second piston.

[0100] Example 18. The gas-driven compressor system of any one of Examples 16 to 17, wherein the shuttle valve including extensions at opposing ends that extend into corresponding extensions of a shuttle valve cavity to selectively block flow from one or more signal lines into the shuttle valve cavity.

[0101] Example 19. The gas-driven compressor system of any one of Examples 16 to 18, wherein the second piston includes a first diaphragm, and a second diaphragm secured together by a piston rod.

[0102] Example 20. The gas-driven compressor system of Example 19, wherein the first diaphragm forms a first chamber including an inlet port and an outlet port, and wherein the second diaphragm forms a second chamber including a port open to the atmosphere.

[0103] Unless otherwise specified or limited, the terms about and approximately, as used herein with respect to a reference value, refer to variations from the reference value of 15% or less, inclusive of the endpoints of the range. Similarly, the term substantially, as used herein with respect to a reference value, refers to variations from the reference value of 5% or less, inclusive of the endpoints of the range.

[0104] Also as used herein with respect to clamped systems, unless otherwise specified or limited, axial is used to refer to a clamping direction and radial is used to refer to directions that are perpendicular to the clamping direction. Thus, for example, in a system applying a vertical clamp force to hold together a heater assembly and a clamp subassembly, an axial direction is parallel to the vertical direction and radial directions are parallel to horizontal.

[0105] Also as used herein, unless otherwise limited or defined, or indicates a non-exclusive list of components or operations that can be present in any variety of combinations, rather than an exclusive list of components that can be present only as alternatives to each other. For example, a list of A, B, or C indicates options of: A; B; C; A and B; A and C; B and C; and A, B, and C. Correspondingly, the term or as used herein is intended to indicate exclusive alternatives only when preceded by terms of exclusivity, such as either, one of, only one of, or exactly one of. For example, a list of one of A, B, or C indicates options of: A, but not B and C; B, but not A and C; and C, but not A and B. A list preceded by one or more (and variations thereon) and including or to separate listed elements indicates options of one or more of any or all of the listed elements. For example, the phrases one or more of A, B, or C and at least one of A, B, or C indicate options of: one or more A; one or more B; one or more C; one or more A and one or more B; one or more B and one or more C; one or more A and one or more C; and one or more of A, one or more of B, and one or more of C. Similarly, a list preceded by a plurality of (and variations thereon) and including or to separate listed elements indicates options of multiple instances of any or all of the listed elements. For example, the phrases a plurality of A, B, or C and two or more of A, B, or C indicate options of: A and B; B and C; A and C; and A, B, and C.

[0106] Also as used herein, unless otherwise defined or limited, directional terms are used for convenience of reference for discussion of particular figures or examples or to indicate spatial relationships relative to particular other components or context, but are not intended to indicate absolute orientation. For example, references to downward, forward, or other directions, or to top, rear, or other positions (or features) may be used to discuss aspects of a particular example or figure, but do not necessarily require similar orientation or geometry in all installations or configurations.

[0107] Also as used herein, unless otherwise limited or defined, configured to indicates that a component, system, or module is particularly adapted for the associated functionality. Thus, for example, a ZZ configured to YY is specifically adapted to YY, as opposed to merely being generally capable of doing so.

[0108] The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the invention. Given the benefit of this disclosure, various modifications to these embodiments will be readily apparent to those skilled in the art, and the principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.