Reconfigurable multi-stage gas compressor

Abstract

Disclosed embodiments include a reconfigurable multi-stage gas compressor having a first-stage compression cylinder, a second-stage compression cylinder, and two stepped cylinders. Each of the stepped cylinders include first and second compression cylinders. The gas flow paths through the stepped cylinders are configured in a user-selectable configuration to be in series or in parallel so that the reconfigurable multi-stage gas compressor functions as one of: a three-stage compressor, as a four-stage compressor, and as a hybrid three/four stage compressor. In first and second configurations, the system generates four stages of compression and outputs 4-stage compressed gas through a single exit port, and through dual exit ports, respectively. In a third configuration, the system outputs hot and cooled 3-stage compressed gas through first and second ports and 4-stage compressed gas through a third port. In a fourth configuration, the system outputs hot and cooled 3-stage compressed gas with no 4-stage compressed gas.

1 . A method of operating a reconfigurable multi-stage gas compressor system, the multi-stage gas compressor system comprising a first-stage compression cylinder, a second-stage compression cylinder, and two stepped cylinders, each stepped cylinder having first and second compression cylinders, the method comprising:
 generating, by the first-stage compression cylinder, a first-stage compressed gas from an inlet gas;   generating, by the second-stage cylinder, a second-stage compressed gas from the first-stage compressed gas;   feeding at least a first portion the second-stage compressed gas in parallel to at least to first compression cylinders of the two stepped cylinders; and   compressing, the second-stage compressed gas received by the first compression cylinders of the two stepped cylinders to generate a third-stage compressed gas from the second-stage compressed gas; and   configuring gas flow paths through second compression cylinders of the stepped cylinders in a series or parallel configuration with the first compression cylinders of the two stepped cylinders such that the multi-stage gas compressor functions as one of: a three stage compressor; as a four stage compressor; and as a hybrid three/four stage compressor.   
     
     
         2 . The method of  claim 1 , further comprising:
 configuring gas flow paths to flow through second compression cylinders of the stepped cylinders in a series configuration with the first compression cylinders, comprising:   feeding the third-stage compressed gas output from the first compression cylinders of the two stepped cylinders to the second compression cylinders of the two stepped cylinders; and   generating, by the second compression cylinders of the stepped cylinders, a fourth-stage compressed gas from the third-stage compressed gas.   
     
     
         3 . The method of  claim 2 , further comprising:
 causing the fourth-stage compressed gas to exit the system through a single discharge outlet.   
     
     
         4 . The method of  claim 2 , further comprising:
 causing the fourth-stage compressed gas to exit the system through dual discharge outlets.   
     
     
         5 . The method of  claim 2 , further comprising:
 causing a portion of the third-stage compressed gas to exit the system through a first discharge outlet; and   causing the fourth-stage gas to exit the system through a second discharge outlet.   
     
     
         6 . The method of  claim 2 , further comprising:
 cooling the first-stage compressed gas, the second-stage compressed gas, and a first portion of the third-stage compressed gas using respective first, second, and third coolers.   
     
     
         7 . The method of  claim 6 , further comprising:
 processing the cooled first-stage compressed gas, the cooled second-stage compressed gas, and the cooled first portion of the third-stage compressed gas using respective first, second, and third scrubbers.   
     
     
         8 . The method of  claim 6 , further comprising:
 causing the fourth-stage compressed gas to exit the system through a first discharge outlet;   causing the first portion of cooled third-stage compressed gas to exit the system through a second discharge outlet; and   causing a second portion of uncooled third-stage compressed gas to exit the system through a third discharge outlet.   
     
     
         9 . The method of  claim 1 , further comprising:
 configuring gas flow paths to flow through second compression cylinders of the stepped cylinders in a parallel configuration with the first compression cylinders;   feeding the first portion of the second-stage compressed gas to the respective first compression cylinders;   feeding a second portion of the second-stage compressed gas to the respective second compression cylinders of the two stepped cylinders; and   generating, by the respective second compression cylinders of the stepped cylinders, a second portion of third-stage compressed gas from the second portion of the second-stage compressed gas.   
     
     
         10 . The method of  claim 9 , further comprising:
 cooling the first portion of the third-stage compressed gas;   causing the cooled first portion of the third-stage compressed gas to exit the system through a first discharge outlet; and   causing the uncooled second portion of third-stage compressed gas to exit the system through a second discharge outlet.   
     
     
         11 . The method of  claim 1 , further comprising:
 configuring gas flow paths to flow through the second compression cylinders of the stepped cylinders in a series and parallel configuration with the first compression cylinders;   feeding the first portion of the second-stage compressed gas to the first compression cylinders of the two stepped cylinders;   feeding a second portion of the second-stage compressed gas to one of the second compression cylinders of the two stepped cylinders; and   generating, by the first compression cylinders and the one of the second compression cylinders the third-stage compressed gas from the second-stage compressed gas;   feeding a portion of the third-stage compressed gas to the other of the second compression cylinders of the two stepped cylinders; and   generating, by the other of the second compression cylinders, a fourth-stage compressed gas from the portion of the third-stage compressed gas.   
     
     
         12 . The method of  claim 11 , further comprising:
 cooling at least a portion of the third-stage compressed gas;   causing the cooled first portion of the third-stage compressed gas to exit the system through a first discharge outlet; and   causing an uncooled second portion of third-stage compressed gas to exit the system through a second discharge outlet.   causing the fourth-stage compressed gas to exit the system through a third discharge outlet.   
     
     
         13 . A method of operating a reconfigurable multi-stage gas compressor system, the multi-stage gas compressor system comprising a first-stage compression cylinder, a second-stage compression cylinder, a first stepped cylinder having a first larger bore stage and a first smaller bore stage, a second stepped cylinder having a second larger bore stage and a second smaller bore stage larger, a first plumbing line fluidly connecting inlets of all bore stages, a second plumbing line fluidly connecting outlets of all the bore stages, and a plurality of valves in the first and second plumbing lines for selecting connecting and isolating one or more of the bore stages, the method comprising:
 generating, by the first-stage compression cylinder, a first-stage compressed gas from an inlet gas;   generating, by the second-stage cylinder, a second-stage compressed gas from the first-stage compressed gas;   feeding at least a first portion the second-stage compressed gas in parallel to at least to the first and second larger bore stages of the first and second stepped cylinders; and   selectively setting the plurality valves to control flow paths through the first and second plumbing lines such that the smaller bore stages are in a series, parallel or series and parallel configuration with the larger bore stages of the two stepped cylinders such that the multi-stage gas compressor functions as one of: a four stage compressor generating fourth-stage compressed gas; as a three-stage compressor generating third-stage compressed gas; and as a hybrid three/four stage compressor generating third-stage compressed gas and fourth-stage compressed gas, respectively.   
     
     
         14 . The method of  claim 13 , further comprising:
 configuring the plurality of valves to cause the flow paths to flow through the smaller stage bores of the stepped cylinders in a series configuration with the larger stage bores compression cylinders, comprising:   feeding third-stage compressed gas output from the larger stage bores of the two stepped cylinders to the smaller stage bores of the two stepped cylinders; and   generating, by the smaller stage bores of the stepped cylinders, a fourth-stage compressed gas from the third-stage compressed gas.   
     
     
         15 . The method of  claim 14 , further comprising:
 causing a portion of the third-stage compressed gas to exit the system through a first discharge outlet; and   causing the fourth-stage gas to exit the system through a second discharge outlet.   
     
     
         16 . The method of  claim 14 , further comprising:
 causing the fourth-stage compressed gas to exit the system through dual discharge outlets.   
     
     
         17 . The method of  claim 13 , further comprising:
 configuring the plurality of valves to cause the flow paths to flow through the smaller stage bores of the stepped cylinders in a parallel configuration with the larger stage bores of the stepped cylinders;   feeding a first portion of the second-stage compressed gas to the larger stage bores of the stepped cylinders;   feeding a second portion of the second-stage compressed gas to the smaller stage bores of the stepped cylinders; and   generating, by the larger stage bores and the smaller stage bores third-stage compressed gas from the first and second portions of the second-stage compressed gas.   
     
     
         18 . The method of  claim 9 , further comprising:
 cooling a first portion of the third-stage compressed gas;   causing the cooled first portion of the third-stage compressed gas to exit the system through a first discharge outlet; and   causing an uncooled second portion of third-stage compressed gas to exit the system through a second discharge outlet.   
     
     
         19 . The method of  claim 13 , further comprising:
 configuring the plurality of valves to cause the flow paths to flow through the smaller bore stages of the stepped cylinders in a series and parallel configuration with the larger bore stages;   feeding a first portion of the second-stage compressed gas to the larger bore stages of the stepped cylinders;   feeding a second portion of the second-stage compressed gas to one of the smaller bore stages of the stepped cylinders; and   generating, by the larger bore stages and the one of the smaller bore stages third-stage compressed gas from the second-stage compressed gas;   feeding a portion of the third-stage compressed gas to the other of the smaller bore stages of the stepped cylinders; and   generating, by the other of the smaller bore stages, a fourth-stage compressed gas from the portion of the third-stage compressed gas.   
     
     
         20 . The method of  claim 19 , further comprising:
 cooling at least a portion of the third-stage compressed gas;   causing the cooled first portion of the third-stage compressed gas to exit the system through a first discharge outlet; and   causing an uncooled portion of third-stage compressed gas to exit the system through a second discharge outlet.   causing the fourth-stage compressed gas to exit the system through a third discharge outlet.