Patent Publication Number: US-2023135006-A1

Title: Electric oil field container package

Description:
BACKGROUND 
     Field 
     The present disclosure is generally related to portable air compressors, and more specifically, to an electric oil field container package involving portable air compressors. 
     Related Art 
     In the related art, there are high flow diesel driven compressor packages that are utilized in oil fields or offshore drilling applications. Oil field and offshore drilling applications require large amounts of compressed air which is currently met by arranging large arrays of such diesel driven compressor packages, which involve individual portable diesel driven compressors provided for transport. 
     However, oil field and offshore drilling sites have specific sound and space constraints due to their location. An offshore drilling site or a remote oil field may have limited space for placement of such portable air compressors. Further, thermal management may also be a problem due to the limited space constraints as air compressors may generate excessive heat while in operation. 
     Additionally, maintenance costs and downtime are of concern for such portable air compressors. As oil fields and offshore drilling sites may be in remote locations, available maintenance for such portable air compressors are limited and often a lengthy process, and any downtime resulting from the need to conduct maintenance on such air compressors can result in reduction or loss of production of oil or gas. 
     SUMMARY 
     The subject invention is a system of electrically powered high flow compressors packaged in a standardized container footprint suitable for oil field and offshore applications. The packaged solution involves of multiple independent air compressors packaged in one container. 
     Through the proposed portable container package with multiple air compressors, the example implementations can address various aspects of the related art diesel compressor systems. The replacement of a diesel engine with an electric motor reduces the heat load and the sound level, and eliminates the maintenance costs and downtime associated with a diesel engine. The electric motor implementation along with the orientation of the air compressors in opposing directions as described herein result in improved reliability in comparison to diesel engine implementations, as well as higher power density. Through the portable container footprint and arrangement of multiple compressor systems within the footprint, it is possible to achieve 40-100% more flow than the related art diesel compressor solutions. Aspects of the present disclosure involve a portable container package, which can include a first air compressor that involves a first cooler disposed at one end of the portable container package; and a first electric motor oriented in a first direction; and a second air compressor involving a second cooler disposed at an opposite end to the one end of the portable container package; and a second electric motor oriented in a second direction opposite to the first direction. 
     Aspects of the present disclosure involve a system, involving a first air compressor installed in a portable container package, the first air compressor including a first cooler disposed at one end of the portable container package; and a first electric motor oriented in a first direction; and a second air compressor installed in the portable container package, the second air compressor involving a second cooler disposed at an opposite end to the one end of the portable container package; and a second electric motor oriented in a second direction opposite to the first direction. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       A general architecture that implements the various features of the disclosure will now be described with reference to the drawings. The drawings and the associated descriptions are provided to illustrate example implementations of the disclosure and not to limit the scope of the disclosure. Throughout the drawings, reference numbers are reused to indicate correspondence between referenced elements. 
         FIG.  1    illustrates an example air compressor, in accordance with an example implementation. 
         FIG.  2    illustrates an example view of a compressor cooling system, in accordance with an example implementation. 
         FIG.  3    illustrates an example of multiple air compressors integrated into a container package, in accordance with an example implementation. 
         FIG.  4    illustrates a simplified block diagram of the air compressor system and further involving one or more baffles, in accordance with another example implementation. 
         FIG.  5    illustrates an example portable container package, in accordance with an example implementation. 
         FIG.  6    illustrates a system involving a plurality of portable container packages networked to a management apparatus, in accordance with an example implementation. 
         FIG.  7    illustrates an example computing environment with an example computer device suitable for use in some example implementations 
     
    
    
     DETAILED DESCRIPTION 
     The following detailed description provides further details of the figures and example implementations of the present application. Reference numerals and descriptions of redundant elements between figures are omitted for clarity. Terms used throughout the description are provided as examples and are not intended to be limiting. For example, the use of the term “automatic” may involve fully automatic or semi-automatic implementations involving user or operator control over certain aspects of the implementation, depending on the desired implementation of one of ordinary skill in the art practicing implementations of the present application. Further, sequential terminology, such as “first”, “second”, “third”, etc., may be used in the description and claims simply for labeling purposes and should not be limited to referring to described actions or items occurring in the described sequence. Actions or items may be ordered into a different sequence or may be performed in parallel or dynamically, without departing from the scope of the present application. 
     Example implementations described herein involve a portable compressor package contained within a portable container footprint (e.g., standard shipping container) and is suitable for use across multiple industries. The portable container is designed to accommodate standard shipping and handling methods and certifications. Each portable compressor package contains a plurality of independent compressor systems. Flows from the multiple systems are combined to deliver a high flow of compressed air. Each independent compressor system is to contain a main electric motor to drive the compressor air-end, air/oil separation system, cooling/lubrication system including electrically driven fan, air discharge system, air intake system, mechanical control systems and electrical control system. 
     Orientation of the independent systems is arranged to manage and optimize cooling airflow, temperatures, sound and performance. Further, an internal baffle system may be used to manage internal airflows. 
     The electrical control system is designed to operate all independent systems from a single user interface. In addition, the control system is capable to control and sequence multiple compressors in an installation to optimally control flow and energy usage. Furthermore, the control system can be remotely controlled to reduce the number of operators required to manage multiple machines in an installation. 
       FIG.  1    illustrates an example configuration of an air compressor, in accordance with an example implementation. Example components of an air compressor can include, but are not limited to an engine motor  19 , compressor cooling system  15 , receiver tank  16 , and instrument panel/on board computer  1 , which can be interconnected by an electrical system. Depending on the desired implementation, the compressor can also be supplied with sound deadening insulation to lower noise emissions to meet specified requirements. 
     The compressor cooling system  15  can involve components such as a radiator, high capacity fan, and thermostats. The high capacity fan draws air through the radiator, keeping the engine motor  19  at the desired operating temperature. The same fan also cools the fluid in the compressor cooling system  15 . While passing through the radiator, the fan air also passes through the compressor fluid cooler. As air passes through the cooler, the heat of compression is removed from the fluid. The same fan also cools the engine intake air supply. While passing through the radiator, the fan air passes through an air to air aftercooler. As air passes through the air to air aftercooler, heat is removed from the engine motor  19 . 
     In example implementations of an air compressor, fluid is injected into the compressor unit and mixes directly with the air as the rotors turn, compressing the air. The fluid flow has several functions. As coolant, the fluid flow controls the rise of air temperature normally associated with the heat of compression. The fluid flow further seals the clearance paths between the rotors and the stator and also between the rotors themselves. The fluid flow also acts as a lubricating film between the rotors allowing one rotor to directly drive the other. 
     After the air/fluid mixture is discharged from the compressor unit, the fluid is separated from the air. At this time, the air flows through an aftercooler and water separator (if equipped) then to a service line while the fluid is being cooled in preparation for reinjection. 
     In example implementations of an air compressor, the air compressor discharges compressed air/fluid mixture into the receiver tank  16 . The receiver tank  16  has several functions including acting as a primary fluid separator, serving as the compressor fluid storage sump and housing the final fluid separator. 
     The compressed air/fluid mixture enters the receiver tank  16  and is directed against the tank side wall. By change of direction and reduction of velocity, large droplets of fluid separate and fall to the bottom of the receiver tank. The fractional percentage of fluid remaining in the compressed air collects on the surface of the final separator element as the compressed air flows through the separator. As more and more fluid collects on the element&#39;s surface, the fluid descends to the bottom of the separator. A return line (or scavenge tube) leads from the bottom of the separator element to the inlet region of the air compressor. Fluid collecting on the bottom of the separator element is returned to the compressor by the pressure difference between the area surrounding the separator element and the compressor inlet. 
       FIG.  2    illustrates an example view of a compressor cooling system, in accordance with an example implementation. The compressor cooling system  15  is configured to provide adequate lubrication as well as maintain the proper operating temperature of the compressor. Example components of a cooling system  15  can involve a compressor fluid filter  21 , a thermal valve  22 , a stop valve  23 , a cooler  24  and a separator tank  25 , in addition to a fan system (not illustrated). Arrows indicate an example of direction of fluid flow within the compressor cooling system. 
     In example air compressors, fluid is used in the system as a coolant and a lubricant. The fluid is housed in the receiver tank  16 . Upon start-up, the temperature of the fluid is cool. The fluid, taking the path of least resistance, flows to the thermal valve  22 . The fluid first enters the thermal valve  22  and then flows to the compressor unit, bypassing the cooler  24 . As the compressor continues to operate, the temperature of the fluid rises and the thermal valve element begins to shift. This forces a portion of the fluid to the fluid cooler. The cooler is a radiator-type that works in conjunction with the engine fan. The fan draws air through the cooler removing the heat of compression from the fluid. From the cooler, the fluid is routed back to the thermal valve. Before the temperature of the fluid reaches the valve set point, cooled fluid is mixed with warmer fluid. When the temperature of the fluid reaches a certain desired implementation (e.g., such as 230° F. (110° C.)), the thermal element shifts completely causing all fluid to flow to the cooler  24 . The thermal valve  22  incorporates a pressure relief valve, which allows fluid to bypass the cooler  24 , if the cooler becomes plugged or frozen. This helps assure that fluid will continue to be provided to the compressor for lubrication. After the fluid passes through the thermal valve  22  it is then directed through the main fluid filter  21 . There, the fluid is filtered in preparation for injection into the compression chamber and bearings of the air compressor. The filter  21  has a replaceable element and a built-in bypass valve which allows the fluid to flow even when the filter element becomes plugged and requires changing or when the viscosity of the fluid is too high for adequate flow. After the fluid is properly filtered, it then flows on to the compressor unit where it lubricates, seals and cools the compression chamber as well as lubricates the bearings and gears. 
     The fluid stop valve  23  functions on shutdown when it shuts off the fluid supply to the compressor unit. The fluid stop valve  23  is held open by a pressure signal from the compressor discharge. At shutdown, the pressure signal is lost and the fluid stop valve  23  closes, isolating the compressor unit from the cooling system. 
     The above description illustrates an example configuration and components of an air compressor, however the components and configuration of the air compressor can be modified to apply to the desired implementation. 
       FIG.  3    illustrates an example of multiple air compressors integrated into a container package, in accordance with an example implementation. Specifically,  FIG.  3    illustrates an example top view of a portable container package integrating multiple air compressors in accordance with an example implementation. To address the issues of the related art air compressor systems while providing a configuration that is suitable for oil field and oil platform use, example implementations describe herein integrate various components of the air compressor systems as illustrated in  FIG.  1    and  FIG.  2    into a portable container package  300  in a side-by-side configuration. In example implementations, the air compressors systems are arranged such that the layout of the air inlet system  32 , motor  30 , and compressor coolant system  31  in opposite orientations/directions in the side-by-side configuration. Through such a configuration, the air intake of each air compressor system flows along the orientation direction of the motor  30  and towards the compressor coolant system  31 . 
     In the example configuration illustrated in  FIG.  3   , the motors  30  are electric motors instead of the related art diesel engines to reduce the size of the compressor within the portable container package. The use of electric motors  30  reduces the heat load and the sound level of the air compressor, and eliminates the maintenance costs and downtime associated with a diesel engine. To further facilitate reduction of size within the portable container package, a split cooler system is utilized for the compressor coolant system  31 , with the coolant systems  31  integrated on opposite ends of the container package  300 . Through this configuration, multiple air compressors can be compactly integrated within a portable container package in contrast to related art air compressor systems that integrate only one singular diesel engine system within a container. As multiple air compressors are integrated within the container package, the power density of the air compressor system as integrated in the container package can thereby be increased while obtaining 40-100% more flow than related art diesel compressor solutions through the layout and orientation of the multiple air inlet systems  32 . 
       FIG.  4    illustrates a simplified block diagram of the portable container package  400  with air compressors and further involving one or more baffles, in accordance with another example implementation. In an example configuration of the portable container package  400  with air compressors, there is a first air compressor oriented towards one end of the container package  400 , and a second air compressor arranged in a side-by-side configuration with the first air compressor and oriented towards the opposite end of the container package  400 . As illustrated in  FIG.  4   , the first air compressor is oriented such that the cooler  403 - 1  is disposed on one end of the portable container package  400 , and the electric motor  401 - 1  is oriented accordingly. To integrate the first air compressor into the container package  400 , an electric motor  401 - 1  and a split cooler  403 - 1  is utilized with a fan to reduce the footprint of the air compressor. Depending on the desired implementation, the split cooler  403 - 1  and  403 - 2  can also be in the form of a water cooler to facilitate water cooling instead of air cooling. 
     Similarly, the second air compressor is oriented in the opposite direction of the first air compressor, such that the split cooler  403 - 2  is disposed on the opposite end of the container package  400 , and the electric motor  401 - 2  is similarly oriented. 
     In an example implementation, the first air compressor takes in air from an air inlet such that cooling air flow is provided through the container  400  from one side into the first air compressor in the direction as shown by the arrow  402 - 1 . The second air compressor takes in air from an air inlet such that cooling air flow is provided through the container  400  from the opposite side of the inlet of the first air compressor, such that cooling air flow is provided into the second air compressor in the direction as shown by the arrow  402 - 2 . Further, additional air inlets  404 - 1  and  404 - 2  can be utilized to draw in air from the primary air inlet to be provided to the opposite air compressor, as shown by the bolded and transparent arrows in  FIG.  4   . 
     To separate the air compressor units, one or more baffles  405  can be provided within the interior of the container  400  to prevent air flow from crossing between air compressors outside of the air inlets  404 - 1 ,  404 - 2 . The one or more baffles  405  can be any kind of physical barrier (e.g., metallic wall made of the same material as the container package  400 ) disposed within the container and separating the air compressor and can be made with any material in accordance with the desired implementation. 
       FIG.  5    illustrates an example exterior view of the portable container package, in accordance with an example implementation. As illustrated in  FIG.  5   , the footprint for the portable container package can involve a substantially rectangular standardized container footprint, with one or more air vents  500  disposed about the exterior of the portable container package to facilitate air intake by the multiple air compressors. Each side of the portable container package can include air vents which can integrated into the structure of the portable container package itself, or can be detachable depending on the desired implementation. 
     Through the integration of the multiple air compressors within the portable container package as illustrated in  FIG.  5   , the example implementations described herein can be made portable and stackable for use in environments with limited space, such as oil fields and oil rigs. Multiple air compressors can thereby be stacked on top of each other for shipment, storage, and use, and transported through standard transportation methods such as by truck or by ship. Other shapes of container packages such as cylindrical containers (e.g. as integrated into a shipping truck) can also be utilized in accordance with the desired implementation, and the present disclosure is not limited thereto. 
       FIG.  6    illustrates a system involving a plurality of portable container packages networked to a management apparatus, in accordance with an example implementation. One or more portable container packages integrated with multiple air compressors  601  are communicatively coupled to a network  600  (e.g., local area network (LAN), wide area network (WAN)) through the corresponding on-board computer of the air compressor  601 , which is connected to a management apparatus  602 . The management apparatus  602  manages a database  603 , which contains historical data collected from the air compressors from each of the portable container packages  601  and also facilitates remote control to each of the air compressors contained in the portable container packages  601 . In alternate example implementations, the data from the air compressors can be stored to a central repository or central database such as proprietary databases that intake data from air compressors, or systems such as enterprise resource planning systems, and the management apparatus  602  can access or retrieve the data from the central repository or central database. 
       FIG.  7    illustrates an example computing environment with an example computer device suitable for use in some example implementations, such as a management apparatus  602  as illustrated in  FIG.  6   , or as an on-board computer  1  as illustrated in  FIG.  1   . Computer device  705  in computing environment  700  can include one or more processing units, cores, or processors  710 , memory  715  (e.g., RAM, ROM, and/or the like), internal storage  720  (e.g., magnetic, optical, solid state storage, and/or organic), and/or I/O interface  725 , any of which can be coupled on a communication mechanism or bus  730  for communicating information or embedded in the computer device  705 . I/O interface  725  is also configured to receive images from cameras or provide images to projectors or displays, depending on the desired implementation. 
     Computer device  705  can be communicatively coupled to input/user interface  735  and output device/interface  740 . Either one or both of input/user interface  735  and output device/interface  740  can be a wired or wireless interface and can be detachable. Input/user interface  735  may include any device, component, sensor, or interface, physical or virtual, that can be used to provide input (e.g., buttons, touch-screen interface, keyboard, a pointing/cursor control, microphone, camera, braille, motion sensor, optical reader, and/or the like). Output device/interface  740  may include a display, television, monitor, printer, speaker, braille, or the like. In some example implementations, input/user interface  735  and output device/interface  740  can be embedded with or physically coupled to the computer device  705 . In other example implementations, other computer devices may function as or provide the functions of input/user interface  735  and output device/interface  740  for a computer device  705 . 
     Examples of computer device  705  may include, but are not limited to, highly mobile devices (e.g., smartphones, devices in vehicles and other machines, devices carried by humans and animals, and the like), mobile devices (e.g., tablets, notebooks, laptops, personal computers, portable televisions, radios, and the like), and devices not designed for mobility (e.g., desktop computers, other computers, information kiosks, televisions with one or more processors embedded therein and/or coupled thereto, radios, and the like). 
     Computer device  705  can be communicatively coupled (e.g., via I/O interface  725 ) to external storage  745  and network  750  for communicating with any number of networked components, devices, and systems, including one or more computer devices of the same or different configuration. Computer device  705  or any connected computer device can be functioning as, providing services of, or referred to as a server, client, thin server, general machine, special-purpose machine, or another label. 
     I/O interface  725  can include, but is not limited to, wired and/or wireless interfaces using any communication or I/O protocols or standards (e.g., Ethernet, 802.11x, Universal System Bus, WiMax, modem, a cellular network protocol, and the like) for communicating information to and/or from at least all the connected components, devices, and network in computing environment  700 . Network  750  can be any network or combination of networks (e.g., the Internet, local area network, wide area network, a telephonic network, a cellular network, satellite network, and the like). 
     Computer device  705  can use and/or communicate using computer-usable or computer-readable media, including transitory media and non-transitory media. Transitory media include transmission media (e.g., metal cables, fiber optics), signals, carrier waves, and the like. Non-transitory media include magnetic media (e.g., disks and tapes), optical media (e.g., CD ROM, digital video disks, Blu-ray disks), solid state media (e.g., RAM, ROM, flash memory, solid-state storage), and other non-volatile storage or memory. 
     Computer device  705  can be used to implement techniques, methods, applications, processes, or computer-executable instructions in some example computing environments. Computer-executable instructions can be retrieved from transitory media, and stored on and retrieved from non-transitory media. The executable instructions can originate from one or more of any programming, scripting, and machine languages (e.g., C, C++, C#, Java, Visual Basic, Python, Perl, JavaScript, and others). 
     Processor(s)  710  can execute under any operating system (OS) (not shown), in a native or virtual environment. One or more applications can be deployed that include logic unit  760 , application programming interface (API) unit  765 , input unit  770 , output unit  775 , and inter-unit communication mechanism  795  for the different units to communicate with each other, with the OS, and with other applications (not shown). The described units and elements can be varied in design, function, configuration, or implementation and are not limited to the descriptions provided. Processor(s)  710  can be in the form of hardware processors such as central processing units (CPUs) or in a combination of hardware and software units. 
     In some example implementations, when information or an execution instruction is received by API unit  765 , it may be communicated to one or more other units (e.g., logic unit  760 , input unit  770 , output unit  775 ). In some instances, logic unit  760  may be configured to control the information flow among the units and direct the services provided by API unit  765 , input unit  770 , output unit  775 , in some example implementations described above. For example, the flow of one or more processes or implementations may be controlled by logic unit  760  alone or in conjunction with API unit  765 . The input unit  770  may be configured to obtain input for the calculations described in the example implementations, and the output unit  775  may be configured to provide output based on the calculations described in example implementations. 
     Processor(s)  710  can be configured to control the air compressors remotely through communication of instructions to a corresponding on-board computer of an air compressor. Such instructions can include, but are not limited to, power down, power up, engaging a maintenance mode, and so on in accordance with a desired implementation. 
     While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed. 
     Some portions of the detailed description are presented in terms of algorithms and symbolic representations of operations within a computer. These algorithmic descriptions and symbolic representations are the means used by those skilled in the data processing arts to convey the essence of their innovations to others skilled in the art. An algorithm is a series of defined steps leading to a desired end state or result. In example implementations, the steps carried out require physical manipulations of tangible quantities for achieving a tangible result. 
     Unless specifically stated otherwise, as apparent from the discussion, it is appreciated that throughout the description, discussions utilizing terms such as “processing,” “computing,” “calculating,” “determining,” “displaying,” or the like, can include the actions and processes of a computer system or other information processing device that manipulates and transforms data represented as physical (electronic) quantities within the computer system&#39;s registers and memories into other data similarly represented as physical quantities within the computer system&#39;s memories or registers or other information storage, transmission or display devices. 
     Example implementations may also relate to an apparatus for performing the operations herein. This apparatus may be specially constructed for the required purposes, or it may include one or more general-purpose computers selectively activated or reconfigured by one or more computer programs. Such computer programs may be stored in a computer readable medium, such as a computer-readable storage medium or a computer-readable signal medium. A computer-readable storage medium may involve tangible mediums such as, but not limited to optical disks, magnetic disks, read-only memories, random access memories, solid state devices and drives, or any other types of tangible or non-transitory media suitable for storing electronic information. A computer readable signal medium may include mediums such as carrier waves. The algorithms and displays presented herein are not inherently related to any particular computer or other apparatus. Computer programs can involve pure software implementations that involve instructions that perform the operations of the desired implementation. 
     Various general-purpose systems may be used with programs and modules in accordance with the examples herein, or it may prove convenient to construct a more specialized apparatus to perform desired method steps. In addition, the example implementations are not described with reference to any particular programming language. It will be appreciated that a variety of programming languages may be used to implement the teachings of the example implementations as described herein. The instructions of the programming language(s) may be executed by one or more processing devices, e.g., central processing units (CPUs), processors, or controllers. 
     As is known in the art, the operations described above can be performed by hardware, software, or some combination of software and hardware. Various aspects of the example implementations may be implemented using circuits and logic devices (hardware), while other aspects may be implemented using instructions stored on a machine-readable medium (software), which if executed by a processor, would cause the processor to perform a method to carry out implementations of the present application. Further, some example implementations of the present application may be performed solely in hardware, whereas other example implementations may be performed solely in software. Moreover, the various functions described can be performed in a single unit, or can be spread across a number of components in any number of ways. When performed by software, the methods may be executed by a processor, such as a general purpose computer, based on instructions stored on a computer-readable medium. If desired, the instructions can be stored on the medium in a compressed and/or encrypted format. 
     The foregoing detailed description has set forth various example implementations of the devices and/or processes via the use of diagrams, schematics, and examples. Insofar as such diagrams, schematics, and examples contain one or more functions and/or operations, each function and/or operation within such diagrams, or examples can be implemented, individually and/or collectively, by a wide range of structures. While certain example implementations have been described, these implementations have been presented by way of example only and are not intended to limit the scope of the protection. Indeed, the novel methods and apparatuses described herein may be embodied in a variety of other forms. Furthermore, various omissions, substitutions and changes in the form of the devices and systems described herein may be made without departing from the spirit of the protection. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the protection.