US20160003558A1 - Fluid processing system, heat exchange sub-system, and an associated method thereof - Google Patents
Fluid processing system, heat exchange sub-system, and an associated method thereof Download PDFInfo
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- US20160003558A1 US20160003558A1 US14/490,096 US201414490096A US2016003558A1 US 20160003558 A1 US20160003558 A1 US 20160003558A1 US 201414490096 A US201414490096 A US 201414490096A US 2016003558 A1 US2016003558 A1 US 2016003558A1
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- Prior art keywords
- fluid
- heat exchange
- condensate
- hot
- liquid
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- 238000012545 processing Methods 0.000 title claims abstract description 38
- 238000000034 method Methods 0.000 title claims description 11
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- 239000007788 liquid Substances 0.000 claims description 24
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- 229930195733 hydrocarbon Natural products 0.000 description 13
- 150000002430 hydrocarbons Chemical class 0.000 description 13
- 239000004215 Carbon black (E152) Substances 0.000 description 11
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- 230000008676 import Effects 0.000 description 4
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- 239000000203 mixture Substances 0.000 description 3
- 238000000926 separation method Methods 0.000 description 3
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- 238000009833 condensation Methods 0.000 description 2
- 230000005494 condensation Effects 0.000 description 2
- 238000006073 displacement reaction Methods 0.000 description 2
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- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
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Images
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D17/00—Radial-flow pumps, e.g. centrifugal pumps; Helico-centrifugal pumps
- F04D17/08—Centrifugal pumps
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
- F28F9/02—Header boxes; End plates
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L3/00—Gaseous fuels; Natural gas; Synthetic natural gas obtained by processes not covered by subclass C10G, C10K; Liquefied petroleum gas
- C10L3/06—Natural gas; Synthetic natural gas obtained by processes not covered by C10G, C10K3/02 or C10K3/04
- C10L3/10—Working-up natural gas or synthetic natural gas
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D19/00—Degasification of liquids
- B01D19/0068—General arrangements, e.g. flowsheets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D19/00—Degasification of liquids
- B01D19/0073—Degasification of liquids by a method not covered by groups B01D19/0005 - B01D19/0042
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L3/00—Gaseous fuels; Natural gas; Synthetic natural gas obtained by processes not covered by subclass C10G, C10K; Liquefied petroleum gas
- C10L3/06—Natural gas; Synthetic natural gas obtained by processes not covered by C10G, C10K3/02 or C10K3/04
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L3/00—Gaseous fuels; Natural gas; Synthetic natural gas obtained by processes not covered by subclass C10G, C10K; Liquefied petroleum gas
- C10L3/06—Natural gas; Synthetic natural gas obtained by processes not covered by C10G, C10K3/02 or C10K3/04
- C10L3/10—Working-up natural gas or synthetic natural gas
- C10L3/101—Removal of contaminants
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/34—Arrangements for separating materials produced by the well
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/34—Arrangements for separating materials produced by the well
- E21B43/36—Underwater separating arrangements
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D25/00—Pumping installations or systems
- F04D25/02—Units comprising pumps and their driving means
- F04D25/06—Units comprising pumps and their driving means the pump being electrically driven
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D25/00—Pumping installations or systems
- F04D25/02—Units comprising pumps and their driving means
- F04D25/06—Units comprising pumps and their driving means the pump being electrically driven
- F04D25/0686—Units comprising pumps and their driving means the pump being electrically driven specially adapted for submerged use
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D29/00—Details, component parts, or accessories
- F04D29/58—Cooling; Heating; Diminishing heat transfer
- F04D29/5806—Cooling the drive system
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D29/00—Details, component parts, or accessories
- F04D29/70—Suction grids; Strainers; Dust separation; Cleaning
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D31/00—Pumping liquids and elastic fluids at the same time
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F15—FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
- F15D—FLUID DYNAMICS, i.e. METHODS OR MEANS FOR INFLUENCING THE FLOW OF GASES OR LIQUIDS
- F15D1/00—Influencing flow of fluids
- F15D1/14—Diverting flow into alternative channels
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F1/00—Tubular elements; Assemblies of tubular elements
Definitions
- the present invention relates to a fluid processing system for deployment in a subsea environment, and more particularly to a heat exchange sub-system used in the fluid processing system.
- Fluid processing systems used in hydrocarbon production in subsea environments typically comprise a heat exchange system disposed upstream relative to a main separator assembly.
- the heat exchange system facilitates temperature reduction of a multiphase fluid (hydrocarbon) being produced from a subsea hydrocarbon reservoir prior to its introduction to the main separator assembly.
- the multiphase fluid is typically a hot mixture of gaseous and liquid components comprising methane, carbon dioxide, hydrogen sulfide and liquid crude oil, and may also contain solid particulates such as sand.
- the main separator assembly separates the gaseous components from the liquid components of the multiphase fluid.
- pipelines are deployed within the subsea environment to move the multiphase fluid from the subsea hydrocarbon reservoir to a fluid storage facility via the fluid processing system.
- These pipelines are generally insulated and/or heated at certain intervals to ensure that the temperature of the multiphase fluid remains above a certain threshold level. Failure to maintain the temperature of the multiphase fluid, for example the liquid components, above the threshold level may lead to formation of sludge within the pipelines.
- the heat exchange system disposed upstream relative to the main separator assembly may inadvertently reduce the temperature of the multiphase fluid thereby increasing the risk of un-desired secondary phases such as wax, scale, hydrates, sludge and/or hydrate formation within the pipelines. Further, the performance of the heat exchange system operating with the multiphase fluid may be difficult to predict and complex in nature.
- the present invention provides a heat exchange sub-system comprising: an inlet header; an outlet header; a plurality of heat exchange tubes in fluid communication with the inlet header and outlet header; said heat exchange tubes being configured to exchange heat with a cold ambient environment; and a liquid-gas separator coupled to the outlet header; wherein the heat exchange sub-system is configured to receive a hot gaseous fluid comprising condensable and non-condensable components, and to condense at least a portion of the condensable components, the cold ambient environment serving as a heat sink.
- the present invention provides a fluid processing system comprising: (a) a main separator assembly configured to separate a hot multiphase fluid into a hot gaseous fluid comprising condensable and non-condensable components and a hot liquid fluid; (b) a heat exchange sub-system comprising: (i) an inlet header; (ii) an outlet header; (iii) a plurality of heat exchange tubes in fluid communication with the inlet header and outlet header; said heat exchange tubes being configured to exchange heat with a cold ambient environment; and (iv) a liquid-gas separator coupled to the outlet header; wherein the heat exchange sub-system is configured to receive the hot gaseous fluid, and to condense at least a portion of the condensable components to produce a condensate and a gaseous fluid depleted in condensable components, the cold ambient environment serving as a heat sink, (c) a gas compressor configured to receive the gaseous fluid from the heat exchange sub-system; and (d) a fluid pump coupled
- the present invention provides a method of transporting a hot, multiphase production fluid, the method comprising: (a) introducing a hot multiphase fluid into a main separator assembly and separating the hot multiphase fluid into a hot gaseous fluid comprising condensable and non-condensable components, and a hot liquid fluid; (b) introducing the hot gaseous fluid comprising condensable and non-condensable components into an energy dissipating device and condensing at least a portion of the condensable components to produce a condensate and a gaseous fluid depleted in condensable components; (c) compressing the gaseous fluid depleted in condensable components to produce a compressed gaseous fluid depleted in condensable components; and (d) combining the compressed gaseous fluid depleted in condensable components with the hot liquid fluid produced in the main separator assembly.
- the present invention provides a fluid processing system comprising: (a) a main separator assembly configured to separate a hot multiphase fluid into a hot gaseous fluid comprising condensable and non-condensable components and a hot liquid fluid; (b) an energy dissipating device configured to receive the hot gaseous fluid and to condense at least a portion of the condensable components to produce a condensate and a gaseous fluid depleted in condensable components; (c) a gas compressor configured to receive the gaseous fluid depleted in condensable components from the energy dissipating device; and (d) a fluid pump coupled to the main separator assembly; wherein the pump is configured to drive the hot liquid fluid toward a fluid storage facility.
- FIG. 1 illustrates a schematic view of a fluid processing system in accordance with one exemplary embodiment
- FIG. 2 illustrates a schematic view of a heat exchange sub-system for the fluid processing system in accordance with the exemplary embodiment of FIG. 1 .
- Embodiments discussed herein disclose a new configuration of a fluid processing system for efficiently moving multiphase fluid (hydrocarbon) being produced from a subsea hydrocarbon reservoir to a distant fluid storage facility.
- the fluid processing system of the present invention comprises an improved heat exchange sub-system disposed downstream relative to a main separator assembly.
- the heat exchange sub-system is configured to receive a hot gaseous fluid comprising condensable and non-condensable components, from the main separator assembly and condense at least a portion of the condensable components to produce a condensate and a gaseous fluid depleted in condensable components.
- Such heat exchange sub-system may additionally include a liquid-gas separator configured to separate the condensate from the gaseous fluid and collect the separated condensate.
- FIG. 1 represents a fluid processing system 100 deployed in a subsea environment 114 .
- the fluid processing system 100 may be located at depths reaching several thousands of meters within a cold ambient environment and proximate to a subsea hydrocarbon reservoir 119 .
- the exemplary fluid processing system 100 includes a main separator assembly 102 , an energy dissipating device 104 , a gas compressor 106 , and a fluid pump 108 .
- the fluid processing system 100 further includes an import line 110 coupled to the main separator assembly 102 , and an export line 112 coupled to the gas compressor 106 and the fluid pump 108 via a mixer 116 .
- the import line 110 and the export line 112 may also be referred as “pipelines”.
- the fluid processing system 100 is configured to move a multiphase fluid 120 , for example hydrocarbon, being produced from the subsea hydrocarbon reservoir 119 to a distant fluid storage facility 130 more efficiently.
- the main separator assembly 102 receives the multiphase fluid 120 from the subsea hydrocarbon reservoir 119 via the import line 110 .
- the multiphase fluid 120 is typically a mixture of a hot gaseous fluid 120 a and a hot liquid fluid 120 b .
- the main separator assembly 102 functions as a pressure vessel and aids in separating the hot gaseous fluid 120 a from the hot liquid fluid 120 b.
- the hot gaseous fluid 120 a includes condensable components such as moisture and low molecular weight hydrocarbons and non-condensable components such as the gases CO 2 and H 2 S.
- Various known separation devices may serve as the main separator assembly 102 , for example, a stage separator, a knockout vessel, a flash chamber, an expansion separator, an expansion vessel, or a scrubber.
- the energy dissipating device 104 is disposed downstream relative to the main separator assembly 102 and is configured to receive the hot gaseous fluid 120 a from the main separator assembly 102 .
- the hot gaseous fluid 120 a is passing within the energy dissipating device 104 acts to condense at least a portion of the condensable components to produce a gaseous fluid 120 c depleted in condensable components and a condensate 120 d.
- the energy dissipating device 104 is a heat exchange sub-system 104 a (as shown in FIG. 2 ) including a plurality of heat exchange tubes configured to exchange heat with the cold ambient environment 114 serving as a heat sink.
- the heat exchange sub-system 104 a and the condensation of the portion of the condensable components within the heat exchange sub-system 104 a are explained in greater detail below.
- the energy dissipating device 104 is a work extraction device. Suitable work extraction devices include turboexpander, hydraulic expander, and hydraulic motor. In yet another embodiment of the present invention, the energy dissipating device 104 is a frictional loss or pressure change device such as throttle device or valve. The energy dissipating device 104 is configured to receive the hot gaseous fluid 120 a, and reduce its total energy content thereby and condensing at least a portion of the condensable components to produce the condensate 120 d and the gaseous fluid 120 c depleted in condensable components.
- a liquid-gas separator 138 is disposed within the energy dissipating device 104 and coupled to the energy dissipating device 104 .
- the liquid-gas separator 138 separates the condensate 120 d from the gaseous fluid 120 c using, for example, a barrier, a filter, or a vortex flow separator.
- the separated condensate 120 d is collected within the liquid-gas separator 138 .
- the liquid-gas separator 138 comprises one or more weir separators, filter separators, cyclone separators, sheet metal separators, or a combination of two or more of the foregoing separators.
- the energy dissipating device 104 is coupled to the gas compressor 106 which receives the gaseous fluid 120 c from the energy dissipating device 104 .
- the liquid-gas separator 138 is coupled to the fluid pump 108 which receives the condensate 120 d collected within the liquid-gas separator 138 .
- the liquid-gas separator 138 may be coupled to the main separator assembly 102 for feeding the condensate 120 d collected within the liquid-gas separator 138 .
- the condensate 120 d may be fed to the main separator assembly 102 either by pumping or gravitational force.
- the condensate 120 d may be drained from the liquid-gas separator 138 by pressure to the subsea environment 114 .
- the separation of the gaseous fluid 120 c from the condensate 120 d is explained in greater detail below.
- the liquid-gas separator 138 may be disposed outside of the energy dissipating device 104 and coupled to the energy dissipating device 104 via a conduit. In such embodiments, the liquid-gas separator 138 may receive the condensate 120 d and the gaseous fluid 120 c from the energy dissipating device 104 . The liquid-gas separator 138 may be further configured to separate the condensate 120 d from the gaseous fluid 120 c and feed the gaseous fluid 120 c to the gas compressor 106 and the condensate 120 d to the fluid pump 108 .
- the gaseous fluid 120 c may be compressed by a motor-driven compressor 106 (see motor 128 ), which increases the pressure of the gaseous fluid 120 c and moves the gaseous fluid 120 c towards the fluid storage facility 130 via the mixer 116 .
- a portion 120 g of the gaseous fluid 120 c may be fed to the main separator assembly 102 via a flow control valve 115 .
- the feeding of the portion 120 g of the gaseous fluid 120 c may assist steady state operation of the compressor 106 , protection of the compressor 106 from pressure variation, and during system 100 start-up.
- the gas compressor 106 may be configured to discharge a slip-stream 120 e of the gaseous fluid 120 c to cool the motor 128 .
- the slip stream 120 e may be discharged from an initial stage 127 of the gas compressor 106 .
- the gas compressor 106 may be a positive displacement compressor or a centrifugal compressor.
- the fluid pump 108 is disposed downstream relative to the main separator assembly 102 and is configured to receive the hot liquid fluid 120 b from the main separator assembly 102 . Further, the fluid pump 108 may also receive the condensate 120 d discharged from the liquid-gas separator 138 . The fluid pump 108 increases pressure of the hot liquid fluid 120 b and/or the condensate 120 d so as to drive the hot liquid fluid 120 b towards the fluid storage facility 130 via the mixer 116 . In one or more embodiments, the fluid pump 108 may be a positive displacement pump or a gear pump or a screw pump.
- the mixer 116 may be configured to combine/mix the gaseous fluid 120 c and the liquid fluid 120 b and/or the condensate 120 d before discharging the mixed fluids to the fluid storage facility 130 via the export line 112 .
- the fluid storage facility 130 may be located within subsea environment 114 or at a surface location.
- FIG. 2 represents a heat exchange sub-system 104 a used in the fluid processing system 100 in accordance with the exemplary embodiment of FIG. 1 .
- the heat exchange sub-system 104 a includes an inlet header 132 , an outlet header 134 , a plurality of heat exchange tubes 136 , and a liquid-gas separator 138 . Further the heat exchange sub-system 104 a includes a condensate re-evaporator 140 coupled to the liquid-gas separator 138 .
- the heat exchange sub-system 104 a is configured to condense at least a portion of condensable components to produce a condensate 120 d and a gaseous fluid 120 c depleted in condensable components.
- the inlet header 132 has an inlet chamber 142 and is configured to receive the hot gaseous fluid 120 a discharged from the main separator assembly 102 (as shown in FIG. 1 ). In the embodiment shown, the inlet header 132 is aligned horizontally at about 0.degree.
- the outlet header 134 has an outlet chamber 152 and is configured to discharge the gaseous fluid 120 c to the gas compressor 106 (as shown in FIG. 1 ). In the embodiment shown, the outlet header 134 is aligned at a pre-determined angle relative to the inlet header 132 . In one or more embodiments, the pre-determined angle may be in a range from about 0.degree to about 60.degrees.
- the plurality of heat exchange tubes 136 are disposed between the inlet header 132 and outlet header 134 .
- the plurality of heat exchange tubes 136 may be coupled directly to the main separator assembly 102 and may be configured to receive the hot gaseous fluid 120 a discharged from the main separator assembly 102 .
- the heat exchange tubes 136 are coupled to the inlet chamber 142 and outlet chamber 152 to establish a fluid communication between the inlet header 132 and outlet header 134 .
- the plurality of heat exchange tubes 136 are straight pipes aligned vertically at about 90.degrees.
- the heat exchange tubes 136 may have spirals or coils, as will be appreciated by those skilled in the art.
- the plurality of heat exchange tubes 136 may additionally include the liquid-gas separator 138 disposed along a length of the tubes 136 .
- the liquid-gas separator 138 may be fluidly coupled to the condensate re-evaporator 140 and a discharge end of the plurality of heat exchange tubes 136 may be coupled to the compressor 106 .
- the liquid-gas separator 138 is disposed within the outlet header 134 and is an integral component thereof.
- the liquid-gas separator 138 is a weir separator having an open tank configuration.
- the weir separator has a weir 139 and a bottom end portion 143 coupled to the weir 139 and the outlet header 134 .
- the weir separator 139 is a horizontal gravity based separator.
- the liquid-gas separator 138 is disposed outside the outlet header 134 and is not an integral component thereof. In such other embodiments, the liquid-gas separator 138 may be coupled to the outlet header 134 via a conduit.
- the liquid-gas separator 138 is fluidly coupled to the condensate re-evaporator 140 .
- the condensate re-evaporator 140 is a shell and tube heat exchanger.
- the condensate re-evaporator 140 includes an inlet plenum chamber 174 , an outlet plenum chamber 176 , and a bundle of tubes 178 coupled to the inlet and outlet plenum chambers 174 , 176 .
- the bundle of tubes 178 is disposed in a condensate chamber 184 formed between the inlet plenum chamber 174 and outlet plenum chamber 176 .
- the tubes 178 are fluidly coupled to the corresponding plenum chambers 174 , 176 .
- the condensate chamber 184 is coupled to the liquid-gas separator 138 through a pipe 187 .
- the condensate chamber 184 is further coupled to the outlet header 134 via a return pipe 189 .
- the condensate re-evaporator 140 is disposed between the main separator assembly 102 and the heat exchange sub-system 104 a.
- the inlet plenum chamber 174 is coupled to the main separator assembly 102 and may be configured to receive the hot gaseous fluid 120 a (hot process gas) from the main separator assembly 102 .
- the outlet plenum chamber 176 is coupled to the heat exchange sub-system 104 a and is configured to feed the hot gaseous fluid 120 a to the heat exchange sub-system 104 a.
- the outlet plenum chamber 176 is coupled to the inlet header 132 via a channel 194 having a by-pass valve 198 .
- the heat exchange sub-system 104 a further includes an intermediate channel 196 coupled to the by-pass valve 198 and the outlet header 134 .
- the inlet plenum chamber 174 may be coupled to import line 120 to receive the multiphase fluid 120 being produced from the subsea hydrocarbon reservoir 119 .
- the outlet plenum chamber 176 may be coupled to the main separator assembly 102 to feed the multiphase fluid 120 to the main separator assembly 102 .
- the condensate re-evaporator 140 further includes a discharge channel 190 having a discharge valve 192 , coupled to the condensate chamber 184 and the fluid pump 108 (as shown in FIG. 1 ).
- the discharge valve 192 is configured to regulate a flow of the condensate 120 d towards the fluid pump 108 .
- the inlet header 132 receives the hot gaseous fluid 120 a from the main separator assembly 102 (as shown in FIG. 1 ) via the condensate re-evaporator 140 .
- the hot gaseous fluid 120 a flows within the inlet plenum chamber 174 , the bundle of tubes 178 , and the outlet plenum chamber 176 of the condensate re-evaporator 140 .
- the hot gaseous fluid 120 a includes the condensable components such as moisture and low molecular weight hydrocarbons, and non-condensable components such as the gases CO 2 and H 2 5 .
- the hot gaseous fluid 120 a flows along the inlet chamber 142 of the inlet header 132 and gets circulated within the plurality of heat exchange tubes 136 .
- the heat exchange tubes 136 exchange heat with the cold ambient environment 114 serving as a heat sink. This heat exchange results in condensation of the condensable components to produce the gaseous fluid 120 c and the condensate 120 d.
- the gaseous fluid 120 c depleted in condensable components and the condensate 120 d produced within the heat exchange tubes 136 flows into the outlet chamber 152 of the outlet header 134 .
- the plurality of heat exchange tubes 136 may additionally function as a distributed separator configured to separate the condensate 120 d from the gaseous fluid 120 c along the length of the plurality of heat exchange tubes 136 .
- the gaseous fluid 120 c may be released from the discharge end of the plurality of heat exchange tubes 136 to the compressor 106 and the condensate 120 d may be transferred from the liquid-gas separator 138 to the condensate re-evaporator 140 .
- the liquid-gas separator 138 separates the condensate 120 d from the gaseous fluid 120 c.
- the weir 139 is configured to separate the condensate 120 d from the gaseous fluid 120 c and the bottom end portion 143 is configured to collect the condensate 120 d.
- Other types of liquid-gas separators 138 are known to those skilled in the art and may be used to separate the condensate 120 d from the gaseous fluid 120 c.
- Other such liquid-gas separators 138 may include a filter separator, a cyclone separator, and a sheet metal separator.
- the filter separator may separate the condensate 120 d from the gaseous fluid 120 c by a filter having a membrane to trap the condensate 120 d and allow the gaseous fluid 120 c to pass through the membrane.
- the cyclone separator may separate the condensate 120 d from the gaseous fluid 120 c through vortex separation.
- the sheet metal separator may use a single or multiple metal layers/sheets to segregate the condensate 120 d from the gaseous fluid 120 c.
- the gaseous fluid 120 c is then released from the outlet header 134 to the gas compressor 106 and the condensate 120 d is transferred from the outlet header 134 to condensate re-evaporator 140 via the pipe 187 .
- Various means of affecting such transfer are known to those skilled in the art, for example, through the use of a pump and a check valve integrated into the pipe 187 .
- the gaseous fluid 120 c is compressed in the gas compressor 106 and is driven towards the fluid storage facility 130 via the mixer 116 .
- the condensate 120 d is circulated across the bundles of tubes 178 disposed within the condensate chamber 184 .
- the gaseous fluid 120 a flowing within the bundle of tubes 178 exchanges heat with the condensate 120 d and evaporates at least a portion of the condensate 120 d so as to produce a re-evaporated gaseous fluid 120 f within the condensate chamber 184 .
- the re-evaporated gaseous fluid 120 f is fed to the outlet header 134 via the return pipe 189 .
- the hot gaseous fluid 120 a after exchanging heat indirectly with the condensate 120 d is fed to the inlet header 132 via the channel 194 .
- the by-pass valve 198 may allow the hot gaseous fluid 120 a to flow towards the outlet header 134 via the intermediate channel 196 .
- the regulation of the by-pass valve 198 may depend on temperature of the gaseous fluid 120 a and an operating condition of the fluid processing system 100 , such as start-up and/or maintenance.
- the by-pass valve 198 is typically opened during start-up of the system 100 to ensure steady and smooth operation of the system 100 . Further, the by-pass valve 198 is opened when the temperature of the hot gaseous fluid 120 a is lower than one or more threshold temperatures of the gaseous fluid 120 c and/or the condensate 120 d.
- the discharge valve 192 is opened intermittently to discharge the condensate 120 d from the condensate chamber 184 into the liquid pump 108 .
- the condensate 120 d may be discharged to the main separator assembly 102 .
- the regulation of the discharge valve 192 may depend on a level of condensate 120 d accumulated within the condensate chamber 184 and an operating condition of the system 100 , such as start-up and/or maintenance.
- the discharge valve 192 may be opened to discharge the condensate 120 d completely from the condensate chamber 184 .
- the discharge valve 192 may be opened to discharge a portion of the condensate 120 d when the level of the condensate is above a threshold level in the condensate chamber.
- the fluid processing system facilitates temperature reduction of only the hot gaseous fluid component of a multiphase fluid without sacrificing heat retained in the liquid component of the multiphase fluid.
- the fluid processing system of the present invention acts to limit sludge and/or hydrate formation within the pipelines connecting the system to a storage facility.
- the heat exchange sub-system separates a condensate from a gaseous fluid and feeds only the gaseous fluid to the gas compressor. The condensate is re-evaporated to enhance the production of the gaseous fluid and facilitate continuous operation of the system.
- the present invention acts to conserve heat derived from the reservoir and may reduce costs by limiting the need for more active heat conservation measures.
Abstract
A heat exchange sub-system and fluid processing system is provided containing an inlet header; an outlet header; a plurality of heat exchange tubes in fluid communication with the inlet header and outlet header. The heat exchange tubes are configured to exchange heat with a cold ambient environment. A liquid-gas separator is coupled to the outlet header. The heat exchange sub-system is configured to receive a hot gaseous fluid comprising condensable and non-condensable components, and to condense at least a portion of the condensable components. The system is configured such that the cold ambient subsea environment serves as a heat sink.
Description
- This application claims priority under 35 U.S.C. §119(e) from Provisional Application No. 62/020,440 filed on 3 Jul. 2014, which is incorporated by reference herein in its entirety.
- The present invention relates to a fluid processing system for deployment in a subsea environment, and more particularly to a heat exchange sub-system used in the fluid processing system.
- Fluid processing systems used in hydrocarbon production in subsea environments typically comprise a heat exchange system disposed upstream relative to a main separator assembly. The heat exchange system facilitates temperature reduction of a multiphase fluid (hydrocarbon) being produced from a subsea hydrocarbon reservoir prior to its introduction to the main separator assembly. The multiphase fluid is typically a hot mixture of gaseous and liquid components comprising methane, carbon dioxide, hydrogen sulfide and liquid crude oil, and may also contain solid particulates such as sand. The main separator assembly separates the gaseous components from the liquid components of the multiphase fluid.
- Typically, pipelines are deployed within the subsea environment to move the multiphase fluid from the subsea hydrocarbon reservoir to a fluid storage facility via the fluid processing system. These pipelines are generally insulated and/or heated at certain intervals to ensure that the temperature of the multiphase fluid remains above a certain threshold level. Failure to maintain the temperature of the multiphase fluid, for example the liquid components, above the threshold level may lead to formation of sludge within the pipelines. However, the heat exchange system disposed upstream relative to the main separator assembly may inadvertently reduce the temperature of the multiphase fluid thereby increasing the risk of un-desired secondary phases such as wax, scale, hydrates, sludge and/or hydrate formation within the pipelines. Further, the performance of the heat exchange system operating with the multiphase fluid may be difficult to predict and complex in nature.
- Thus, there is a need for an improved fluid processing system for efficiently handling a multiphase fluid being produced from a subsea environment and also an improved heat exchange system for such fluid processing system.
- In one embodiment, the present invention provides a heat exchange sub-system comprising: an inlet header; an outlet header; a plurality of heat exchange tubes in fluid communication with the inlet header and outlet header; said heat exchange tubes being configured to exchange heat with a cold ambient environment; and a liquid-gas separator coupled to the outlet header; wherein the heat exchange sub-system is configured to receive a hot gaseous fluid comprising condensable and non-condensable components, and to condense at least a portion of the condensable components, the cold ambient environment serving as a heat sink.
- In another embodiment, the present invention provides a fluid processing system comprising: (a) a main separator assembly configured to separate a hot multiphase fluid into a hot gaseous fluid comprising condensable and non-condensable components and a hot liquid fluid; (b) a heat exchange sub-system comprising: (i) an inlet header; (ii) an outlet header; (iii) a plurality of heat exchange tubes in fluid communication with the inlet header and outlet header; said heat exchange tubes being configured to exchange heat with a cold ambient environment; and (iv) a liquid-gas separator coupled to the outlet header; wherein the heat exchange sub-system is configured to receive the hot gaseous fluid, and to condense at least a portion of the condensable components to produce a condensate and a gaseous fluid depleted in condensable components, the cold ambient environment serving as a heat sink, (c) a gas compressor configured to receive the gaseous fluid from the heat exchange sub-system; and (d) a fluid pump coupled to the main separator assembly; wherein the pump is configured to drive the hot liquid fluid toward a fluid storage facility.
- In yet another embodiment, the present invention provides a method of transporting a hot, multiphase production fluid, the method comprising: (a) introducing a hot multiphase fluid into a main separator assembly and separating the hot multiphase fluid into a hot gaseous fluid comprising condensable and non-condensable components, and a hot liquid fluid; (b) introducing the hot gaseous fluid comprising condensable and non-condensable components into an energy dissipating device and condensing at least a portion of the condensable components to produce a condensate and a gaseous fluid depleted in condensable components; (c) compressing the gaseous fluid depleted in condensable components to produce a compressed gaseous fluid depleted in condensable components; and (d) combining the compressed gaseous fluid depleted in condensable components with the hot liquid fluid produced in the main separator assembly.
- In yet another embodiment, the present invention provides a fluid processing system comprising: (a) a main separator assembly configured to separate a hot multiphase fluid into a hot gaseous fluid comprising condensable and non-condensable components and a hot liquid fluid; (b) an energy dissipating device configured to receive the hot gaseous fluid and to condense at least a portion of the condensable components to produce a condensate and a gaseous fluid depleted in condensable components; (c) a gas compressor configured to receive the gaseous fluid depleted in condensable components from the energy dissipating device; and (d) a fluid pump coupled to the main separator assembly; wherein the pump is configured to drive the hot liquid fluid toward a fluid storage facility.
- These and other features and aspects of embodiments of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
-
FIG. 1 illustrates a schematic view of a fluid processing system in accordance with one exemplary embodiment; and -
FIG. 2 illustrates a schematic view of a heat exchange sub-system for the fluid processing system in accordance with the exemplary embodiment ofFIG. 1 . - Embodiments discussed herein disclose a new configuration of a fluid processing system for efficiently moving multiphase fluid (hydrocarbon) being produced from a subsea hydrocarbon reservoir to a distant fluid storage facility. The fluid processing system of the present invention comprises an improved heat exchange sub-system disposed downstream relative to a main separator assembly. The heat exchange sub-system is configured to receive a hot gaseous fluid comprising condensable and non-condensable components, from the main separator assembly and condense at least a portion of the condensable components to produce a condensate and a gaseous fluid depleted in condensable components. Such heat exchange sub-system may additionally include a liquid-gas separator configured to separate the condensate from the gaseous fluid and collect the separated condensate.
-
FIG. 1 represents afluid processing system 100 deployed in asubsea environment 114. Thefluid processing system 100 may be located at depths reaching several thousands of meters within a cold ambient environment and proximate to asubsea hydrocarbon reservoir 119. In one embodiment, the exemplaryfluid processing system 100 includes amain separator assembly 102, anenergy dissipating device 104, agas compressor 106, and afluid pump 108. Thefluid processing system 100 further includes animport line 110 coupled to themain separator assembly 102, and anexport line 112 coupled to thegas compressor 106 and thefluid pump 108 via amixer 116. Theimport line 110 and theexport line 112 may also be referred as “pipelines”. Thefluid processing system 100 is configured to move amultiphase fluid 120, for example hydrocarbon, being produced from thesubsea hydrocarbon reservoir 119 to a distantfluid storage facility 130 more efficiently. - The
main separator assembly 102 receives themultiphase fluid 120 from thesubsea hydrocarbon reservoir 119 via theimport line 110. Themultiphase fluid 120 is typically a mixture of a hotgaseous fluid 120 a and a hotliquid fluid 120 b. Themain separator assembly 102 functions as a pressure vessel and aids in separating the hotgaseous fluid 120 a from the hotliquid fluid 120 b. The hotgaseous fluid 120 a includes condensable components such as moisture and low molecular weight hydrocarbons and non-condensable components such as the gases CO2 and H2S. Various known separation devices may serve as themain separator assembly 102, for example, a stage separator, a knockout vessel, a flash chamber, an expansion separator, an expansion vessel, or a scrubber. - The
energy dissipating device 104 is disposed downstream relative to themain separator assembly 102 and is configured to receive the hotgaseous fluid 120 a from themain separator assembly 102. The hotgaseous fluid 120 a is passing within the energydissipating device 104 acts to condense at least a portion of the condensable components to produce agaseous fluid 120 c depleted in condensable components and acondensate 120 d. Specifically, in one embodiment, theenergy dissipating device 104 is aheat exchange sub-system 104 a (as shown inFIG. 2 ) including a plurality of heat exchange tubes configured to exchange heat with the coldambient environment 114 serving as a heat sink. Theheat exchange sub-system 104 a and the condensation of the portion of the condensable components within theheat exchange sub-system 104 a are explained in greater detail below. - In another embodiment of the present invention, the
energy dissipating device 104 is a work extraction device. Suitable work extraction devices include turboexpander, hydraulic expander, and hydraulic motor. In yet another embodiment of the present invention, theenergy dissipating device 104 is a frictional loss or pressure change device such as throttle device or valve. Theenergy dissipating device 104 is configured to receive the hotgaseous fluid 120 a, and reduce its total energy content thereby and condensing at least a portion of the condensable components to produce thecondensate 120 d and thegaseous fluid 120 c depleted in condensable components. - In one embodiment shown, a liquid-
gas separator 138 is disposed within theenergy dissipating device 104 and coupled to theenergy dissipating device 104. The liquid-gas separator 138 separates thecondensate 120 d from thegaseous fluid 120 c using, for example, a barrier, a filter, or a vortex flow separator. Theseparated condensate 120 d is collected within the liquid-gas separator 138. In one or more embodiments, the liquid-gas separator 138 comprises one or more weir separators, filter separators, cyclone separators, sheet metal separators, or a combination of two or more of the foregoing separators. - The
energy dissipating device 104 is coupled to thegas compressor 106 which receives thegaseous fluid 120 c from theenergy dissipating device 104. The liquid-gas separator 138 is coupled to thefluid pump 108 which receives thecondensate 120 d collected within the liquid-gas separator 138. In another embodiment, the liquid-gas separator 138 may be coupled to themain separator assembly 102 for feeding thecondensate 120 d collected within the liquid-gas separator 138. Thecondensate 120 d may be fed to themain separator assembly 102 either by pumping or gravitational force. In yet another embodiment, thecondensate 120 d may be drained from the liquid-gas separator 138 by pressure to thesubsea environment 114. The separation of thegaseous fluid 120 c from thecondensate 120 d is explained in greater detail below. - Alternatively, the liquid-
gas separator 138 may be disposed outside of theenergy dissipating device 104 and coupled to theenergy dissipating device 104 via a conduit. In such embodiments, the liquid-gas separator 138 may receive thecondensate 120 d and thegaseous fluid 120 c from theenergy dissipating device 104. The liquid-gas separator 138 may be further configured to separate thecondensate 120 d from thegaseous fluid 120 c and feed thegaseous fluid 120 c to thegas compressor 106 and thecondensate 120 d to thefluid pump 108. - The
gaseous fluid 120 c may be compressed by a motor-driven compressor 106 (see motor 128), which increases the pressure of thegaseous fluid 120 c and moves thegaseous fluid 120 c towards thefluid storage facility 130 via themixer 116. In another embodiment, aportion 120 g of thegaseous fluid 120 c may be fed to themain separator assembly 102 via aflow control valve 115. The feeding of theportion 120 g of thegaseous fluid 120 c may assist steady state operation of thecompressor 106, protection of thecompressor 106 from pressure variation, and duringsystem 100 start-up. Further, thegas compressor 106 may be configured to discharge a slip-stream 120 e of thegaseous fluid 120 c to cool themotor 128. Theslip stream 120 e may be discharged from aninitial stage 127 of thegas compressor 106. In one or more embodiments, thegas compressor 106 may be a positive displacement compressor or a centrifugal compressor. - The
fluid pump 108 is disposed downstream relative to themain separator assembly 102 and is configured to receive the hot liquid fluid 120 b from themain separator assembly 102. Further, thefluid pump 108 may also receive thecondensate 120 d discharged from the liquid-gas separator 138. Thefluid pump 108 increases pressure of the hot liquid fluid 120 b and/or thecondensate 120 d so as to drive the hot liquid fluid 120 b towards thefluid storage facility 130 via themixer 116. In one or more embodiments, thefluid pump 108 may be a positive displacement pump or a gear pump or a screw pump. - The
mixer 116 may be configured to combine/mix thegaseous fluid 120 c and theliquid fluid 120 b and/or thecondensate 120 d before discharging the mixed fluids to thefluid storage facility 130 via theexport line 112. Thefluid storage facility 130 may be located withinsubsea environment 114 or at a surface location. -
FIG. 2 represents aheat exchange sub-system 104 a used in thefluid processing system 100 in accordance with the exemplary embodiment ofFIG. 1 . Theheat exchange sub-system 104 a includes aninlet header 132, anoutlet header 134, a plurality ofheat exchange tubes 136, and a liquid-gas separator 138. Further theheat exchange sub-system 104 a includes acondensate re-evaporator 140 coupled to the liquid-gas separator 138. Theheat exchange sub-system 104 a is configured to condense at least a portion of condensable components to produce acondensate 120 d and agaseous fluid 120 c depleted in condensable components. - The
inlet header 132 has aninlet chamber 142 and is configured to receive the hot gaseous fluid 120 a discharged from the main separator assembly 102 (as shown inFIG. 1 ). In the embodiment shown, theinlet header 132 is aligned horizontally at about 0.degree. Theoutlet header 134 has anoutlet chamber 152 and is configured to discharge thegaseous fluid 120 c to the gas compressor 106 (as shown inFIG. 1 ). In the embodiment shown, theoutlet header 134 is aligned at a pre-determined angle relative to theinlet header 132. In one or more embodiments, the pre-determined angle may be in a range from about 0.degree to about 60.degrees. - The plurality of
heat exchange tubes 136 are disposed between theinlet header 132 andoutlet header 134. In certain other embodiments, the plurality ofheat exchange tubes 136 may be coupled directly to themain separator assembly 102 and may be configured to receive the hot gaseous fluid 120 a discharged from themain separator assembly 102. Theheat exchange tubes 136 are coupled to theinlet chamber 142 andoutlet chamber 152 to establish a fluid communication between theinlet header 132 andoutlet header 134. In the embodiment shown, the plurality ofheat exchange tubes 136 are straight pipes aligned vertically at about 90.degrees. In certain other embodiments, theheat exchange tubes 136 may have spirals or coils, as will be appreciated by those skilled in the art. In another embodiment, the plurality ofheat exchange tubes 136 may additionally include the liquid-gas separator 138 disposed along a length of thetubes 136. In such embodiments, the liquid-gas separator 138 may be fluidly coupled to thecondensate re-evaporator 140 and a discharge end of the plurality ofheat exchange tubes 136 may be coupled to thecompressor 106. - In the embodiment shown, the liquid-
gas separator 138 is disposed within theoutlet header 134 and is an integral component thereof. In the illustrated embodiment, the liquid-gas separator 138 is a weir separator having an open tank configuration. The weir separator has aweir 139 and abottom end portion 143 coupled to theweir 139 and theoutlet header 134. Theweir separator 139 is a horizontal gravity based separator. In certain other embodiments, the liquid-gas separator 138 is disposed outside theoutlet header 134 and is not an integral component thereof. In such other embodiments, the liquid-gas separator 138 may be coupled to theoutlet header 134 via a conduit. - The liquid-
gas separator 138 is fluidly coupled to thecondensate re-evaporator 140. In one embodiment, thecondensate re-evaporator 140 is a shell and tube heat exchanger. Thecondensate re-evaporator 140 includes aninlet plenum chamber 174, anoutlet plenum chamber 176, and a bundle oftubes 178 coupled to the inlet andoutlet plenum chambers tubes 178 is disposed in acondensate chamber 184 formed between theinlet plenum chamber 174 andoutlet plenum chamber 176. Thetubes 178 are fluidly coupled to thecorresponding plenum chambers condensate chamber 184 is coupled to the liquid-gas separator 138 through apipe 187. Thecondensate chamber 184 is further coupled to theoutlet header 134 via areturn pipe 189. - In the embodiment shown, the
condensate re-evaporator 140 is disposed between themain separator assembly 102 and theheat exchange sub-system 104 a. Specifically, theinlet plenum chamber 174 is coupled to themain separator assembly 102 and may be configured to receive the hot gaseous fluid 120 a (hot process gas) from themain separator assembly 102. Similarly, theoutlet plenum chamber 176 is coupled to theheat exchange sub-system 104 a and is configured to feed the hot gaseous fluid 120 a to theheat exchange sub-system 104 a. In one embodiment, theoutlet plenum chamber 176 is coupled to theinlet header 132 via achannel 194 having a by-pass valve 198. Theheat exchange sub-system 104 a further includes anintermediate channel 196 coupled to the by-pass valve 198 and theoutlet header 134. - In certain other embodiments, the
inlet plenum chamber 174 may be coupled to importline 120 to receive themultiphase fluid 120 being produced from thesubsea hydrocarbon reservoir 119. In such embodiments, theoutlet plenum chamber 176 may be coupled to themain separator assembly 102 to feed themultiphase fluid 120 to themain separator assembly 102. - The
condensate re-evaporator 140 further includes adischarge channel 190 having adischarge valve 192, coupled to thecondensate chamber 184 and the fluid pump 108 (as shown inFIG. 1 ). Thedischarge valve 192 is configured to regulate a flow of thecondensate 120 d towards thefluid pump 108. - During operation of the
fluid processing system 100, theinlet header 132 receives the hot gaseous fluid 120 a from the main separator assembly 102 (as shown inFIG. 1 ) via thecondensate re-evaporator 140. Specifically, the hot gaseous fluid 120 a flows within theinlet plenum chamber 174, the bundle oftubes 178, and theoutlet plenum chamber 176 of thecondensate re-evaporator 140. The hot gaseous fluid 120 a includes the condensable components such as moisture and low molecular weight hydrocarbons, and non-condensable components such as the gases CO2 and H2 5. - The hot gaseous fluid 120 a flows along the
inlet chamber 142 of theinlet header 132 and gets circulated within the plurality ofheat exchange tubes 136. Theheat exchange tubes 136 exchange heat with the coldambient environment 114 serving as a heat sink. This heat exchange results in condensation of the condensable components to produce thegaseous fluid 120 c and thecondensate 120 d. Thegaseous fluid 120 c depleted in condensable components and thecondensate 120 d produced within theheat exchange tubes 136 flows into theoutlet chamber 152 of theoutlet header 134. In another embodiment, the plurality ofheat exchange tubes 136 may additionally function as a distributed separator configured to separate thecondensate 120 d from thegaseous fluid 120 c along the length of the plurality ofheat exchange tubes 136. In such embodiments, thegaseous fluid 120 c may be released from the discharge end of the plurality ofheat exchange tubes 136 to thecompressor 106 and thecondensate 120 d may be transferred from the liquid-gas separator 138 to thecondensate re-evaporator 140. - The liquid-
gas separator 138 separates thecondensate 120 d from thegaseous fluid 120 c. In the illustrated embodiment, theweir 139 is configured to separate thecondensate 120 d from thegaseous fluid 120 c and thebottom end portion 143 is configured to collect thecondensate 120 d. Other types of liquid-gas separators 138 are known to those skilled in the art and may be used to separate thecondensate 120 d from thegaseous fluid 120 c. Other such liquid-gas separators 138 may include a filter separator, a cyclone separator, and a sheet metal separator. The filter separator may separate thecondensate 120 d from thegaseous fluid 120 c by a filter having a membrane to trap thecondensate 120 d and allow thegaseous fluid 120 c to pass through the membrane. The cyclone separator may separate thecondensate 120 d from thegaseous fluid 120 c through vortex separation. The sheet metal separator may use a single or multiple metal layers/sheets to segregate thecondensate 120 d from thegaseous fluid 120 c. - The
gaseous fluid 120 c is then released from theoutlet header 134 to thegas compressor 106 and thecondensate 120 d is transferred from theoutlet header 134 tocondensate re-evaporator 140 via thepipe 187. Various means of affecting such transfer are known to those skilled in the art, for example, through the use of a pump and a check valve integrated into thepipe 187. - The
gaseous fluid 120 c is compressed in thegas compressor 106 and is driven towards thefluid storage facility 130 via themixer 116. Thecondensate 120 d is circulated across the bundles oftubes 178 disposed within thecondensate chamber 184. Thegaseous fluid 120 a flowing within the bundle oftubes 178 exchanges heat with thecondensate 120 d and evaporates at least a portion of thecondensate 120 d so as to produce a re-evaporatedgaseous fluid 120 f within thecondensate chamber 184. - The re-evaporated
gaseous fluid 120 f is fed to theoutlet header 134 via thereturn pipe 189. The hot gaseous fluid 120 a after exchanging heat indirectly with thecondensate 120 d is fed to theinlet header 132 via thechannel 194. The by-pass valve 198 may allow the hot gaseous fluid 120 a to flow towards theoutlet header 134 via theintermediate channel 196. The regulation of the by-pass valve 198 may depend on temperature of thegaseous fluid 120 a and an operating condition of thefluid processing system 100, such as start-up and/or maintenance. The by-pass valve 198 is typically opened during start-up of thesystem 100 to ensure steady and smooth operation of thesystem 100. Further, the by-pass valve 198 is opened when the temperature of the hot gaseous fluid 120 a is lower than one or more threshold temperatures of thegaseous fluid 120 c and/or thecondensate 120 d. - The
discharge valve 192 is opened intermittently to discharge thecondensate 120 d from thecondensate chamber 184 into theliquid pump 108. In certain other embodiments, thecondensate 120 d may be discharged to themain separator assembly 102. The regulation of thedischarge valve 192 may depend on a level ofcondensate 120 d accumulated within thecondensate chamber 184 and an operating condition of thesystem 100, such as start-up and/or maintenance. During maintenance of thesystem 100, thedischarge valve 192 may be opened to discharge thecondensate 120 d completely from thecondensate chamber 184. Further, thedischarge valve 192 may be opened to discharge a portion of thecondensate 120 d when the level of the condensate is above a threshold level in the condensate chamber. - In accordance with embodiments discussed herein, the fluid processing system facilitates temperature reduction of only the hot gaseous fluid component of a multiphase fluid without sacrificing heat retained in the liquid component of the multiphase fluid. In doing so, the fluid processing system of the present invention acts to limit sludge and/or hydrate formation within the pipelines connecting the system to a storage facility. Further, the heat exchange sub-system separates a condensate from a gaseous fluid and feeds only the gaseous fluid to the gas compressor. The condensate is re-evaporated to enhance the production of the gaseous fluid and facilitate continuous operation of the system. The present invention acts to conserve heat derived from the reservoir and may reduce costs by limiting the need for more active heat conservation measures.
- While only certain features of embodiments have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended embodiments are intended to cover all such modifications and changes as falling within the spirit of the invention.
Claims (25)
1. A heat exchange sub-system comprising:
an inlet header;
an outlet header;
a plurality of heat exchange tubes in fluid communication with the inlet header and outlet header; said heat exchange tubes being configured to exchange heat with a cold ambient environment; and
a liquid-gas separator coupled to the outlet header;
wherein the heat exchange sub-system is configured to receive a hot gaseous fluid comprising condensable and non-condensable components, and to condense at least a portion of the condensable components, the cold ambient environment serving as a heat sink.
2. The heat exchange sub-system of claim 1 , wherein the liquid-gas separator comprises at least one weir separator.
3. The heat exchange sub-system of claim 1 , further comprising a condensate re-evaporator coupled to the liquid-gas separator.
4. The heat exchange sub-system of claim 3 , wherein the condensate re-evaporator comprises a shell and tube heat exchanger configured to evaporate at least a portion of a condensate formed within the heat exchange sub-system.
5. The heat exchange sub-system of claim 4 , wherein the condensate re-evaporator is configured to receive a hot process gas.
6. The heat exchange sub-system of claim 5 , further comprising a by-pass valve configured to regulate a flow of the hot gaseous fluid to the inlet header and outlet header.
7. The heat exchange sub-system of claim 1 , wherein the liquid-gas separator is disposed within the outlet header.
8. A fluid processing system comprising:
(a) a main separator assembly configured to separate a hot multiphase fluid into a hot gaseous fluid comprising condensable and non-condensable components and a hot liquid fluid;
(b) a heat exchange sub-system comprising:
(i) an inlet header;
(ii) an outlet header;
(iii) a plurality of heat exchange tubes in fluid communication with the inlet header and outlet header; said heat exchange tubes being configured to exchange heat with a cold ambient environment; and
(iv) a liquid-gas separator coupled to the outlet header;
wherein the heat exchange sub-system is configured to receive the hot gaseous fluid, and to condense at least a portion of the condensable components to produce a condensate and a gaseous fluid depleted in condensable components, the cold ambient environment serving as a heat sink,
(c) a gas compressor configured to receive the gaseous fluid from the heat exchange sub-system; and
(d) a fluid pump coupled to the main separator assembly;
wherein the pump is configured to drive the hot liquid fluid toward a fluid storage facility.
9. The fluid processing system of claim 8 , wherein the liquid-gas separator comprises at least one weir separator.
10. The fluid processing system of claim 8 , further comprising a condensate re-evaporator coupled to the outlet header.
11. The fluid processing system of claim 10 , wherein the condensate re-evaporator comprises a shell and tube heat exchanger configured to evaporate at least a portion of the condensate formed within the heat exchange sub-system.
12. The fluid processing system of claim 11 , wherein the condensate re-evaporator is configured to receive a hot process gas.
13. The fluid processing system of claim 12 , further comprising a by-pass valve configured to regulate a flow of the hot gaseous fluid to the inlet header and outlet header.
14. The fluid processing system of claim 8 , wherein said gas compressor is driven by a motor configured to be cooled by a slip stream of the gaseous fluid produced by one or more stages of the gas compressor.
15. The fluid processing system of claim 8 , wherein the liquid-gas separator is disposed within the outlet header.
16. A method of transporting a hot, multiphase production fluid, the method comprising:
(a) introducing a hot multiphase fluid into a main separator assembly and separating the hot multiphase fluid into a hot gaseous fluid comprising condensable and non-condensable components, and a hot liquid fluid;
(b) introducing the hot gaseous fluid comprising condensable and non-condensable components into an energy dissipating device and condensing at least a portion of the condensable components to produce a condensate and a gaseous fluid depleted in condensable components;
(c) compressing the gaseous fluid depleted in condensable components to produce a compressed gaseous fluid depleted in condensable components; and
(d) combining the compressed gaseous fluid depleted in condensable components with the hot liquid fluid produced in the main separator assembly.
17. The method of claim 16 , further comprising the step of separating the condensate from the gaseous fluid and collecting the condensate in a liquid-gas separator coupled to the energy dissipating device.
18. The method of claim 17 , further comprising the step of re-evaporating at least a portion of the condensate by transferring heat from the hot gaseous fluid comprising the condensable and non-condensable components to the condensate in a condensate re-evaporator coupled to the liquid-gas separator.
19. The method of claim 18 , further comprising the step of intermittently discharging the condensate from the condensate re-evaporator into a fluid pump.
20. A fluid processing system comprising:
(a) a main separator assembly configured to separate a hot multiphase fluid into a hot gaseous fluid comprising condensable and non-condensable components and a hot liquid fluid;
(b) an energy dissipating device configured to receive the hot gaseous fluid and to condense at least a portion of the condensable components to produce a condensate and a gaseous fluid depleted in condensable components;
(c) a gas compressor configured to receive the gaseous fluid depleted in condensable components from the energy dissipating device; and
(d) a fluid pump coupled to the main separator assembly;
wherein the pump is configured to drive the hot liquid fluid toward a fluid storage facility.
21. The fluid processing system of claim 20 , wherein the energy dissipating device comprises a work extraction device.
22. The fluid processing system of claim 21 , wherein the energy dissipating device is selected from the group consisting of turboexpanders, hydraulic expanders, and hydraulic motors.
23. The fluid processing system of claim 20 , wherein the energy dissipating device is a frictional loss or pressure change device.
24. The fluid processing system of claim 23 , wherein the energy dissipating device is a throttle device.
25. The fluid processing system of claim 20 , wherein the energy dissipating device is a heat exchange sub-system comprising:
(i) an inlet header;
(ii) an outlet header;
(iii) a plurality of heat exchange tubes in fluid communication with the inlet header and outlet header; said heat exchange tubes being configured to exchange heat with a cold ambient environment; and
(iv) a liquid-gas separator coupled to the outlet header.
Priority Applications (6)
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US14/490,096 US20160003558A1 (en) | 2014-07-03 | 2014-09-18 | Fluid processing system, heat exchange sub-system, and an associated method thereof |
GB1621411.6A GB2542962A (en) | 2014-07-03 | 2015-06-16 | Fluid processing system, heat exchange sub-system, and an associated method thereof |
BR112017000003A BR112017000003A2 (en) | 2014-07-03 | 2015-06-16 | heat exchange subsystem, fluid processing systems and fluid transport method |
PCT/US2015/035950 WO2016003637A1 (en) | 2014-07-03 | 2015-06-16 | Fluid processing system, heat exchange sub-system, and an associated method thereof |
AU2015284617A AU2015284617C1 (en) | 2014-07-03 | 2015-06-16 | Fluid processing system, heat exchange sub-system, and an associated method thereof |
NO20161974A NO20161974A1 (en) | 2014-07-03 | 2016-12-13 | Fluid processing system, heat exchange sub-system, and an associated method thereof |
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US14/490,096 US20160003558A1 (en) | 2014-07-03 | 2014-09-18 | Fluid processing system, heat exchange sub-system, and an associated method thereof |
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US14/490,183 Abandoned US20160003255A1 (en) | 2014-07-03 | 2014-09-18 | Fluid processing system, an energy-dissipating device, and an associated method thereof |
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AU (2) | AU2015284617C1 (en) |
BR (2) | BR112017000003A2 (en) |
GB (2) | GB2542962A (en) |
NO (2) | NO20161974A1 (en) |
WO (2) | WO2016003637A1 (en) |
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US20190010796A1 (en) * | 2015-12-30 | 2019-01-10 | General Electric Company | Underwater gas/liquid-liquid method and separation system and use of deoling membrane |
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FR3072429B1 (en) * | 2017-10-16 | 2020-06-19 | L'air Liquide Societe Anonyme Pour L'etude Et L'exploitation Des Procedes Georges Claude | COMPRESSION DEVICE AND METHOD |
FR3072428B1 (en) * | 2017-10-16 | 2019-10-11 | L'air Liquide Societe Anonyme Pour L'etude Et L'exploitation Des Procedes Georges Claude | COMPRESSION DEVICE AND METHOD AND REFRIGERATION MACHINE |
US11067000B2 (en) | 2019-02-13 | 2021-07-20 | General Electric Company | Hydraulically driven local pump |
EP3686436A1 (en) * | 2019-07-31 | 2020-07-29 | Sulzer Management AG | Multistage pump and subsea pumping arrangement |
CN110566812B (en) * | 2019-08-06 | 2021-08-03 | 李珊 | Natural gas station gas transmission process |
CN113483368A (en) * | 2021-05-17 | 2021-10-08 | 孙杰 | Oil smoke purification separator |
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- 2015-06-16 BR BR112017000003A patent/BR112017000003A2/en not_active Application Discontinuation
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Also Published As
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GB2542962A (en) | 2017-04-05 |
GB201621411D0 (en) | 2017-02-01 |
NO20161974A1 (en) | 2016-12-13 |
GB2542297A (en) | 2017-03-15 |
WO2016004271A1 (en) | 2016-01-07 |
BR112016029424A2 (en) | 2017-08-22 |
WO2016003637A1 (en) | 2016-01-07 |
US20160003255A1 (en) | 2016-01-07 |
GB201621412D0 (en) | 2017-02-01 |
WO2016003637A8 (en) | 2017-02-02 |
AU2015284617A1 (en) | 2017-01-05 |
AU2015284617B2 (en) | 2018-10-04 |
AU2015283998B2 (en) | 2018-10-18 |
BR112017000003A2 (en) | 2017-10-31 |
NO20161988A1 (en) | 2016-12-15 |
AU2015283998A1 (en) | 2017-01-12 |
AU2015284617C1 (en) | 2019-01-31 |
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