A natural gas separator integrated device

Abstract

This application relates to the field of natural gas processing technology, specifically to an integrated natural gas separator device. The device includes a separator, valve assembly, level gauge, control unit, sensing unit, electric valve, and audible and visual alarm device. The separator is composed of a dual-cylinder separator, a slug trap, and a flash separator connected in sequence. The valve assembly includes a control valve installed on the separator's inlet pipe, a shut-off valve on the outlet pipe, and a bypass valve on the drain pipe. The level gauge includes a magnetic level gauge and a radar level gauge, respectively installed in the separator's level observation window and on its top. The control unit is connected to the level gauge, sensing unit, and electric valve. The sensing unit includes a pressure sensor and a flow sensor, respectively installed on the separator's inlet and outlet pipes. The electric valve is installed on the drain pipe and connected to the control unit. The audible and visual alarm device is installed externally to the device and connected to the control unit.

Description

Technical Field

[0001] This application relates to the field of natural gas processing technology, and more specifically, to an integrated natural gas separator device. Background Technology

[0002] Natural gas needs to undergo strict gas-liquid separation and solid-liquid impurity removal processes before transportation and compression to ensure that the gas quality at the compressor inlet meets the requirements, extend the service life of the equipment, and ensure long-term trouble-free operation of the system.

[0003] Traditional separators rely heavily on manual monitoring and adjustment, which is inefficient and prone to operational errors.

[0004] Therefore, there is an urgent need for an intelligent control method to improve the automation level and operational stability of integrated natural gas systems. Utility Model Content

[0005] In view of this, this application provides a natural gas separator integrated device.

[0006] The embodiments of this application are implemented as follows:

[0007] This application provides an integrated natural gas separator device, including a separator, valve group, level gauge, control unit, sensing unit, electric valve, and audible and visual alarm device:

[0008] The separator is composed of a twin-cylinder separator, a slug flow trap and a flash separator connected in sequence.

[0009] The valve group includes a control valve installed on the separator inlet pipe, a shut-off valve on the outlet pipe, and a bypass valve on the drain pipe.

[0010] The level gauge includes a magnetic float level gauge and a radar level gauge, which are respectively installed in the level observation window and the top of the separator;

[0011] The control unit is connected to the level gauge, the sensing unit and the electric valve, and is used to receive data and send control commands.

[0012] The sensing unit includes a pressure sensor and a flow sensor, which are respectively installed on the inlet pipe and outlet pipe of the separator.

[0013] The electric valve is installed on the sewage pipe and connected to the control unit for adjusting the sewage discharge volume;

[0014] The audible and visual alarm device is installed outside the device and connected to the control unit for use in alarming abnormal situations.

[0015] In one possible implementation, the dual-cylinder separator is equipped with a gas-liquid distributor and a mist trap, the slug flow collector is equipped with a specially shaped collection net, and the flash separator separates trace amounts of liquid from the gas using the principle of pressure difference.

[0016] In one possible implementation, the components of the separator are connected by flanges.

[0017] In one possible implementation, the control valve, shut-off valve, and bypass valve of the valve group are all connected to the drive device via valve stems, and the drive device is connected to the control unit via control cables.

[0018] In one possible implementation, the magnetic float level gauge drives the magnetic float to flip and display the liquid level height through changes in liquid level, and the radar level gauge measures the distance to the liquid surface through microwave pulses. Both are connected to the control unit via a 4-20mA analog signal line.

[0019] In one possible implementation, the control unit is an industrial-grade ARM processor equipped with RAM and solid-state storage, and supports multiple industrial communication protocols.

[0020] In one possible implementation, the electric valve is driven by an AC motor, with an opening adjustment range of 0-100%, and has a built-in limit switch and overload protection device.

[0021] In one possible implementation, the audible and visual alarm device includes a buzzer and an LED flashing light. When triggered, the buzzer emits an alarm sound of more than 85dB, and the LED flashes at a frequency of 2Hz.

[0022] In one possible implementation, the pressure sensor is a diffused silicon pressure transmitter, and the flow sensor is a turbine flow meter.

[0023] In one possible implementation, the control unit is connected to the station control system via an Ethernet interface.

[0024] The technical solution provided in this application can achieve at least the following beneficial effects:

[0025] This application provides an integrated natural gas separator device that integrates data acquisition, analysis, and control functions at the separator site, reducing data transmission delay and improving response speed. It is widely used in the field of natural gas processing, and is particularly valuable in scenarios such as gas gathering stations and compressor stations. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0027] Figure 1 This is a schematic diagram of the overall structure of a natural gas separator integrated device according to an exemplary embodiment of this application;

[0028] Figure 2 This is a schematic flowchart illustrating a control method for a natural gas separator integrated device according to an exemplary embodiment of this application.

[0029] Figure label:

[0030] 1. Electric regulating valve; 2. Level gauge; 3. Control unit; 4. Separator; 5. Pressure sensor; 6. Flow sensor. Detailed Implementation

[0031] To make the objectives, implementation methods and advantages of this application clearer, the exemplary implementation methods of this application will be clearly and completely described below with reference to the accompanying drawings of the exemplary embodiments of this application. Obviously, the exemplary embodiments described are only some embodiments of this application, and not all embodiments. It should be understood that the specific embodiments described herein are only used to explain this application and are not intended to limit this application.

[0032] It should be noted that the brief descriptions of terms in this application are only for the convenience of understanding the embodiments described below, and are not intended to limit the embodiments of this application. Unless otherwise stated, these terms should be understood in their ordinary and common meaning.

[0033] The terms "first," "second," "third," etc., used in the specification, claims, and accompanying drawings of this application are used to distinguish similar or related objects or entities, and do not necessarily imply a specific order or sequence, unless otherwise specified. It should be understood that such terms are interchangeable where appropriate.

[0034] The terms “comprising” and “having”, and any variations thereof, are intended to cover but not exclude inclusion, for example, a product or device that includes a range of components is not necessarily limited to all of the components that are clearly listed, but may include other components that are not clearly listed or that are inherent to such product or device.

[0035] Before explaining the integrated natural gas separator device provided in the embodiments of this application, the application scenarios and implementation environment of the embodiments of this application will be introduced first.

[0036] Natural gas needs to undergo strict gas-liquid separation and solid-liquid impurity removal processes before transportation and compression to ensure that the gas quality at the compressor inlet meets the requirements, extend the service life of the equipment, and ensure long-term trouble-free operation of the system.

[0037] Traditional separators rely heavily on manual monitoring and adjustment, which is inefficient and prone to operational errors.

[0038] Therefore, there is an urgent need for an intelligent control method to improve the automation level and operational stability of integrated natural gas systems.

[0039] Next, the technical solutions of this application and how they solve the aforementioned technical problems will be described in detail through embodiments and in conjunction with the accompanying drawings. The embodiments can be combined with each other, and the same or similar concepts or processes may not be repeated in some embodiments. Obviously, the described embodiments are only some, not all, of the embodiments of this application.

[0040] In one exemplary embodiment, such as Figure 1 As shown, a natural gas separator integrated device is provided. In this embodiment, the device includes a separator, a valve group, a level gauge, a control unit, a sensing unit, an electric valve, and an audible and visual alarm device.

[0041] The separator 4 is composed of a double-cylinder separator, a slug flow trap and a flash separator connected in sequence.

[0042] In one embodiment, the separator consists of a dual-cylinder separator, a slug flow trap, and a flash separator connected sequentially via flanges.

[0043] Dual-cylinder separator: Internally equipped with a gas-liquid distributor and a mist eliminator, it is used for preliminary separation of gas and liquid. The gas-liquid distributor ensures uniform gas distribution and prevents liquid entrainment by the airflow; the mist eliminator captures entrained liquid particles, improving the separation effect.

[0044] Slug Flow Collector: Equipped with a specially shaped collecting net to further capture liquid or impurities in the slug flow. The specially shaped net increases the collecting area and improves collecting efficiency.

[0045] Flash separator: Utilizes the principle of pressure difference to further separate trace amounts of liquid from gas. When the gas pressure decreases, the gas dissolved in the liquid is released, thus achieving gas-liquid separation.

[0046] The valve assembly includes a control valve installed on the separator inlet pipe, a shut-off valve on the outlet pipe, and a bypass valve on the drain pipe.

[0047] In one embodiment, the valve assembly includes an electrically controlled regulating valve, a safety shut-off valve, and a bypass valve, which are respectively installed on the inlet pipe, outlet pipe, and drain pipe of the separator.

[0048] Electric regulating valve 1: It adopts a pneumatic actuator, receives commands from the control unit via a signal line, and adjusts the opening range from 0-100%. The pneumatic actuator has a fast response speed and high control accuracy.

[0049] Safety shut-off valve: Automatically cuts off the gas supply in emergencies to ensure system safety. When the system pressure exceeds the set value or other emergency occurs, the safety shut-off valve will quickly close, cutting off the gas supply.

[0050] Bypass valve: Used to switch processes during maintenance or failure. Bypass valves allow gas to bypass the separator, ensuring the normal operation of downstream equipment.

[0051] The level gauge 2 includes a magnetic float level gauge and a radar level gauge, which are respectively installed in the level observation window and the top of the separator.

[0052] In one embodiment, the level gauge includes a magnetic float level gauge and a radar level gauge.

[0053] Magnetic float level gauge: Installed in the liquid level observation window of the separator, it drives the magnetic float to flip according to the liquid level change, so as to intuitively display the liquid level height. The magnetic float level gauge has a simple structure and is easy to read.

[0054] Radar level gauge: Installed on top of the separator, it uses microwave pulses to measure the distance to the liquid level, with an accuracy of ±5mm. The radar level gauge offers high measurement accuracy and is unaffected by medium density, viscosity, or other factors.

[0055] Both are connected to the control unit via 4 to 20mA analog signal lines to transmit liquid level data in real time.

[0056] The control unit 3 is connected to the level gauge, the sensing unit and the electric valve, and is used to receive data and send control commands.

[0057] In one embodiment, the control unit is an edge computing controller employing an industrial-grade ARM processor with a clock speed of up to 1.5GHz, equipped with 2GB of RAM and 16GB of solid-state storage. Its communication module supports multiple industrial protocols such as Profibus and Modbus RTU, enabling communication with devices such as level gauges, pressure sensors, and flow sensors. The control unit connects to the station control system via an Ethernet interface, enabling data uploading and remote monitoring.

[0058] The sensing unit includes a pressure sensor and a flow sensor, which are respectively installed on the inlet pipe and outlet pipe of the separator.

[0059] In one embodiment, the sensing unit includes a pressure sensor 5 and a flow sensor 6.

[0060] Pressure sensor: A diffused silicon pressure transmitter with a range of 0-10MPa and an accuracy of 0.2 is used. It is installed on the pipe wall of the separator's inlet and outlet pipes.

[0061] Flow sensor: a turbine flow meter with an accuracy of 0.5, installed on the outlet pipe.

[0062] Both transmit pressure and flow data to the control unit via signal lines for real-time monitoring and control.

[0063] The electric valve is installed on the sewage pipe and connected to the control unit to regulate the sewage discharge volume.

[0064] In one embodiment, the electric valve is installed on the sewage pipe, driven by an AC motor, and has an opening adjustment range of 0-100%. The control unit sends a PWM signal through a control cable to control the opening of the electric valve, thereby achieving precise adjustment of the sewage discharge volume. The electric valve has built-in limit switches and overload protection devices to ensure safe operation.

[0065] The audible and visual alarm device is installed outside the device and connected to the control unit for use in alarming abnormal situations.

[0066] In one embodiment, the audible and visual alarm device includes a buzzer and a flashing LED light, installed in a conspicuous location on the exterior of the device. When the liquid level is too high or the pressure is abnormal, the control unit triggers the alarm device via a control line. The buzzer emits an alarm sound of 85dB or higher, and the LED light flashes at a frequency of 2Hz, alerting on-site personnel to take timely action.

[0067] Using the same inventive concept, in one exemplary embodiment, this application also provides a control method for a natural gas separator integrated device, comprising:

[0068] Step 100: Real-time operating data within the separator is collected using a level gauge, pressure sensor, and flow sensor, and transmitted to the control unit via a signal line. The operating data includes liquid level height, gas pressure, and flow rate data.

[0069] In one embodiment, a level gauge, pressure sensor, and flow sensor collect real-time data on liquid level, gas pressure, and flow rate within the separator at a frequency of 1 Hz. The data is transmitted to the control unit via a signal line, where it undergoes preliminary filtering to remove interference signals and ensure data accuracy.

[0070] Step 200: Based on the operating data, the control unit performs filtering to fit the change curves of liquid level, pressure and flow rate.

[0071] In one embodiment, after receiving the processed data, the control unit analyzes and processes it using a preset PID control algorithm and a slug flow prediction model. Specifically, it performs curve fitting on the liquid level, pressure, and flow rate data to generate parameter change trend curves. Using the least squares method or curve fitting algorithm, the changing trends of the parameters can be accurately reflected.

[0072] Step 300: Based on the change curve, calculate the control parameters through the control unit. The control parameters include valve opening adjustment parameters and alarm threshold parameters.

[0073] In one embodiment, the calculation process involves determining whether abnormal conditions such as slug flow have occurred based on the curve slope and a preset threshold. If the liquid level exceeds the set 70% warning value, the control unit calculates the electric valve opening adjustment parameters to ensure that the liquid level remains stable within the set range.

[0074] Step 400: Generate control commands corresponding to the control parameters through the control unit and send them to the corresponding electric valve or audible and visual alarm device.

[0075] In one embodiment, the control unit generates corresponding control commands based on the calculated control parameters.

[0076] Specifically, when the liquid level reaches 80% (high liquid level), the control unit generates a command to increase the opening of the electric valve by 30%.

[0077] Step 500: Based on the control command, adjust the opening degree of the electric valve and trigger an alarm prompt through the audible and visual alarm device.

[0078] In one embodiment, after receiving a command, the electric valve drives the motor to adjust the opening degree, thereby achieving precise control of the sewage discharge volume. At the same time, the control unit sends an alarm signal to the audible and visual alarm device to trigger an alarm prompt.

[0079] Step 600: Continuously monitor the operating status of the separator and dynamically adjust the control parameters based on real-time operating data to form a closed-loop control.

[0080] In one embodiment, the control unit continuously monitors the operating status of the separator and dynamically adjusts the control parameters based on real-time data.

[0081] Specifically, if the slug flow prediction model determines that a slug flow is imminent, the control unit adjusts the opening of the electric regulating valve in the intake pipeline in advance to reduce the liquid inlet flow rate, and at the same time controls the electric regulating valve for the drain to maintain the liquid level at the midline, forming a closed-loop control to ensure the stable operation of the separator.

[0082] In one possible implementation, the control unit connects to the station control system via an Ethernet interface to upload operational data in real time and receive remote monitoring commands.

[0083] In one embodiment, the control unit is connected to the station control system via an Ethernet interface to enable data uploading and remote monitoring. The station control system can view the separator's operating status and historical data in real time and remotely adjust control parameters. At the same time, the control unit supports connection with a mobile terminal APP, making it convenient for maintenance personnel to monitor the equipment's operation anytime and anywhere.

[0084] Work process:

[0085] The process begins, and the system prepares to enter the data acquisition and control phase.

[0086] Real-time acquisition of equipment operating data is achieved using field instruments. Various field instruments installed on the equipment (such as temperature sensors, pressure sensors, level gauges, flow meters, etc.) are used to collect various parameter data of the equipment during operation. It is important to ensure that all field instruments are working properly and calibrated. The data collected by the instruments is transmitted to the edge controller through a data acquisition system (such as a data acquisition card, PLC, etc.). The data acquisition frequency should be set according to the characteristics of the equipment and control requirements to ensure the real-time performance and accuracy of the data.

[0087] The edge controller processes the collected production operation data, fits the curves of key parameters, and completes the allocation of computational tasks and the calculation of control parameters. The edge controller processes and analyzes the collected production operation data, fits the variation curves of key parameters, and completes the allocation of computational tasks and the calculation of control parameters based on these curves. It is important to note that the collected data undergoes preprocessing, such as filtering and noise reduction, to improve data quality. Mathematical methods (such as least squares method and curve fitting algorithms) are used to fit the key parameters, generating parameter variation curves. Based on the fitted parameter curves and the operating status of the equipment, computational tasks are rationally allocated to ensure efficient use of computing resources. Based on the fitted curves and task allocation results, the various control parameters required for the operation of the control equipment are calculated, such as the opening degree of regulating valves and the opening / closing of electric valves.

[0088] Based on the calculated control parameters, the corresponding regulating valves are controlled to coordinate and regulate the operation of the equipment. Based on the control parameters calculated by the edge controller, the actuators such as regulating valves on the equipment are controlled to achieve coordinated regulation of the equipment's operating status. It should be noted that the calculated control parameters are sent to the corresponding actuators, such as regulating valves and electric switching valves. The actuators act according to the received control parameters, such as adjusting the opening of the regulating valve or opening / closing the electric valve. Through the coordinated actions of multiple actuators, precise control of the overall operating status of the equipment is achieved, ensuring that the equipment operates in the optimal state.

[0089] After the process is completed, the equipment enters a stable operating state after being adjusted by the above control logic.

[0090] It can be seen that some embodiments of this application have the following advantages:

[0091] Real-time data acquisition: Utilizing field instruments to acquire equipment operating data in real time ensures the timeliness, accuracy, and comprehensiveness of the data, specifically manifested in:

[0092] Real-time performance: Data is collected in real time by field instruments, which can reflect the operating status of the equipment in a timely manner and avoid the problem of untimely control caused by data lag.

[0093] Accuracy: Field instruments are directly installed on the equipment, enabling accurate acquisition of various parameters of the equipment and reducing errors in the data transmission process.

[0094] Comprehensiveness: The collected data includes various parameters such as temperature, pressure, and flow rate, which can comprehensively reflect the operating status of the equipment and provide sufficient data support for subsequent analysis and control.

[0095] Data processing and parameter fitting: The edge controller processes the collected production operation data, fits the main parameter curves, and completes the calculation task allocation and control parameter calculation, thereby improving the efficiency and accuracy of data processing. Specifically, this is reflected in:

[0096] Data processing: The edge controller preprocesses the collected data, such as filtering and noise reduction, which improves the data quality and provides a reliable foundation for subsequent analysis and calculation.

[0097] Parameter fitting: By fitting the main parameters using mathematical methods, parameter variation curves are generated, which can intuitively reflect the changing trend of the parameters and provide a scientific basis for the formulation of control strategies.

[0098] Task allocation: Based on the fitted parameter curves and the operating status of the equipment, computational tasks are allocated reasonably, which improves the utilization efficiency of computing resources and avoids the waste of computing resources.

[0099] Control parameter calculation: Based on the fitted curve and task allocation results, the various control parameters required for the operation of the control equipment are calculated, ensuring the accuracy and effectiveness of the control.

[0100] Precise control and coordinated adjustment: Based on calculated control parameters, corresponding regulating valves are controlled, thereby coordinating the operation of the equipment and achieving precise control over the equipment's operating status. Specifically, this is manifested in:

[0101] Precise control: By controlling actuators such as regulating valves through calculated control parameters, the operating status of the equipment can be precisely adjusted, avoiding the instability of equipment operation caused by control errors.

[0102] Coordinated adjustment: Through the coordinated actions of multiple actuators, precise control of the overall operating status of the equipment can be achieved, ensuring that the equipment operates in the optimal state and improving the operating efficiency and stability of the equipment.

[0103] Flexibility: The control parameters and actuator actions can be flexibly adjusted according to the equipment's operating status and control requirements, which can adapt to different operating conditions and control requirements, thus improving the flexibility and adaptability of the control system.

[0104] Real-time monitoring and feedback: Through real-time data acquisition and processing, real-time monitoring and feedback of equipment operating status are achieved, improving the operational safety and reliability of the equipment. Specifically, this is reflected in:

[0105] Real-time monitoring: By collecting and processing equipment operation data in real time, abnormal situations in equipment operation can be detected in a timely manner, avoiding production interruptions and economic losses caused by equipment failure.

[0106] Feedback adjustment: Based on real-time monitoring data, control parameters and actuator actions are adjusted in a timely manner, realizing closed-loop control of equipment operation status and improving equipment operation safety and reliability.

[0107] Early warning function: By analyzing and processing equipment operation data, it can provide early warning of possible equipment failures and problems, providing a scientific basis for equipment maintenance and extending the service life of the equipment.

[0108] Traditional separation units do not have independent controllers on their main body; all transmitters are connected to the station control system via cables from a junction box. This means the unit must rely on the station control system and cannot operate independently, which also hinders the expansion of the unit's intelligent functions.

[0109] In some embodiments of this application, the control unit provided is an independent edge control unit, which has independent functions, facilitates application expansion, performs front-end calculations, reduces back-end load, has high reliability, operates normally independently, is easy to migrate, and allows for flexible adjustment between stations. Simultaneously, through edge control algorithms, the control process is optimized, improving the separation efficiency and stability of the equipment.

[0110] The above are merely preferred embodiments of this utility model and are not intended to limit the scope of this utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

[0111] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0112] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A natural gas separator integrated device, characterized by, Includes separator, valve assembly, level gauge, control unit, sensing unit, electric valve, and audible and visual alarm device: The separator is composed of a twin-cylinder separator, a slug flow trap and a flash separator connected in sequence. The valve group includes a control valve installed on the separator inlet pipe, a shut-off valve on the outlet pipe, and a bypass valve on the drain pipe. The level gauge includes a magnetic float level gauge and a radar level gauge, which are respectively installed in the level observation window and the top of the separator; The control unit is connected to the level gauge, the sensing unit and the electric valve, and is used to receive data and send control commands. The sensing unit includes a pressure sensor and a flow sensor, which are respectively installed on the inlet pipe and outlet pipe of the separator. The electric valve is installed on the sewage pipe and connected to the control unit for adjusting the sewage discharge volume; The audible and visual alarm device is installed outside the device and connected to the control unit for use in alarming abnormal situations.

2. The natural gas separator integrated device of claim 1, wherein, The dual-cylinder separator is equipped with a gas-liquid distributor and a mist-catching net inside. The slug flow collector is equipped with a specially shaped collecting net inside. The flash separator separates trace amounts of liquid from the gas using the principle of pressure difference.

3. The natural gas separator integrated device of claim 2, wherein, The components of the separator are connected by flanges.

4. The natural gas separator integrated device of claim 1, wherein, The control valve, shut-off valve, and bypass valve of the valve group are all connected to the drive device via valve stems, and the drive device is connected to the control unit via control cables.

5. The natural gas separator integrated device of claim 1, wherein, The magnetic float level gauge drives the magnetic float to flip and display the liquid level height by changing the liquid level. The radar level gauge measures the distance to the liquid surface by microwave pulses. Both are connected to the control unit via a 4-20mA analog signal line.

6. The natural gas separator integrated device of claim 1, wherein, The control unit is an industrial-grade ARM processor, equipped with RAM and solid-state storage, and supports multiple industrial communication protocols.

7. The natural gas separator integrated unit of claim 1, wherein, The electric valve is driven by an AC motor, with an opening adjustment range of 0-100%, and has a built-in limit switch and overload protection device.

8. The natural gas separator integrated unit of claim 1, wherein, The audible and visual alarm device includes a buzzer and an LED flashing light. When triggered, the buzzer emits an alarm sound of more than 85dB, and the LED flashes at a frequency of 2Hz.

9. The natural gas separator integrated unit of claim 1, wherein, The pressure sensor is a diffused silicon pressure transmitter, and the flow sensor is a turbine flow meter.

10. The natural gas separator integrated device of claim 1, wherein, The control unit is connected to the station control system via an Ethernet interface.

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