Cooler Apparatus Self-Cleaning via Localized Thermal Cycling
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Solution Overview
Problem
Current flow assurance technologies in hydrocarbon production face challenges with the buildup of waxes and hydrates, leading to clogging and reduced production rates, particularly in subsea environments, due to the complexity and high cost of existing methods such as insulation, chemical inhibition, and hot oil flushing.
Innovation Solution
A method and apparatus that control the flow of fluid and cooling medium to create a local increase in temperature within the heat exchange conduit, releasing solid deposits from the inner surface into the flowing fluid, using thermal energy from the process fluid to clean the cooler system without the need for external heating or frequent shutdowns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flow assurance methods such as insulation, chemical inhibition, and heating are used to prevent wax and hydrate buildup, then production flow reliability is improved, but system complexity and cost increase
Solution Approach 1:
The cooler system uses its own operational characteristics to clean deposits. By temporarily stopping cooling to selected pipe sections, the deposited materials are released into the fluid stream due to temperature equalization, cleaning the pipes without external intervention. This self-service mechanism eliminates the need for separate heating systems, chemical injection, or mechanical cleaning equipment.
Solution Approach 2:
The system implements periodic cleaning cycles where cooling is temporarily stopped to selected pipe sections for predetermined time periods. This periodic action allows deposits to accumulate during normal operation and then be released during cleaning cycles, maintaining flow reliability without continuous complex interventions.
2Productivity
If hot oil flushing or chemical injection is used to remove deposits, then production rates are maintained, but environmental impact and operational cost increase
Solution Approach 1:
The system converts the harmful effect of temperature differences that cause deposit formation into a beneficial cleaning mechanism. By temporarily stopping cooling, the temperature equalization between the pipe wall and fluid stream releases deposits naturally, transforming the thermal conditions that create problems into a self-cleaning solution without chemicals or external heating.
3Reliability
If external heating systems are installed to prevent solid deposition, then deposit formation is reduced, but device complexity and energy consumption increase
Solution Approach 1:
The system uses the inherent thermal energy already present in the fluid stream and pipe wall to clean deposits. By temporarily stopping cooling, the stored thermal energy in the pipe wall heats the fluid and releases deposits without requiring external heating systems or additional energy input. The system serves itself using its own operational characteristics.
4Reliability
If frequent pipeline pigging and hot oil flushing are performed to clean deposits, then flowline clogging is avoided, but production downtime and maintenance cost increase
Solution Approach 1:
The system maintains continuous production by performing cleaning operations during normal operational cycles rather than requiring shutdowns. The periodic stopping of cooling to selected sections for brief predetermined periods allows cleaning to occur while the rest of the system continues to produce, eliminating the need for extended maintenance downtime associated with traditional pigging and flushing methods.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables continuous production with stable exit temperatures, effectively removing deposits from cooler systems, reducing maintenance costs, and minimizing the environmental impact by utilizing inherent thermal energy, thus addressing the limitations of existing methods.
Implementation Method 1
flowing a fluid to be cooled through the at least one heat exchange conduit from a first cooler inlet to a first cooler outlet, to cool the fluid from an inflow temperature to an exit temperature by heat exchange with the cooling medium
Implementation Method 2
controlling the flow of the fluid through the at least one heat exchange conduit and the flow of the cooling medium to cause a local increase in a temperature in a selected portion of the at least one heat exchange conduit
Data Source
AI summary
The invention provides a cooler apparatus and a method use. The cooler apparatus has at least one heat exchange conduit passing through a cooling medium. The method comprises flowing a fluid to be cooled through the at least one heat exchange conduit from a first cooler inlet to a first cooler outlet, to cool the fluid from an inflow temperature to an exit temperature by heat exchange with the cooling medium. In an aspect of the invention, the flow of the fluid through the at least one heat exchange conduit and the flow of the cooling medium are controlled to cause a local increase in a temperature in a selected portion of the at least one heat exchange conduit. This causes deposits of solids to be released from an inner surface of the selected portion of the at least one heat exchange conduit into the flowing fluid. The method may comprise restricting or containing the cooling medium around the selected portion of the at least one heat exchange conduit, and/or controlling the flow of the fluid to be cooled by re-routing the flow path of the fluid through a selected inlet of the at least one heat exchange conduit.