Hydrocarbon Pump Engine Load Control for Gas Conservation
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Solution Overview
Problem
In hydrocarbon production, casing gas is often vented or flared due to cost considerations and regulatory constraints, leading to safety risks and production losses, especially when gas volumes fluctuate, and storage or pipelining is not feasible.
Innovation Solution
A system and method that monitor gas pressure and adjust engine throttle and external load to maintain the engine within an optimal RPM range, using a programmable logic controller and generator to burn increasing gas volumes, thereby reducing venting and flaring while ensuring engine safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the engine is allowed to burn whatever volume of gas is produced, then gas conservation is improved, but the engine operation increases to dangerous levels possibly to redline where damage to the engine can occur
Solution Approach 1:
The system continuously monitors engine RPM and gas volume, and automatically adjusts the engine throttle and external load in real-time. When gas volume increases, the controller increases throttle to burn more gas while simultaneously adjusting load to maintain RPM within the optimal range, preventing dangerous operating conditions while maximizing gas utilization.
Solution Approach 2:
The system dynamically adjusts both the engine throttle position and external load based on real-time gas volume conditions. This dynamic control allows the engine to adapt to varying gas volumes by changing operating parameters, enabling the engine to burn increased gas volumes safely without exceeding RPM limits or compromising reliability.
2Adaptability or versatility
If gas volumes are allowed to vary substantially over time, then production flexibility is improved, but complex equipment solutions are required which could be economically unfeasible
Solution Approach 1:
The controller serves multiple functions: it monitors engine RPM, regulates engine throttle position, manages external load, and coordinates the interaction between engine and generator. This multi-functional control system handles varying gas volumes through a single integrated unit rather than requiring separate complex equipment for each function, making the solution economically feasible.
Solution Approach 2:
The system automatically monitors and adjusts its own operating parameters without external intervention. The controller self-regulates engine throttle and load based on real-time conditions, eliminating the need for complex manual control systems or additional safety equipment, thereby reducing overall system complexity while maintaining adaptability to gas volume variations.
3Loss of substance
If the engine throttle is increased to burn increasing amounts of gas, then gas conservation is improved, but the engine may exceed optimal RPM range causing damage
Solution Approach 1:
The system uses continuous feedback from RPM sensors to monitor engine speed and automatically adjusts the throttle position and external load to maintain operation within the optimal RPM range. This closed-loop control ensures that increased gas volumes are burned efficiently while preventing the engine from exceeding precise operating parameters that could cause damage.
Solution Approach 2:
The system changes multiple operating parameters simultaneously - increasing throttle position to burn more gas while also adjusting external load to maintain optimal RPM. By coordinating changes in multiple parameters rather than adjusting throttle alone, the system achieves improved gas conservation while maintaining precise engine operation within safe limits.
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 reduces gas venting and flaring, maintains engine safety, and prevents production losses by efficiently managing varying gas volumes, even in remote locations where personnel may not be present to address engine issues.
Implementation Method 1
the oil pumps are driven by engines that are configured to burn natural gas
Implementation Method 2
using the engine to drive one or more generators to create electricity
Data Source
AI summary
Systems and methods for reducing produced gas venting from a hydrocarbon well, in which the engine driving the pump burns produced gas from the well, the engine made to increase its throttle to burn more gas in response to an increased gas pressure indicator, and an external load such as a generator directed to increase the load on the engine and maintain the engine operating within a desired revolutions-per-minute range to avoid redline condition.