Mobile Gas Processing Skid With Fold-Down Dehydration Tower
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Solution Overview
Problem
Conventional gas processing systems for hydrocarbon wells are not mobile and require significant time, human effort, and cost for mobilization and demobilization, with a large site footprint, and are unable to handle a wide range of hydrocarbon gas qualities efficiently.
Innovation Solution
A mobile gas processing plant with permanently installed components on a transport unit that can quickly convert between operational and transportation modes, processing raw or partially processed hydrocarbon gas into purified, sales-quality gas without additional piping, capable of handling any hydrocarbon gas quality and producing clean, dry gas for use as fuel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If conventional gas processing systems are used, then gas processing can be performed, but the system requires significant time and cost for mobilization and demobilization
Solution Approach 1:
The gas processing system is divided into modular skid-mounted units that can be independently transported and assembled. Each module contains specific processing functions (separation, dehydration, compression) that can be configured based on gas quality requirements, enabling rapid deployment without complex site preparation
Solution Approach 2:
The system transitions from a static conventional installation to a dynamic mobile platform that can be quickly relocated. The skid-mounted design with pre-assembled modules allows the system to be transported on trailers and deployed at different well sites, adapting to varying production locations and gas qualities
2Area of stationary object
If conventional gas processing systems are used, then gas processing can be performed, but the system occupies a large site footprint
Solution Approach 1:
The system consolidates multiple processing functions into vertically stacked skid-mounted modules, transitioning from a horizontal spread of equipment to a compact vertical arrangement. This dimensional reorganization maintains full processing capability while reducing the ground footprint to a fraction of conventional systems
Solution Approach 2:
Multiple gas processing functions (liquid-gas separation, dehydration, compression, heating) that would traditionally require separate equipment groups are merged into integrated skid-mounted modules. This consolidation eliminates the need for extensive piping and interconnections between separate units, reducing both footprint and complexity
3Ease of operation
If conventional gas processing systems are used, then gas processing can be performed, but manual rigging and additional piping are required
Solution Approach 1:
All piping, instrumentation, and equipment connections are pre-assembled and tested on skid-mounted modules before shipment to the site. This preliminary preparation eliminates the need for complex on-site rigging and piping installation, requiring only simple module placement and connection to existing well infrastructure
Solution Approach 2:
The system incorporates self-contained modules with integrated components that require minimal external assembly. Each skid is a self-sufficient processing unit with all necessary connections and support structures pre-installed, enabling rapid deployment without specialized installation equipment or extensive manual rigging
4Adaptability or versatility
If conventional gas processing systems are used, then gas processing can be performed, but the system cannot efficiently handle a wide range of hydrocarbon gas qualities
Solution Approach 1:
The skid-mounted modules are designed with universal processing capabilities that can handle various gas qualities (wet gas, sour gas, sweet gas) through configurable component selections. The same basic module design can be adapted to different gas compositions by adjusting operating parameters and selecting appropriate filtration, dehydration, and separation components
Solution Approach 2:
The system allows for localized customization of processing components based on specific gas quality requirements at each well site. While the overall module design is standardized for versatility, individual components (such as filter specifications, dehydration capacity, or separation efficiency) can be optimized for the local gas composition, achieving both adaptability and operational simplicity
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
The mobile gas processing plant achieves efficient, high-quality gas processing with a smaller footprint, reduced mobilization time, and lower costs, producing purified hydrocarbon gas ready for use as fuel, while maintaining operational readiness without manual rigging.
Implementation Method 1
a first Joule-Thompson (JT) valve unit, and a second JT valve unit... flowing the received hydrocarbon gas mixture through a first JT valve unit to convert a portion of the hydrocarbon gas mixture into a liquid-phase... flowing the third hydrocarbon gas mixture through a second JT valve unit to convert a portion of the third hydrocarbon gas mixture into a liquid-phase
Implementation Method 2
heating the second hydrocarbon gas mixture by flowing the second hydrocarbon gas mixture into a contact tower of a dehydration unit to generate a third hydrocarbon gas mixture
Data Source
AI summary
A mobile gas processing plant includes an inlet and an outlet, first and second Joule-Thompson (JT) valve units, an inlet scrubber, a dehydration unit including a contact tower, inlet and outlet filter separators, a vertical separator, and a dual pass line heater including first and second heating coils. The mobile gas processing plant is a mobile unit that is permanently mounted on at least one transport. The dehydration unit includes a contact tower that is permanently mounted on the at least one transport such that the contact tower is rotated up to be in an upright position relative to a base frame of the transport in an operational mode, and the contact tower is rotated down to be in a prostrated position relative to the base frame in a transportation mode. Each of the first and second JT valve units includes a first JT valve and a second JT valve. In the operational mode, and for each of the first and second JT valve units, a hydrocarbon gas stream flows through one of the first and second JT valves operating as a primary valve, and does not flow through the other of the first and second JT valves operating as a backup valve.