Modular Multi-Stage Regulator for Wet Gas Pressure Conditioning
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Solution Overview
Problem
Existing systems for sampling pressurized process fluids, particularly wet gas, face challenges in providing a compact, customizable, and easily maintainable solution that prevents condensation and fractionation while ensuring accurate analysis, often requiring complex and non-field-serviceable components.
Innovation Solution
A multi-stage regulator with modular, drop-in pressure reducing components that allow for staged pressure reduction, featuring self-adjusting and self-controlling pistons, and optional heaters to limit Joule-Thomson effect cooling, enabling easy field service and reconfiguration without disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a discrete vaporizer with complex heating and pressure control systems is used, then vaporization and pressure reduction can be achieved, but the system becomes non-field-serviceable and difficult to maintain
Solution Approach 1:
The system is divided into separate modular components: a vaporizer assembly and a pressure regulator assembly that can be independently accessed, serviced, and replaced. The pressure regulator uses discrete pistons for each pressure stage that can be individually removed and serviced without affecting other components, enabling field maintenance while reducing overall system complexity.
2Reliability
If multiple pressure reduction stages are implemented, then condensation and fractionation are prevented, but the device size and complexity increase
Solution Approach 1:
Multiple pressure reduction stages are nested within a single compact regulator body. Each piston and its associated components are arranged concentrically or in compact stacked configurations, allowing multiple functional stages to occupy minimal space while maintaining the benefits of staged pressure reduction for preventing condensation and fractionation.
3Ease of operation
If preset calibration and spring/stem/seat adjustment are required, then pressure regulation can be achieved, but the system requires preset calibration and cannot be easily adjusted in the field
Solution Approach 1:
The pressure regulator uses adjustable pistons with external adjustment mechanisms that allow dynamic modification of pressure stages in the field. The pistons can be repositioned or reconfigured without requiring preset calibration or complex adjustment procedures, enabling flexible adaptation to different operating conditions while simplifying field operations.
4Productivity
If Joule-Thomson effect cooling is not limited, then pressure reduction can occur, but condensation occurs in wet gas
Solution Approach 1:
Heating elements are positioned to pre-heat the gas before it enters the pressure reduction stages. This preliminary heating counteracts the cooling effect of pressure reduction, preventing condensation in wet gas while maintaining efficient pressure reduction. The heating can be applied at multiple stages to ensure continuous temperature control throughout the pressure reduction process.
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 system provides enhanced efficiency, reduced energy consumption, and simplified maintenance, delivering an analytically correct sample with a compact footprint, addressing the limitations of prior art systems.
Implementation Method 1
with a heater to heat the sample to vaporize entrained liquids and prevent condensation
Implementation Method 2
staged pressure reducing components to reduce the sample pressure in staged reductions
Implementation Method 3
with a heater to heat the sample to vaporize entrained liquids and prevent condensation, and with optional heating to limit Joule-Thomson effect cooling
Data Source
AI summary
A multi-stage fluid conditioning device formed to receive a series of drop-in modular conditioning components, the exemplary embodiment in the form of single-stage regulators, is provided for stepped pressure reduction in radial and stacked configurations, the system providing enhanced efficiencies including reduced footprint as well as easy access to individual stages for repair, maintenance or reconfiguration, even in the field, via the provision of an exterior access port for each conditioning component in the device in alternative configurations, the present device further providing enhanced energy efficiencies, decreased cost of implementation, and significantly reduced complexity, when compared to prior systems.