Modular Slug Catcher Skid Assembly for Scalable Compressor Facilities
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Solution Overview
Problem
Traditional natural gas gathering compressor facilities face challenges in initial infrastructure sizing due to dynamic drilling plans and uncertain well production flows, leading to costly over- or under-sizing, which affects economic expansion and operational efficiency.
Innovation Solution
The design of a slug catcher skid assembly with an integral inlet separator, sized for a single compressor, allows for proportional growth in liquid handling capacity as more skids are added, eliminating the need for extensive upfront infrastructure and reducing construction costs by matching equipment and piping sizes to specific compressor flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional separate equipment with extensive piping is used, then functional completeness is achieved, but device complexity and construction cost increase
Solution Approach 1:
The patent combines multiple separate pieces of equipment (compressor, slug catcher, separator, heater, etc.) into a single integrated modular unit. This merging eliminates the need for extensive external piping and civil works while maintaining all necessary functions, thereby reducing device complexity without sacrificing adaptability to future growth through additional modular units.
Solution Approach 2:
The patent divides the compressor facility into discrete modular units that can be independently sized and configured. Each module contains specific equipment tailored to its function, allowing the overall facility to be scaled by adding or removing complete modules rather than reconfiguring extensive piping systems, thus reducing complexity while preserving growth adaptability.
2Adaptability or versatility
If equipment is oversized for future growth, then adaptability is improved, but initial construction cost increases
Solution Approach 1:
The modular design allows the facility to dynamically adapt to actual growth needs. Instead of statically oversizing all infrastructure upfront, the system enables progressive addition of modular units as demand increases, ensuring that infrastructure volume matches actual production requirements at each stage while maintaining future growth capacity.
Solution Approach 2:
The standardized modular design performs preliminary configuration of equipment and piping within each module during manufacturing. This allows modules to be pre-assembled and tested off-site, then rapidly deployed as complete functional units, eliminating the need for extensive on-site construction and reducing initial infrastructure volume while preserving adaptability.
3Ease of manufacture
If modularization is implemented, then construction cost is reduced, but device complexity increases
Solution Approach 1:
The patent creates universal modular units with standardized interfaces and configurations that can serve multiple functions and be deployed in various arrangements. This universality simplifies integration between modules despite the complexity of individual module contents, as standardized connections and procedures reduce the overall integration complexity while maintaining construction cost benefits.
4Adaptability or versatility
If inlet system is sized for maximum future capacity, then adaptability is improved, but initial cost increases
Solution Approach 1:
The inlet separation system is divided into modular components distributed within individual modular units rather than consolidated into a single large centralized system. This segmentation allows the inlet capacity to be scaled by adding modular units with proportional inlet capabilities, matching infrastructure volume to actual production needs while preserving adaptability to future growth.
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 modular approach reduces initial construction costs and future expansion expenses by allowing the inlet separator capacity to grow with the number of compressors, providing a cost-effective and efficient solution for expanding compressor facilities.
Implementation Method 1
an integral inlet separator designed for using gravity to separate the gas from the condensate of a well flow
Data Source
AI summary
Disclosed is a slug catcher skid that is comprised of an integral inlet separator sized for a single compressor flow and each slug catcher skid is only used with a single compressor. The flow through the integral inlet separator is determined by the flow rate through the single compressor to which it is attached. Additionally, the other piping on an individual slug catcher skid such as the common gas inlet pipe headers, the common liquid drain pipe headers, and the common gas discharge pipe headers are sized for the flow of multiple compressors in a single facility. Some embodiments of the slug catcher skid are further comprised of an inlet filter separator, a Positive Shut Off (PSO) system, and/or an equalizing system in various combinations. The slug skids of the claimed invention may be further comprised of post compressor functional equipment including but not limited to a discharge gas oil separation vessel and a glycol separation vessel.