Reconfigurable Multi-Stage Gas Compressor for Condensation Control
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Solution Overview
Problem
Conventional gas lift compressors face limitations in fluid lift rates and are susceptible to hydrocarbon condensation issues due to fluctuating discharge pressures and the presence of heavier hydrocarbon molecules, particularly in HPGL applications, which affect well production efficiency and operational costs.
Innovation Solution
A reconfigurable multi-stage gas compressor system with user-selectable series or parallel gas flow paths through stepped cylinders, incorporating cooling and scrubbing stages, designed to maintain gas in the vapor phase and adapt to varying pressure requirements, thereby preventing hydrocarbon condensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional gas lift compressors are used, then the system is simple and easy to operate, but fluid lift rates are limited and hydrocarbon condensation occurs
Solution Approach 1:
The compressor system is divided into multiple independent compression stages (first-stage, second-stage, and stepped cylinders with third and fourth stages). Each stage can be independently configured and controlled, allowing the system to achieve higher fluid lift rates through multi-stage compression while maintaining operational simplicity through modular design
Solution Approach 2:
The system incorporates reconfigurable gas flow paths that can dynamically switch between series and parallel configurations through valve mechanisms. This dynamic reconfiguration allows the compressor to adapt to varying production requirements and maintain optimal performance across different operating conditions, thereby increasing fluid lift rates
2Reliability
If discharge pressure fluctuates in conventional compressors, then the system is easier to operate, but hydrocarbon condensation occurs due to pressure fluctuations
Solution Approach 1:
The system incorporates pressure sensing and control mechanisms that monitor discharge pressure fluctuations and automatically adjust compression parameters to maintain stable pressure conditions. This feedback control prevents hydrocarbon condensation by ensuring pressure remains above the dew point while adapting to changing production conditions
Solution Approach 2:
The compressor system can change operational parameters such as compression ratio, stage configuration, and flow path arrangement to maintain discharge pressure within the optimal range that prevents hydrocarbon condensation. By dynamically adjusting these parameters, the system maintains reliability while managing operational complexity
3Productivity
If multi-stage compression is implemented, then fluid lift rate increases, but device complexity increases
Solution Approach 1:
The multi-stage compression system is segmented into modular cylinders (first-stage, second-stage, and stepped cylinders for third and fourth stages), each with standardized interfaces and control mechanisms. This segmentation allows the complex multi-stage system to be managed as independent units, facilitating easier operation and maintenance while achieving high fluid lift rates
Solution Approach 2:
The stepped cylinders are designed with universal functionality, capable of operating in multiple configurations (series or parallel) and serving different compression stages. This multi-functionality reduces the need for separate dedicated components for each stage, thereby increasing productivity while controlling overall device complexity
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 enhances fluid lift rates and reduces hydrocarbon condensation, providing flexible and efficient gas injection pressures suitable for both HPGL and conventional gas lift operations, minimizing operational issues and costs.
Implementation Method 1
a first-stage compression cylinder configured to generate a first-stage compressed gas from an inlet gas; a second-stage compression cylinder configured to generate a second-stage compressed gas from the first-stage compressed gas
Implementation Method 2
incorporating cooling and scrubbing stages, designed to maintain gas in the vapor phase and adapt to varying pressure requirements, thereby preventing hydrocarbon condensation
Implementation Method 3
incorporating cooling and scrubbing stages, designed to maintain gas in the vapor phase and adapt to varying pressure requirements, thereby preventing hydrocarbon condensation
Data Source
AI summary
Disclosed embodiments include a reconfigurable multi-stage gas compressor having a first-stage compression cylinder, a second-stage compression cylinder, and two stepped cylinders. Each of the stepped cylinders include first and second compression cylinders. The gas flow paths through the stepped cylinders are configured in a user-selectable configuration to be in series or in parallel so that the reconfigurable multi-stage gas compressor functions as one of: a three-stage compressor, as a four-stage compressor, and as a hybrid three/four stage compressor. In first and second configurations, the system generates four stages of compression and outputs 4-stage compressed gas through a single exit port, and through dual exit ports, respectively. In a third configuration, the system outputs hot and cooled 3-stage compressed gas through first and second ports and 4-stage compressed gas through a third port. In a fourth configuration, the system outputs hot and cooled 3-stage compressed gas with no 4-stage compressed gas.