Shuttle Valve Assembly for Gas Compression Systems
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Solution Overview
Problem
Conventional subsurface processing and reinjection compressor (SPARC) systems face damage during startup or shutdown due to surging production streams, which can lead to turbine and compressor damage from alternating slugs of liquid and gas, necessitating a smoother transition between operational phases.
Innovation Solution
A shuttle valve assembly that transitions between circulation and production modes based on pressure differential, using a biasing device to ensure safe operation and prevent damage, allowing the system to bypass the turbine-compressor during startup and revert to natural circulation when pressure is equalized.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the system operates in production mode during startup, then gas compression and injection can begin, but the turbine and compressor are damaged by alternating slugs of liquid and gas
Solution Approach 1:
The system performs preliminary separation of gas from liquid in the separator before directing flow to the compressor. During startup, the system first establishes liquid-only flow through the bypass annulus, then gradually transitions to gas-compressed flow, preventing damaging slugs from reaching the turbine-compressor unit
Solution Approach 2:
The shuttle valve assembly acts as an intermediary device that controls flow distribution between the bypass annulus and the gas inlet tube. It mediates the transition between circulation mode and production mode, ensuring smooth flow transitions that protect the turbine-compressor from surge conditions
2Adaptability or versatility
If heavy spring loaded valves and radially installed check valves are used for path switching, then flow path change is achieved, but the compressor is damaged during startup or shutdown
Solution Approach 1:
The shuttle valve assembly provides dynamic flow control by allowing gradual transition between circulation and production modes. The valve responds to pressure differential changes in real-time, enabling smooth, continuous adjustment of flow paths rather than abrupt switching, which prevents compressor surge during transitions
Solution Approach 2:
The system replaces heavy spring-loaded valves and radially installed check valves with a shuttle valve assembly that uses pressure differential and a biasing device for more controlled and gentler flow path transitions, reducing mechanical shock and surge to the compressor
3Ease of operation
If the system allows surging production streams during startup, then operational flexibility is maintained, but alternating slugs of liquid and gas damage the turbine and compressor
Solution Approach 1:
The system maintains continuous, controlled flow through the turbine-compressor unit by using the shuttle valve to regulate the transition from liquid-only circulation to gas-compressed production flow. This continuous control prevents discontinuous surging while maintaining operational flexibility throughout the startup and shutdown sequences
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 shuttle valve assembly enables a smoother transition between operational phases, preventing damage to the compressor and turbine, ensuring efficient and safe operation during startup and shutdown procedures.
Implementation Method 1
a biasing device arranged within a piston chamber cooperatively defined by the piston and the mandrel assembly, wherein the biasing device engages and urges the piston to the closed position
Implementation Method 2
increasing a pressure of the compressed gas stream to move the piston from a closed position, where the piston rests on the valve seat and prevents the compressed gas stream from bypassing the valve seat, and an open position, where the piston is separated from the valve seat
Data Source
AI summary
A gas separation and injection system includes a lower separator that receives and separates a production stream into higher and lower density streams, a turbine-compressor including a turbine that receives the lower density stream to rotate a shaft that drives a compressor and subsequently recombines the lower and higher density streams into a recombined production stream. An upper separator receives the recombined production stream and includes a gas inlet tube that conveys a gas stream to the compressor to produce a compressed gas stream. A shuttle valve assembly axially interposes the upper separator and the turbine-compressor and includes a mandrel assembly received within a body and having the gas inlet tube extending within the mandrel assembly, a valve seat secured to the gas inlet tube, a piston movably arranged within the inner annulus between closed and open positions, and a shuttle valve operatively coupled to the piston.