Steam Injection Pipe Preheating to Prevent Condensate Loss

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Solution Overview

Problem

The existing steam generation facilities for hydrocarbon recovery face significant costs and efficiency issues due to heat loss and condensate formation in long steam pipes, leading to reduced steam quality and potential pipeline damage from water hammer events.

Innovation Solution

The use of heat traces along the steam pipe, controlled by resistance temperature detectors, to preheat and maintain the pipe temperature, ensuring consistent steam quality over long distances by preventing condensate formation and reducing heat loss through insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of stationary object

If steam is transported through long pipes to the injection well, then the steam can reach distant reservoirs, but heat loss occurs and steam quality deteriorates

Engineering Contradiction:

Improvepipe lengthVSAvoidheat loss

Core Design Contradiction:

Length of stationary objectVSLoss of energy

Solution Approach 1:

The pipe is preheated using electric heat traces before steam injection begins. This preliminary heating action raises the pipe temperature to near steam temperature, eliminating the temperature differential that drives heat loss. When steam enters the preheated pipe, minimal condensation occurs and heat loss is significantly reduced, maintaining steam quality over long distances

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Electric heat traces serve as an intermediary heating mechanism between the steam source and the pipe. These heat traces wrap around the pipe and provide continuous thermal input, acting as a mediator that compensates for heat loss along the pipe length. The heat traces are controlled by temperature sensors to maintain optimal pipe temperature without overheating

Inventive Principle:

Principle #24Intermediary (Mediator)

2Length of stationary object

If steam is transported through long pipes, then distant reservoirs can be reached, but condensate formation occurs causing water hammer events

Engineering Contradiction:

Improvepipe lengthVSAvoidwater hammer damage

Core Design Contradiction:

Length of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The pipe is preheated before steam flow begins, which prevents condensate formation from the start. By raising the pipe temperature above the dew point of the steam before injection, the system eliminates the conditions that lead to condensation and subsequent water hammer events throughout the steam transport process

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The heat traces provide preliminary anti-action against condensation by maintaining pipe temperature above the steam dew point. This preemptive thermal compensation counteracts the natural tendency for steam to condense in cool pipes, preventing the harmful water hammer effect before it can occur

Inventive Principle:

Principle #9Preliminary anti-action

3Temperature

If high steam temperature is maintained in the pipe, then steam quality is preserved, but energy consumption increases

Engineering Contradiction:

Improvesteam temperatureVSAvoidenergy consumption

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The pipe is preheated to near steam temperature before injection begins, which eliminates the need for continuous high-energy heating during steam transport. This one-time preliminary energy investment maintains steam temperature and quality throughout the process without requiring sustained high energy input

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Temperature sensors positioned along the pipe provide feedback to a control system that regulates heat trace power. The system continuously monitors pipe temperature and adjusts heat trace output accordingly, maintaining optimal temperature while minimizing energy consumption by reducing or shutting off heat traces when temperature targets are achieved

Inventive Principle:

Principle #23Feedback

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 approach maintains high steam quality, reduces condensate formation, and minimizes pipeline damage, thereby enhancing the economic viability and safety of hydrocarbon recovery processes by efficiently delivering steam over extended distances.

Implementation Method 1

heating the pipe utilizing heat traces along the pipe to preheat the pipe

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 2

controlling heat traces extending along the pipe

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS11781406B2Process for providing steam for a hydrocarbon recovery process

Publication Date: 2023.10.10 CENOVUS ENERGY INC

AI summary

A hydrocarbon recovery process for recovering hydrocarbons from a hydrocarbon-bearing formation includes preheating a pipe coupling a steam generation facility to a well for injection of steam into the hydrocarbon-bearing formation by controlling heat traces extending along the pipe, directing steam generated at the steam generation facility, through the pipe after preheating, and injecting the steam into the hydrocarbon-bearing formation via the well, and controlling heat input to the pipe by controlling the heat traces extending along the pipe as the steam travels through the pipe. Fluids are produced from the hydrocarbon-bearing formation.