Subsea Cooler Recirculation and Bypass Control
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Solution Overview
Problem
Existing subsea cooler systems lack flexibility in accommodating varying flow rates and temperatures of hydrocarbon flows, which can lead to hydrate formation and blockages, and require robust and low-maintenance compressors due to harsh subsea conditions.
Innovation Solution
A cooler system with a recirculation loop and bypass circuit, allowing for adjustable cooling by directing fluid flow through multiple coolers in series and parallel connections, and incorporating MEG-injection to prevent hydrate formation, with flow control devices and adjustable perforated plates for natural convection and temperature management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If cooling the hydrocarbon flow is increased to improve compressor efficiency, then compressor efficiency is improved, but hydrate formation risk increases
Solution Approach 1:
The system employs dynamic flow control through multiple valves (first, second, third, and fourth valves) that can adjust the distribution of hydrocarbon flow between parallel cooling paths and recirculation loops. This dynamic adjustment allows the system to optimize cooling efficiency while preventing hydrate formation by adapting to varying flow rates and temperature conditions throughout the well's lifetime.
Solution Approach 2:
The system changes operational parameters by controlling flow rates through adjustable valves and adjusting the degree of cooling in different parallel paths. By varying these parameters, the system can maintain optimal compressor efficiency while staying above the hydrate formation temperature threshold, thus resolving the contradiction between cooling efficiency and hydrate prevention.
2Adaptability or versatility
If the cooler system is made more complex to accommodate varying flow rates and temperatures, then adaptability is improved, but device complexity increases
Solution Approach 1:
The cooling system is divided into multiple independent parallel cooling paths, each with its own flow control valve. This segmentation allows each path to be independently controlled and adjusted according to specific cooling requirements, providing high adaptability to varying flow rates and temperatures without requiring a completely redesigned complex system.
Solution Approach 2:
The system incorporates a recirculation loop that can serve multiple functions: it can recirculate cooling medium to enhance cooling capacity when needed, or be bypassed when sufficient cooling is achieved. This multi-functional design allows the same structural elements to serve different purposes under different operating conditions, increasing adaptability without proportionally increasing complexity.
3Temperature
If cooling is applied continuously to maintain temperature control, then temperature stability is improved, but energy consumption increases
Solution Approach 1:
The system incorporates temperature sensors that continuously monitor the temperature of the cooled flow and provide feedback to the control system. Based on this feedback, the flow control valves automatically adjust the cooling medium flow rate to maintain the temperature within the desired range, avoiding excessive cooling and reducing energy consumption while ensuring temperature stability.
Solution Approach 2:
Instead of continuous full-capacity cooling, the system uses periodic adjustment of cooling intensity through the controllable valves. The cooling intensity is modulated based on actual temperature needs, applying cooling only when and where required, thus maintaining temperature stability while minimizing energy consumption.
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 flexible cooling capabilities, preventing hydrate formation and maintaining a predetermined temperature range, ensuring efficient compressor operation and minimizing maintenance needs across the lifetime of a well flow.
Implementation Method 1
each of said coolers may be provided with a recirculation loop for recirculating at least an amount of the flow if the temperature is above a threshold value
Implementation Method 2
it might be arranged a bypass circuit over said first cooler and/or second cooler, which bypass circuit allows at least fractions of the flow, alternatively the whole flow, to bypass the cooler
Implementation Method 3
The system may be provided with means for MEG-injection to prevent the formation of hydrates
Implementation Method 4
A cooler system with a recirculation loop and bypass circuit, allowing for adjustable cooling by directing fluid flow through multiple coolers in series and parallel connections
Data Source
Figure 1A~1F
Figure 2A~2K
Figure 3A~3B
AI summary
A cooler system having an inlet (A) and an outlet (B), the cooler system comprising; at least a first cooler (20, 21, 22, 23, 24) and a second cooler (20, 21, 22, 23, 24), wherein the first cooler (20, 21, 22, 23, 24) and second cooler (20, 21, 22, 23, 24) are arranged in a series connection, the cooler system further comprises at least a third cooler (20, 21, 22, 23, 24) which is arranged in parallel connection with the first cooler (20, 21, 22, 23, 24) and second cooler (20, 21, 22, 23, 24), and the cooler system comprises at least one flow control device for directing flow through at least one cooler(20, 21, 22, 23, 24)wherein at least one of the coolers (20, 21, 22, 23, 24) comprises a bypass circuit and/ or recirculation loop (35).