Variable Load Hydrocarbon Flow Control Generator
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Solution Overview
Problem
Existing hydrocarbon flow control systems face inefficiencies due to fixed expansion devices that do not proportionally decrease resistance as wellhead pressure and flow decline, leading to energy loss and frequent manual adjustments of choke valves.
Innovation Solution
A hydrocarbon flow control generator system with a variable load device and processor-controlled expansion device, allowing real-time and remote adjustments of hydrocarbon flow and pressure, reducing the need for manual interventions and minimizing energy loss by optimizing electrical demand based on pressure changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a fixed expansion device is used to capture energy from hydrocarbon flow, then electricity generation is achieved, but the device cannot adapt to declining wellhead pressure and flow over time, resulting in energy loss and reduced efficiency
Solution Approach 1:
The expansion device is replaced with a variable speed drive system that dynamically adjusts its operating parameters in response to changing wellhead pressure and flow conditions. The drive system includes a motor coupled to the generator through a variable speed drive, allowing the expansion device to adapt its resistance and energy capture characteristics as the well matures and pressure declines, thereby maintaining optimal energy capture efficiency throughout the well's production lifecycle.
2Reliability
If manual adjustment of choke valves is performed to maintain optimal flow control, then pressure and flow regulation is achieved, but frequent manual interventions increase operational complexity and time loss
Solution Approach 1:
The system incorporates sensors that continuously monitor wellhead pressure and flow conditions, coupled with a control system that automatically adjusts the variable speed drive parameters to maintain optimal pressure control. This self-regulating mechanism eliminates the need for frequent manual interventions, allowing the system to adapt automatically as the well's production characteristics change over time.
3Productivity
If a variable speed drive system is implemented to optimize energy capture, then electricity generation efficiency is improved, but device complexity increases
Solution Approach 1:
The variable speed drive system serves multiple functions simultaneously: it optimizes energy capture from the expanding hydrocarbon stream, controls generator speed to maximize electricity generation efficiency, regulates downstream pressure, and adapts to changing well conditions. By consolidating these functions into a single integrated control system, the patent reduces overall system complexity despite the advanced capabilities provided.
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
Enables efficient real-time and remote control of hydrocarbon flow and pressure, reducing well pad visits, minimizing mechanical wear, and maximizing electricity generation from hydrocarbon streams by adapting to changing pressure conditions.
Implementation Method 1
converting kinetic energy of the gas into useful electric energy. As the gas flows from the high-pressure stream into the expansion device, the gas rotates the turbine of the expansion device
Implementation Method 2
the turbine of the expansion device, which, in turn, spins the generator, thereby allowing the generator to produce electricity
Data Source
AI summary
A hydrocarbon flow control generator system includes a pressurized hydrocarbon flow inlet, an expansion device in pressurized hydrocarbon flow communication with the pressurized hydrocarbon flow inlet, a generator connected to the expansion device, a drive system connecting the generator and the expansion device, a gathering point at which depressurized hydrocarbon stream is delivered to an end use location, and a variable load device via which an electrical power stream generated by the generator is delivered to an electric load. The expansion device is configured to receive a highly pressurized hydrocarbon stream from the pressurized hydrocarbon flow inlet, control and regulate a received hydrocarbon stream, and depressurize the hydrocarbon stream. The variable load device is configured to adjust load on the generator by adjusting electrical demand on the generator based on a pressure of the depressurized hydrocarbon stream sensed between the expansion device and the gathering point.