METHOD AND APPARATUS FOR RECOVERY OF LEAKING GASES FROM COMPRESSION AND REGULATION SYSTEMS
20230417239 ยท 2023-12-28
Inventors
Cpc classification
F04B53/164
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B41/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B53/144
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B19/22
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F17D5/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B49/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B2201/0605
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B41/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F17D5/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B53/14
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A system and method for recovering fugitive natural gas emissions from compressors. Leak capture devices can be connected to piston rods of the compressor for collecting emissions both during operation and periods where the compressor is shutdown. Captured natural gas is repressurized with cylindrical pumps based on the flow rate of the captured emissions. The equipment can also be configured for capturing blow down events of the equipment.
Claims
1.-13. (canceled)
14. A method of recovering natural gas from a natural gas system comprising: connecting at least one gas capture device to a natural gas compressor; collecting the recovered natural gas from the at least one gas capture device in at least one collection tank; pressurizing the recovered natural gas in the at least one collection tank with a recovered gas compression system; and returning the recovered natural gas pressurized by the gas compression system to the natural gas system.
15. The method of claim 14 wherein the natural gas is collected when a piston rod or rotating shaft is in motion.
16. The method of claim 14 wherein the natural gas is collected when a piston rod or rotating shaft is in stationary.
17. The method of claim 14 wherein pressurization with the recovered gas compression system is based on a pressure of the recovered natural gas in the at least one collection tank.
18. The method of claim 14 further comprising: collecting blowdowns of equipment within a specified section within the pipeline system.
19. The method of claim 14 further comprising: monitoring a recovered natural gas flow rate.
20. The method of claim 19 further comprising: alerting a compressor operator when the recovered natural gas flow rate exceeds a predetermined threshold flow rate.
Description
BRIEF DESCRIPTION OF DRAWINGS
[0018] The present technology will be better understood on reading the following detailed description of non-limiting embodiments thereof, and on examining the accompanying drawings, in which:
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DETAILED DESCRIPTION OF THE INVENTION
[0037] The foregoing aspects, features, and advantages of the present technology will be further appreciated when considered with reference to the following description of preferred embodiments and accompanying drawings, wherein like reference numerals represent like elements. In describing the preferred embodiments of the technology illustrated in the appended drawings, specific terminology will be used for the sake of clarity. The technology, however, is not intended to be limited to the specific terms used, and it is to be understood that each specific term can include equivalents that operate in a similar manner to accomplish a similar purpose.
[0038] When introducing elements of various embodiments of the present technology, the articles a, an, the, and said are intended to mean that there are one or more of the elements. The terms comprising, including, and having are intended to be inclusive and mean that there may be additional elements other than the listed elements. Any examples of operating parameters and/or environmental conditions are not exclusive of other parameters/conditions of the disclosed embodiments. Additionally, it should be understood that references to one embodiment, an embodiment, certain embodiments, or other embodiments of the present technology are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Furthermore, reference to terms such as above, below, upper, lower, side, front, back, or other terms regarding orientation are made with reference to the illustrated embodiments and are not intended to be limiting or exclude other orientations.
[0039] In typical compressors, a distance piece (shown in
[0040] Generally, the distance piece can achieve sufficient separation that any leaks of natural gas at the seal pack would not be of high enough concentration to be combustible at the crankcase assembly. However, seal failures can result in high leakage rates of natural gas and have resulted in crankcase explosions in the wrong circumstances. The present technology can capture these natural gas leaks before reaching atmosphere to further prevent such problems due to seal failure.
[0041] The present technology can be a system that is fitted to existing natural gas compressors. The system can capture gas leaked through the compressor seal packs. The leaked gas can be captured before it is exposed to air so that all that is captured is gas. This gas can then be re-introduced to the pipeline system in one of two places.
[0042] If the compressor power source is an internal combustion engine, the captured gas can be re-introduced into the gas fuel source for the engine, typically at a pressure of 100 to 150 psig. If the power source does not use natural gas for fuel, such as if the power source is an electric motor, the leaked gas can be re-introduced into the compressor inlet, typically at pressures of up to 600 psig, and can require two stages of compression.
[0043] This technology can work with both reciprocating and rotary compressors. Rotary compressors can be of the roots, screw, centrifugal, and/or turbine type.
[0044] This technology can include either one or two assemblies around the diameter of the piston rod (or rotating shaft) and is attached to the end of the packing seal cartridge. The rod capture assembly can gather leakage of an operational compressor, while the static seal assembly can capture leakage of a non-operational compressor.
[0045] The rod capture assembly can capture natural gas at a pressure of, for example, 0-10 psig. The captured natural gas can be restricted to enable a variable speed recovery pump that can track the natural gas leakage rate. A slight back-pressure on the system can prevent pressurization of the distance piece outside of normal operating conditions.
[0046] The rod capture assembly can be assembled using a split-seal or single-piece seal onto either an assembled or disassembled compressor. The use of the single-piece seal can result in better natural gas capture rates.
[0047] The static sealing system can be used with compressors driven by internal combustion engine using fuel supplies with a range of 100-150 psig. Natural gas captured by the static sealing system can be directed to the fuel supply line for the remaining operating compressors, which can require substantially more natural gas than the leakage rate from non-operational compressors as a fuel supply.
[0048]
[0049] The pump assemblies 36, 36b, 36c can be pneumatically driven by the pressure differential between high pressure pipeline 32 and lower pressure pipeline 34, through lines 35 and 37, respectively.
[0050] The pump(s) 36, 36b, 36c can be variable speed in order to closely match the leakage rate. The speed control assembly 38 can sequentially modulate driving pressure to the three pump assemblies 36, 36b, 36c based on the demand for leakage pumping.
[0051] The isolation valve 40 can be used to circumvent the speed control assembly 38 for the purpose of converting the pump assemblies 36, 36b, 36c from leakage mitigation to capture of blow down volumes. For capturing blow downs of specific components and/or piping conduits, the system can be connected to a source within the area to be blown down. When blow down mode is selected, the speed control assembly can be bypassed such that all pumps 36, 36b, 36c operate at full capacity.
[0052] The diagnostic module 42 can have multiple sensors that indicate excessive leakage from the seal pack. One module can be required for each compressor throw of multi-cylinder compressors.
[0053]
[0054] Pressure in the compressor volume 65 can leak through the multiple packing seals 60 and can result in leakage between the piston rod 55 and the packing seal cartridge 59. Leaked gases can flow into the distance piece 57 and out to the atmosphere through the annular clearance 59a.
[0055]
[0056] The rod capture assembly 70 can capture leakage from the periphery of piston rod 55 and can divert the leakage through lines 71 and 71a. Both pipes can flow to the same tank. The purpose of redundant pipes can be to promote oil in the lower portion of the rod capture assembly to flow slowly to the tank. This can keep the lighter gases at the top and the mist and liquids near the bottom. Light gas to be used further can be taken from the top of the tank without the heavy and/or liquid components at the bottom. Similarly, the static capture assembly 72 can divert leakage through lines 73 and 73a.
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[0058] Abutting housing 80 can be rod seal housing 76 that contains rod seal 78. These two parts can comprise the rod seal assembly 70. When the compressor is operational, this system can collect the leakage flow from the annular clearance 59a and divert the leakage flow into lines 71 and 71a.
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[0064] The pump valve assembly 128 can control the alternating pressures in lines 150 and 151 that drive opposite sides of major piston 118. As the piston assembly approaches the end of its stroke, it can contact the end of the trigger valve assembly 124, initiating a shift within the pump valve assembly 128. This can cause the pressures in lines 150 and 151 to reverse.
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[0067] The trigger pulse line 133 can communicate with end volume 153 and the trigger pulse line 135 can communicate with end volume 154. The other end of each line 133 and 135 can be connected to its respective trigger valve assembly 124, mounted to the pump assembly cylinder head 129. Each trigger valve assembly 124 can be normally open and can always communicate with a low-pressure source except when the trigger valve assembly is contacted by piston head 122.
[0068] The design of the pump valve assembly can contain a feature to ensure the spool valve movement is positive and holds its position until commanded to move. In operation, there can be low pressure in end volume 153 and medium pressure in end volume 154. This pressure differential can be required to keep the spool valve locked in this position. In order to shift the spool valve 136 to its right-most position, a high-pressure pulse can be briefly sent to volume 153. At this instant, the pressure in volume 153 can be high and the pressure in volume 154 can be medium. This differential pressure can be required to command a change in spool valve position when the trigger valve assembly is energized.
[0069] Assuming the pressure conditions of the pump valve assembly shown in
[0070] Lines 140 can be high-pressure, unregulated, and connected to high-pressure pipeline 32. Lines 148L and 148R can be variable high-pressure and connected to the outlet of the speed control regulator 38. Line 137 can be connected to the lower-pressure pipeline 34. Line 151 can communicate with volume 119R and line 150 can communicate with volume 119L. The piston assembly 114 can move to the left because regulated high-pressure in line 148L communicates through annular groove 152 with line 151 and volume 119R. Further, lower-pressure line 137 can communicate through annular groove 139 with line 150 and volume 119L. This pressure differential across major piston 118 can drive the piston assembly 114 in order to pump leakage gases with minor pistons 116L and 116R.
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[0073] As the gas leakage from a compressor increases, the pressure in leakage gathering tank 44 can increase. This can cause the actuator assembly 185 to command higher pumping rate by moving the plate cam 186. As the leakage flow rate increases from zero, pump assembly 36 begins pumping and can increase its pumping capacity by reciprocating at a higher frequency. Once pump assembly 36 has reached its limit of pumping capacity, the second pump assembly 36b can proportionally increase its output until it has also reached its pumping capacity limit. At this point, the system can be pumping at of total system capacity. Further increase in leakage rate can linearly ramp up the third pump assembly 36c, in the same manner as with the first two pump assemblies.
[0074] The 3-pump system of
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[0076] The cam follower rocker arm 204 can be linked to housing 180 with a cylindrical axle. The 2-part cam follower system can eliminate side loading of the cylindrical follower 207. The side-loading due to the cam actuation can instead be taken up by the rocker arm 204 and follower roller 190. The vertical force component of cam actuation can be translated to the intermediate cam follower roller 206 and the cylindrical follower 207. The cylindrical follower 207 can slidably move within cylindrical follower guide 208 and transmit vertical motion to the small push rod 209 and on to the throttling valve 196 and spring 198. The small push rod 209 can be slidably guided by bushing 210 and sealed by seal 211. The push rod 209 can be small in diameter to minimize its axial force created by the high differential pressures on each of its ends. The lower end can be at atmospheric pressure and the upper end can have a higher pressure. Axial forces created by this pressure differential can have a profoundly negative effect on system performance as they counter the forces commanded by actuator assembly 185. For this reason, throttling valve 196 can be pressure-balanced and have a vent hole 215 to expose both of its ends to equal pressure.
[0077] As compressor packing seal leakage rate increases, the 3-pump system can initiate pumping by the second pump assembly once the first pumping assembly has reached its capacity. When the first two pump assemblies are running at capacity, the third can initiate pumping. It is important to not run a pumping assembly too slowly if the demand for its operation is marginal. Operating too slowly can result in a chattering motion due to stick-then-slip conditions. This unacceptably slow operation can also make the triggering and valving indecisive and inconsistent. To combat this scenario, the regulator valve assembly 182 can be designed so that the minimum flow (once operation is commanded) through line 189 to pump assembly 36 can be between 10-25% of the maximum flow. In order to prevent over-pumping during the transition to the next pump, the output of regulator valve assembly 182 can be trimmed. The throttling valve 196 can have a flow reducing limiter 212 that reduces the flow area between throttling valve 196 and valve seat edge 214 as the cam follower roller reaches maximum lift on top of the plate cam 186.
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[0082] Although the technology herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present technology. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present technology as defined by the appended claims.