Systems and methods for controlling, monitoring, and operating remote oil and gas field equipment over a data network with applications to raw natural gas processing and flare gas capture

• US 10,000,704 B2
• Filed: 06/22/2017
• Issued: 06/19/2018
• Est. Priority Date: 06/18/2013
• Status: Active Grant

• Current Assignee: Pioneer Energy, Inc.
• Original Assignee: Pioneer Energy, Inc.
• Inventors: Young, Andrew, Lewis, Matthew, Sargsyan, Gevorg, Hotton, Kevin, Zubrin, Robert M
• Primary Examiner(s): Sasaki, Shogo
• Application Number:
  US15/630,093
• Publication Number:
  US 20170292077A1
• Time in Patent Office: 362 Days
• CPC Class Codes: C10G 5/06 by cooling or compressing
• CPC Class Codes: C10L 2290/30 Pressing, compressing or compacting
• CPC Class Codes: C10L 2290/46 Compressors or pumps
• CPC Class Codes: C10L 2290/567 Mobile or displaceable apparatus
• CPC Class Codes: C10L 2290/58 Control or regulation of the fuel preparation of upgrading process
• CPC Class Codes: C10L 2290/60 Measuring or analysing fractions, components or impurities or process conditions during preparation or upgrading of a fuel
• CPC Class Codes: C10L 3/10 Working-up natural gas or synthetic natural gas
• CPC Class Codes: C10L 3/101 Removal of contaminants
• CPC Class Codes: C10L 3/106 of water
• CPC Class Codes: F25J 2200/02 in a single pressure main column system
• CPC Class Codes: F25J 2200/70 Refluxing the column with a condensed part of the feed stream, i.e. fractionator top is stripped or self-rectified
• CPC Class Codes: F25J 2205/04 in the feed line, i.e. upstream of the fractionation step
• CPC Class Codes: F25J 2205/60 using adsorption on solid adsorbents, e.g. by temperature-swing adsorption [TSA] at the hot or cold end
• CPC Class Codes: F25J 2205/66 Regenerating the adsorption vessel, e.g. kind of reactivation gas
• CPC Class Codes: F25J 2205/70 Heating the adsorption vessel
• CPC Class Codes: F25J 2215/62 Ethane or ethylene
• CPC Class Codes: F25J 2220/68 Separating water or hydrates
• CPC Class Codes: F25J 2230/22 Compressor driver arrangement, e.g. power supply by motor, gas or steam turbine
• CPC Class Codes: F25J 2230/30 Compression of the feed stream
• CPC Class Codes: F25J 2240/80 Hot exhaust gas turbine combustion engine
• CPC Class Codes: F25J 2260/60 : Integration in an installation using hydrocarbons, e.g. for fuel purposes
• CPC Class Codes: F25J 2270/12 : External refrigeration with liquid vaporising loop
• CPC Class Codes: F25J 2270/18 : External refrigeration with incorporated cascade loop
• CPC Class Codes: F25J 2270/60 : Closed external refrigeration cycle with single component refrigerant [SCR], e.g. C1-, C2- or C3-hydrocarbons
• CPC Class Codes: F25J 2270/66 : Closed external refrigeration cycle with multi component refrigerant [MCR], e.g. mixture of hydrocarbons
• CPC Class Codes: F25J 2290/42 : Modularity, pre-fabrication of modules, assembling and erection, horizontal layout, i.e. plot plan, and vertical arrangement of parts of the cryogenic unit, e.g. of the cold box
• CPC Class Codes: F25J 2290/70 : Processing device is mobile or transportable, e.g. by hand, car, ship, rocket engine etc.
• CPC Class Codes: F25J 3/0209 : Natural gas or substitute natural gas
• CPC Class Codes: F25J 3/0233 : separation of CnHm with 1 carbon atom or more
• CPC Class Codes: F25J 3/0238 : separation of CnHm with 2 carbon atoms or more
• CPC Class Codes: F25J 3/0242 : separation of CnHm with 3 carbon atoms or more
• CPC Class Codes: F25J 3/08 : Separating gaseous impurities from gases or gaseous mixtures or from liquefied gases or liquefied gaseous mixturescold traps B01D8/00
• CPC Class Codes: G05B 15/02 : electric
• CPC Class Codes: H04W 76/10 : Connection setup

Abstract

An intelligent controls system for remotely monitoring and controlling a chemical process is disclosed. The system comprises a piece of remote field equipment for performing the chemical process, a user device, a server, and program codes to perform the steps of establishing an equipment-server and a client-server connection, receiving a set of chemical process input parameters and a set of desired chemical process output parameters, controlling a set of chemical process control parameters to achieve the desired chemical process output parameters, and providing an interface to allow an operator to manually control and/or manually override the set of chemical process control parameters. The controls system allows any piece of remote field equipment for performing complex chemical processing to be monitored, controlled, and operated remotely. A large array of distributed field equipment situated around the world can all be controlled primarily through a single interface provided in a central control center.

Claims

1. A system for remotely monitoring and controlling a separation process of a raw natural gas stream into two controlled product streams comprising a methane stream and a natural gas liquids (NGLs) stream and a third uncontrolled ethane-rich stream, to control ethane content in the two controlled product streams, the system comprising:

a plurality of remote field equipment for performing the separation process that are adapted to be responsive to electromagnetic signals resulting in control of a plurality of process parameters;

a server comprising a hardware processor and a non-transitory digital storage medium storing executable program code;

a communications-link between said server and said piece of remote field equipment; and

a plurality of program code embodied on said non-transitory digital storage medium, said plurality of program code which when executed causes said hardware processor to execute a process performing the steps of;

establishing an equipment-server connection between said piece of remote field equipment and said server;

establishing a client-server connection between a user device and said server;

providing an interface to allow a user to display the plurality of process parameters on said user device;

receiving a set of separation process input parameters corresponding to parameters of an input stream of the raw natural gas;

receiving a set of desired process output parameters corresponding to desired parameters of an output chemical stream comprising a methane stream and a natural gas liquids (NGLs) stream and a third uncontrolled ethane-rich stream, to control ethane content in the two controlled product streams;

controlling a set of separation process control parameters to achieve the desired chemical process output parameters given the separation process input parameters and the desired separation process output parameters;

wherein the controlling comprises monitoring a methane number of the methane stream to determine ethane content in the methane stream, wherein a higher methane number of the methane stream indicates a lower ethane content in the methane stream;

monitoring a vapor pressure of the NGLs stream to determine ethane content in the NGLs stream, wherein a lower vapor pressure of the NGLs stream indicates a lower ethane content in the NGLs stream;

receiving a desired minimum methane number (MMN) and a desired maximum vapor pressure (MVP);

determining an inlet flow rate for the separation process, wherein the inlet flow rate is controllable by an inlet control valve of the plurality of remote field equipment;

determining a system operating pressure for the separation process, wherein the system operating pressure is controllable by a pressure control valve;

determining a temperature setpoint for the separation process, wherein the temperature setpoint is controllable by a temperature setpoint controller; and

adjusting the inlet flow rate by the inlet control valve, the system operating pressure by the pressure control valve, and the temperature setpoint by the temperature setpoint controller to maintain the desired minimum methane number (MMN) and the desired maximum vapor pressure (MVP) by separating ethane from the two controlled product streams into the third uncontrolled ethane-rich stream; and

providing a human-machine interface (HMI) adapted to allow supervisory intervention and specification of operating points to allow an operator to manually control the set of separation process control parameters.

2. The system of claim 1, wherein the separation process is separating a raw natural gas stream into at least one output product stream to control an ethane content in the at least one output product stream.

3. The system of claim 1, wherein the separation process is separating a raw natural gas stream into at least two output product streams to control an ethane content in each of the two output product streams.

4. The system of claim 3, further comprising program code, which when executed causes said hardware processor to perform steps to:

controlling an inlet flow rate of the raw natural gas stream to a track a predetermined flow rate;

controlling a system operating pressure to track a predetermined system operating pressure; and

controlling a temperature setpoint of a separation subsystem to track a predetermined temperature setpoint,

wherein the inlet flow rate, the system operating pressure, and the temperature setpoint are controlled to maintain a minimum methane number of a dry gas output stream and a maximum vapor pressure a natural gas liquids stream (NGLs), and

wherein the inlet flow rate, the system operating pressure, and the temperature setpoint are determined by a heat content and a well flow rate of the raw natural gas stream.

5. The system of claim 1, wherein the equipment-server connection utilizes a communication protocol selected from the group consisting of Modbus, CANbus, TCP/IP, UDP, 3G, 4G, LTE, coaxial, IEEE 802.11a/b/g/n, IEEE 802.15.4, Bluetooth, VPN, IPsec, ISAKMP, near-field communication, Fieldbus, 900 MHz radio, and combinations thereof.

6. The system of claim 1, further comprising program code, which when executed causes said hardware processor to perform a process of controlling separation of a raw natural gas stream into at least two useable streams comprising a dry natural gas stream (NG) having a desired minimum methane number and a natural gas liquids stream (NGLs) having a desired maximum vapor pressure, the program code causing the processor to perform steps comprising:

controlling one or more process parameters, the one or more process parameters selected from the group consisting of an inlet flow rate of a raw natural gas stream, a system operating pressure, and a temperature setpoint of a separation subsystem,

wherein the one or more process parameters are controlled to maintain the desired minimum methane number and the desired maximum vapor pressure.

7. The system of claim 6, wherein the inlet flow rate, the system operating pressure, and the temperature setpoint are determined by one or more input parameters selected from the group consisting of a heat content of the raw natural gas stream, a volume flow rate of the raw natural gas stream, the desired minimum methane number, and the desired maximum vapor pressure.

8. The system of claim 6, wherein the inlet flow rate is controlled by controlling an inlet control valve or a compressor speed on one or more compressors.

9. The system of claim 6, wherein the inlet flow rate is between about 120 mcf per day to about 1200 mcf per day.

10. The system of claim 6, wherein the system operating pressure is controlled by controlling a pressure control valve in the separation subsystem.

11. The system of claim 6, wherein the system operating pressure is between about 6 bar to about 35 bar.

12. The system of claim 6, wherein the temperature setpoint of the separation subsystem is a reboiler temperature setpoint of a reboiler in the separation subsystem.

13. The system of claim 12, wherein the reboiler temperature setpoint is controlled by a reboiler controller.

14. The system of claim 12, wherein the reboiler temperature setpoint is between about 0 degrees C. to about 120 degrees C.

15. The system of claim 6, wherein a composition of a third stream, comprising an ethane-rich stream, is allowed to vary in composition.

16. The system of claim 6, wherein the desired minimum methane number of the dry natural gas stream corresponds to a methane content selected from the group consisting of 60% methane, 65% methane, 70% methane, 75% methane, 80% methane, 85% methane, 90% methane, and 95% methane.

17. The system of claim 6, wherein the desired maximum vapor pressure of the NGLs stream is no more than 17 bar at 38°

C.

18. The system of claim 6, wherein the desired maximum vapor pressure of the NGLs stream is between about 5 bar and about 20 bar at 38°

C.

19. The system of claim 6, wherein the heat content of the raw natural gas stream is between about 1100 BTU to about 1800 BTU.

20. The system of claim 6, wherein the volume flow rate of the raw natural gas stream is between about 100 mcf per day to about 5000 mcf per day.