All-in-one skid assembly

• US 10,274,133 B2
• Filed: 06/19/2017
• Issued: 04/30/2019
• Est. Priority Date: 06/29/2016
• Status: Active Grant

• Current Assignee: TK Skids LLC
• Original Assignee: Thomas Kunkel
• Inventors: Kunkel, Thomas
• Primary Examiner(s): Buck, Matthew R
• Assistant Examiner(s): Lembo, Aaron L
• Application Number:
  US15/626,737
• Publication Number:
  US 20180003342A1
• Time in Patent Office: 680 Days
• CPC Class Codes: F17C 1/00 Pressure vessels, e.g. gas cylinder, gas tank, replaceable cartridge pressurised apparatus for purposes other than storage, see the relevant subclasses such as A62C, B05B; associated with vehicles, see the appropriate subclass of classes B60 - B64; pressure vessels in general F16J12/00 ; autoclaves B01J3/04; tank vehicles B60P3/22; railway tank wagons for carrying fluent materials B61D5/00; accumulators for supplying fluid under pressure F15B1/04; liquefied gas stoves F24C3/00
• CPC Class Codes: F17C 2221/033 Methane, e.g. natural gas, CNG, LNG, GNL, GNC, PLNG
• CPC Class Codes: F17C 2223/0123 gaseous, e.g. CNG, GNC
• CPC Class Codes: F17C 2225/0153 Liquefied gas, e.g. LPG, GPL
• CPC Class Codes: F17C 2225/035 High pressure, i.e. between 10 and 80 bars
• CPC Class Codes: F17C 2227/0157 Compressors
• CPC Class Codes: F17C 2227/0171 Arrangement
• CPC Class Codes: F17C 2250/01 Intermediate tanks
• CPC Class Codes: F17C 2270/01 for fluid transport or storage
• CPC Class Codes: F17C 5/06 for filling with compressed gases

Abstract

Disclosed is an assembly that is an all-in-one combination of piping and equipment systems designed to provide a compact, simple, pre-fabricated assembly on single skid platform to meet all the functional needs of a petrochemical gas compression facility. The skid platform assembly provides a traveling pathway for the fluid generated from a well and is designed to provide all required pre-compressor and post-compressor functional equipment needs for each individual installed gas compressor. The skid platform assembly comprises an integrated liquid separator that also functions as a common liquid sump for all liquid generated by the pre-compressor and post-compressor functional equipment.

Claims

1. An All-in-One skid for use with an individual compressor, the skid comprising a plurality of functional equipment used to operate a petrochemical gas gathering compressor facility and providing a traveling pathway for fluid generated from a well to the individual compressor and from the individual compressor to a utility gas service, the fluid being comprised of gas and condensate the skid being comprised of:

a common gas inlet pipe header that receives the fluid generated from the well, a skid gas inlet pipe connecting the common gas inlet pipe header to an integral inlet separator, the integral inlet separator functioning to gravity separate out the gas from the condensate in the fluid generated from the well and accumulating a condensate level inside, wherein the condensate can be drained from the integral inlet separator via an integral inlet separator drain pipe;

the integral inlet separator being sized for gravity separation and to process a flow as required by the individual compressor, and the integral inlet separator being fluidly connected to each one of the plurality functional equipment and to the individual compressor via at least one drain system;

wherein the plurality of functional equipment is comprised of pre-compressor functional equipment and post-compressor functional equipment;

wherein one component of the pre-compressor functional equipment is an inlet filter separator vessel, the inlet filter separator vessel is comprised of a first stage and a second stage;

the first stage being fluidly connected to the integral inlet separator via a pipe to inlet filter and a gravity drain pipe, the second stage being fluidly connected to the integral inlet separator via a low pressure drain pipe;

whereby the gas travels from the integral inlet separator up the pipe to inlet filter into the first stage of the inlet filter separator vessel;

whereby the gas travels from the first stage of the inlet filter separator to the second stage of the inlet filter separator, whereby the gas travels out of the second stage of the inlet filer separator into a compressor inlet pipe through a compressor inlet suction control valve into the individual compressor;

the individual compressor transforming the gas that is separated out into compressor discharge gas, the compressor discharge gas then travels through each one of the plurality of post-compressor functional equipment and ultimately through a common gas discharge pipe header ending at the utility gas service, and wherein any condensate generated by each one of the plurality functional equipment and individual compressor ultimately drains back into to the integral inlet separator.

2. The skid of claim 1,

whereby the condensate generated by the first stage of the inlet filter separator vessel travels down the gravity drain pipe into the integral inlet separator vessel;

whereby the condensate generated by the second stage of the inlet filter separator vessel travels down the low pressure drain pipe to a blowcase vessel through a level control automated diverter valve;

the blowcase vessel and the level control automated diverter valve being fluidly connected to the inlet filter separator via a low pressure drain pipe and the blowcase vessel and the level control automated diverter valve being fluidly connected to the integral inlet separator via a blowcase pressurized drain pipe,

whereby when the blowcase vessel is full of condensate, the blowcase level controller on the blowcase vessel will actuate the level control automated diverter valve to close off the diverter valve low pressure drain pipe connection and to open the diverter valve pressurized feed gas pipe connection allowing the compressor discharge gas at a high pressure originating from the individual compressor via a plurality of pipes emanating from a utility gas outlet connection on the common gas discharge pipe header, to blow the condensate from the blowcase vessel into the integral inlet separator via the blowcase pressurized drain pipe;

whereby when the blowcase vessel is empty, the blowcase level controller on the blowcase will actuate the automated diverter valve to close off the diverter valve pressurized feed gas pipe connection and open the diverter valve low pressure drain pipe connection;

a small volume of the pressurized gas in the blowcase vessel is vented up the low pressure drain pipe into the second stage of the inlet filter separator vessel;

whereby the small volume of pressured gas travels out of the second stage of the inlet filer separator into the compressor inlet pipe through the compressor inlet suction control valve into the individual compressor.

3. The skid of claim 1 wherein the compressor inlet pipe further comprises a pressure equalizing pipe comprised of a equalizing pipe inlet connection and a generic backflow preventer valve, the equalizing pipe inlet connection being located on the compressor inlet pipe downstream of the compressor inlet suction control valve and ending at an equalizing pipe outlet connection on the integral inlet separator;

whereby when the individual compressor is stopped thereby trapping the compressor discharge gas is at a high pressure, the compressor discharge gas at the high pressure can automatically depressurize into the integral inlet separator via the pressure equalizing pipe and whereby the generic backflow preventer valve prevents back-flow from the integral inlet separator during normal compressor operation.

4. The skid of claim 1, further comprising an inlet slug catcher liquid PSO system having a mechanical float inside, the inlet slug catcher liquid PSO system is fluidly connected in between the skid gas inlet pipe and the integral inlet separator, the inlet slug catcher liquid PSO system connecting to the skid gas inlet pipe via a PSO inlet connection and the inlet slug catcher liquid PSO system connecting to the integral inlet separator via both a PSO upper discharge connection and a PSO lower discharge connection;

whereby a discharge of condensate from the integral inlet separator through the PSO lower discharge connection influences the mechanical float inside the liquid PSO device to rise and fall in coordination with the condensate level inside the integral inlet separator, whereby when the condensate level rises to a maximum design condensate level inside the integral inlet separator, the mechanical float will rise to plug the PSO inlet connection and therefore stop all flow to the integral inlet separator until the condensate level inside the integral inlet separator is lowered via the integral inlet separator drain pipe.

5. The skid of claim 1 wherein the common gas inlet pipe header and the common gas discharge pipe header are both flanged on each end allowing two or more skids to be connected in series.

6. The skid of claim 1,

wherein one component of the post-compressor functional equipment is a discharge oil separator vessel, the discharge oil separator vessel receiving the compressor discharge gas from the individual compressor via a compressor discharge pipe,

the discharge oil separator vessel comprising a first stage and a second stage, the first stage of the discharge oil separator vessel is fluidly connected to the integral inlet separator via the oil separator pressurized first stage drain, and the second stage of the discharge oil separator vessel is fluidly connected to the integral inlet separator via the oil separator pressurized second stage drain, whereby the condensate generated by the first stage of discharge oil separator vessel travels down the oil separator pressurized first stage drain into the integral inlet separator vessel;

whereby the condensate generated by the second stage of discharge oil separator vessel travels down the oil separator pressurized second stage drain into the integral inlet separator vessel;

wherein the compressor discharge gas flows out of the discharge oil separator vessel through the second stage of the discharge oil separator vessel outlet to an oil free discharge pipe.

7. The skid of claim 6, wherein the oil separator pressurized first stage drain and the oil separator pressurized second stage drain are further comprised of globe-type pressure reducing valves to reduce pressure and flow of condensate traveling to the integral inlet separator.

8. The skid of claim 6,

further comprising a dehydration contactor tower, the dehydration contactor tower being fluidly connected to the discharge oil separator vessel via the oil free discharge pipe and the dehydration contactor tower receiving the compressor discharge gas from the oil free discharge pipe, the dehydration contactor tower being fluidly connected to a glycol separator vessel, wherein the compressor discharge gas flows out of the dehydration contactor tower via a dehydration contactor tower-to-glycol separator pipe to the glycol separator vessel;

the glycol separator vessel comprising a first stage and a second stage, the first stage of the glycol separator is fluidly connected to the integral inlet separator via a glycol separator pressurized first stage drain, and the second stage of the glycol separator vessel is fluidly connected to the integral inlet separator via a glycol separator pressurized second stage drain, whereby the condensate generated by the first stage of glycol separator vessel travels down the glycol separator pressurized first stage drain into the integral inlet separator vessel;

whereby the condensate generated by the second stage of glycol separator vessel travels down the glycol separator pressurized second stage drain into the integral inlet separator vessel;

whereby compressor discharge gas flows out of the second stage of glycol separator vessel to a dry gas discharge pipe, the dry gas discharge pipe being fluidly connected to the glycol separator vessel and being fluidly connected to a common gas discharge pipe header;

the common discharge pipe header also being fluidly connected to the utility gas service.

9. The skid of claim 8, wherein the glycol separator pressurized first stage drain and the glycol separator pressurized second stage drain are further comprised of globe-type pressure reducing valves to reduce pressure and flow of the condensate traveling to the integral inlet separator.

10. The skid of claim 1, whereby the utility gas services is comprised of a utility gas outlet, a high pressure utility gas feed pipe, a utility systems filter, a first pressure cut regulator and a pressurized utility systems drain pipe;

wherein the compressor discharge gas is fed from the common discharge pipe through the utility gas outlet connection into the high pressure utility gas feed pipe that is fluidly connected the utility systems filter via the first pressure cut regulator;

the utility systems filter separates out any condensate generated by the first pressure cut regulator;

the separated condensate is then drained from the utility systems filter back to the integral inlet separator through the pressurized utility systems drain pipe.

11. The skid of claim 10 further comprised of a fuel gas system, a starting gas system, and an instrument gas system.

12. The skid of claim 10, wherein the pressurized utility systems drain pipe is further comprised of a globe-type pressure reducing valve to reduce pressure and flow of the condensate draining back to the integral inlet separator.

13. The skid in claim 1, wherein the common gas inlet pipe header is further comprised of an inlet ESD (emergency shutdown) valve and a blowdown automated valve to be used for emergency isolation and skid de-gassing.

14. The skid of claim 1 wherein the condensate level inside the integral inlet separator is measured by a level gauge connected to the integral inlet separator at an upper level gauge connection and at a lower level gauge connection;

the integral inlet separator drain pipe is fluidly connected to the integral inlet separator at a primary liquid drain connection and a secondary liquid drain connection;

an automated drain valve located on the integral inlet separator drain pipe is controlled by an integral inlet separator level controller installed on the level gauge;

whereby when the condensate level rises up to the upper level gauge connection, the integral inlet separator level controller opens the automated drain valve allowing the condensate to drain and when the condensate level inside drains down to the lower gauge connection, the integral inlet separator level controller closes the automated drain valve.

15. An assembly comprising a plurality of pre-compressor systems and a plurality of post-compressor systems for use in a petrochemical gas gathering compressor facility;

wherein the plurality of pre-compressor systems comprises an integral inlet separator and an inlet filter separator vessel;

wherein the integral inlet separator is sized to gravity separate out gas from condensate;

whereby the separated gas then travels directly to the inlet filter separator vessel;

wherein the integral inlet separator is a common sump for any condensate generated by all the pre-compressor and post-compressor systems;

the integral inlet separator being connected to all the pre-compressor and post-compressor systems to allow for either gravity drainage or low pressure drainage into the integral inlet separator;

the assembly being a single skid platform for use with a single compressor of the petrochemical gas gathering compressor facility.

16. The assembly of claim 15 wherein the plurality of post-compressor systems comprises a discharge oil separator and a utility gas service.

17. The assembly of claim 15 wherein the plurality pre-compressor systems is further comprised of an inlet slug catcher liquid PSO system.

18. The assembly of claim 15 wherein the plurality pre-compressor systems is further comprised of a blowcase.

19. The assembly of claim 16 wherein the plurality of post-compressor systems is further comprised of a dehydration contact tower.

20. The assembly of claim 16 wherein the plurality of post-compressor systems is further comprised of a glycol separator vessel.

21. The assembly of claim 16 wherein the plurality of post-compressor systems is further comprised of a fuel gas system, a starting gas system, and an instrument gas system.

22. The assembly of claim 15, whereby the skid is capable of being connected in series to another skid.