Patent Application
20230400182
The present invention generally relates to the field of gas distribution and delivery to one or more gas consuming assets, and more particularly, to a method and system for efficiently and safely distributing fuel gas to a gas consuming asset on demand.
In many applications, it is often desirable to distribute fuel gas to one or more fuel consuming assets. The fuel consuming assets may be located a distance from the source of the fuel gas and may require differing amounts of fuel gas.
Fuel gas, such as natural gas, may be delivered to one or more fuel consuming assets located at a job site, such as a fracking location. In typical fuel gas delivery systems, fuel consuming assets may be fed off of a single supply line in a “daisy chain” configuration, in which each subsequent fuel consuming asset is fed off the same line as the prior asset in the chain.
The typical arrangement has several shortcomings, a non-exhaustive list of which follows. For instance, a fuel consuming asset at the end of the daisy chain arrangement may receive less flow and/or fuel gas pressure than assets located near the beginning of the feed line. This may lead to fuel starvation at fuel consuming assets near the end of the line and unbalanced fuel consumption by assets along the line. Additionally, prior arrangements for providing fuel gas on-site have the disadvantage of scaling poorly if additional fuel-consuming assets are added to the daisy-chain arrangement. Adding one or more fuel consuming assets may change the feed flows and pressures to the fuel consuming assets previously present, which may result in sub-optimal performance.
There is therefore a need for a method and system to safely and efficiently deliver fuel gas to such fuel consuming assets that addresses these and other shortcomings of prior art fuel gas distribution systems.
The present disclosure may comprise one or more of the following features and combinations thereof.
According to an illustrative embodiment, a fuel gas manifold comprises a manifold body configured to fluidically couple to a fuel gas source. The manifold body comprises a central body having a first end and a second end, wherein the central body has a first internal diameter. The manifold body also comprises a plurality of branch line take-off pipes coupled to the central body. The internal diameter of each of the plurality of branch line take-off pipes is smaller than the first internal diameter, the plurality of branch line take-off pipes are coupled to the manifold body such that the longitudinal axes of each of the plurality of the branch line take-off pipes is substantially perpendicular to the longitudinal axis of the central body, and each of the plurality of branch line take-off pipes is configured to fluidically couple the manifold body to a branch line corresponding to one or more fuel gas consuming assets. The fuel gas manifold also comprises a manifold coupler attached to the first end of the manifold body, wherein the manifold coupler is operable to fluidically couple the manifold body to a fuel gas feed line. The fuel gas manifold also comprises a branch line coupler coupled to each branch line take-off pipe by a branch line valve, wherein each branch line coupler is operable to couple to a corresponding branch line.
According to another illustrative embodiment, a system for distributing fuel gas to one or more fuel gas consuming assets comprises a fuel gas feed line configured to fluidically couple to a fuel gas source and a manifold body fluidically coupled to the fuel gas feed line. The manifold body comprises a central body having a first end and a second end, wherein the central body has a first internal diameter. The manifold body also comprises a plurality of branch line take-off pipes coupled to the central body. The internal diameter of each of the plurality of branch line take-off pipes is smaller than the first internal diameter, the plurality of branch line take-off pipes are coupled to the manifold body such that the longitudinal axes of each of the plurality of the branch line take-off pipes is substantially perpendicular to the longitudinal axis of the central body, and each of the plurality of branch line take-off pipes fluidically couples the manifold body to a branch line corresponding to one of the one or more fuel gas consuming assets. The system for distributing fuel gas also includes a manifold coupler attached to the first end of the manifold body, wherein the manifold coupler is operable to fluidically couple the manifold body to the fuel gas feed line. The system for distributing fuel gas also includes a branch line coupler coupled to each branch line take-off pipe by a branch line valve wherein at least one of the branch lines is coupled to at least one of the branch line couplers. The system for distributing fuel gas also includes at least one fuel gas consuming asset fluidically coupled to the manifold body by at least one of the branch lines.
According to another illustrative embodiment, A method for distributing fuel gas comprises supplying fuel gas to one or more fuel gas consuming assets through a fuel gas manifold system. The fuel gas manifold system comprises a fuel gas feed line configured to fluidically couple to a fuel gas source and a manifold body fluidically coupled to the fuel gas feed line. The manifold body comprises a central body having a first end and a second end, wherein the central body has a first internal diameter. The manifold body also comprises a plurality of branch line take-off pipes coupled to the central body. The internal diameter of each of the plurality of branch line take-off pipes is smaller than the first internal diameter, the plurality of branch line take-off pipes are coupled to the manifold body such that the longitudinal axes of each of the plurality of the branch line take-off pipes is substantially perpendicular to the longitudinal axis of the central body, and each of the plurality of branch line take-off pipes fluidically couples the manifold body to a branch line corresponding to one of the one or more fuel gas consuming assets. The fuel gas manifold system also comprises a manifold coupler attached to the first end of the manifold body, wherein the manifold coupler is operable to fluidically couple the manifold body to the fuel gas feed line. The fuel gas manifold system also comprises a branch line coupler coupled to each branch line take-off pipe by a branch line valve, wherein at least one of the branch lines is coupled to at least one of the branch line couplers. The method for distributing fuel gas also comprises at least one of the one or more fuel gas consuming assets fluidically coupled to the manifold body by at least one of the branch lines.
The objects, advantages and other features of the present invention will become more apparent upon reading of the following non-restrictive description of a preferred embodiment thereof, given by way of example only with reference to the accompanying drawings. Although various features are disclosed in relation to specific exemplary embodiments of the invention, it is understood that the various features may be combined with each other, or used alone, with any of the various exemplary embodiments of the invention without departing from the scope of the invention.
For a more complete understanding of the present invention and its features and advantages, reference is now made to the following description, taken in conjunction with the accompanying drawings, in which:
While embodiments of this disclosure have been depicted and described and are defined by reference to example embodiments of the disclosure, such references do not imply a limitation on the disclosure, and no such limitation is to be inferred. The subject matter disclosed is capable of considerable modification, alteration, and equivalents in form and function, as will occur to those skilled in the pertinent art and having the benefit of this disclosure. The depicted and described embodiments of this disclosure are illustrative examples only, and not exhaustive of the scope of the disclosure.
The following detailed description illustrates embodiments of the present disclosure. These embodiments are described in sufficient detail to enable a person of ordinary skill in the art to practice these embodiments without undue experimentation. It should be understood, however, that the embodiments and examples described herein are given by way of illustration only, and not by way of limitation. Various substitutions, modifications, additions, and rearrangements may be made that remain potential applications of the disclosed techniques. Therefore, the description that follows is not to be taken as limiting on the scope of the appended claims. In particular, an element associated with a particular embodiment should not be limited to association with that particular embodiment but should be assumed to be capable of association with any embodiment discussed herein.
As used herein, the terms “coupled” or “couple” include both a direct connection and an indirect connection between components. Similarly, the term “fluidically coupled” includes both a direct connection allowing fluid flow between two components as well as an indirect connection allowing fluid flow between two components. Further, in the figures and the description, like numerals are intended to represent like elements.
As used herein, “fuel gas” includes any gas that may be combusted, including hydrocarbon gasses. Examples of fuel gasses include natural gas, compressed natural gas (CNG), field gas, synthesis gas, liquified natural gas (LNG), gas residue, sale line gas, hydrogen, methane, propane, butane and combinations thereof. Field gas may include any hydrocarbon gas that is obtained directly from an oil and/or natural gas well or field of wells.
As used herein, the term “fuel gas consuming asset” includes any equipment or component of a system that consumes fuel gas and may need to be fed with fuel gas on location. The term “fuel gas consuming asset” further includes any fuel gas consuming equipment that needs to be fed fuel gas “on-location” because, for example, it is remotely located and/or it needs to operate continuously and therefore taking it offline to refuel or moving it to a fuel source to refuel results in asset downtime and is expensive, time consuming and/or otherwise inefficient. In one embodiment, the fuel consuming asset may be equipment used in oilfield applications such as, for example, equipment used to provide power for, in construction of, or development of oil and gas fields. The term “fuel gas consuming asset” may include a number of other equipment including, for example, electrical generators, irrigation pumps, emergency response generators, or any oilfield services equipment (e.g., fracturing equipment, etc.).
In one or more exemplary embodiments there is disclosed herein a new and improved distribution system for fuel gas and associated methods used to distribute fuel gas to a fuel gas consuming asset.
The manifold body 110 includes a central body 111 (e.g., a pipe) with one or more branch line take-offs 112 welded to the central body 111. Each branch line take-off 112 is a short pipe that has a smaller internal diameter (ID) than the central body 111 and is fluidically coupled to the central body 111 such that fuel gas supplied to manifold body 110 through the feed line 101 may flow out of the manifold body 110 through the branch line take-offs 112. In some embodiments, one or more branch line take-offs may be attached to the central body 111 and arranged opposite each other on each side of the central body 111. In some embodiments, the branch line take-offs 112 are coupled to the central body 11 such that the longitudinal axes of the branch line take-offs 112 are substantially perpendicular to the longitudinal axis of the central body 111. Branch line take-offs 112 on one side of the central body 112 may have an angle between approximately 0 and 180 degrees with the branch line take-offs 112 located on the other side of the central body 111. In a particular embodiment, the manifold body 110 may have a central body 111 with a plurality of branch line take-offs 112 on each side of the central body 111 with an angle of about 90 degrees between each bank of the branch line take-offs 112, in other words the longitudinal axis of a branch line take off 112 disposed on one side of central body 111 may form an angle of approximately 90 degrees with the longitudinal axis of a branch line take off 112 disposed on the other side of central body 111. For instance, in the illustrative embodiment of
The manifold body 110, including the central body 111 and the branch line take-offs 112, may be made of any suitable material as would be understood by a person having skill in the art having the benefit of this disclosure, including, but not limited to carbon fiber, fiberglass, PVC, high density polyethylene, steel, stainless steel, titanium, Monel, Inconel, and other alloys. The wall thickness of the manifold body 110, including the central body 111 and the branch line take-offs 112, may have a wall pipe thickness of approximately between schedule 40 and schedule 160. In certain illustrative embodiments, the manifold body 110 may be made of steel and have a central body 111 with an internal diameter of approximately in the range of between 2.5-3.5 inches and include twelve branch line takes-offs 112 with an internal diameter of approximately in the range of between 1.5-2.5 inches arranged in two banks of six branch line take-offs 112 having an angle of 90 degrees between each bank (i.e. 45 degrees from vertical).
The manifold body 110 may also include a manifold pressure gauge 106 to provide for monitoring of fuel gas pressure within the manifold body 110. The manifold pressure gauge 106 may be fluidically coupled to the central body 111 and provide a measurement of the pressure of the fuel gas flowing through the central body 111. The manifold pressure gauge 106 may be any digital or analog pressure gauge suitable for use in fuel gas service, as would be understood by a person having skill in the art with the benefit of the present disclosure. The manifold body 110 may also include one or more ports 109 (a single port shown in the illustrative embodiment) that may be used for installation of instrumentation or a pressure relief valve. The port 109 may be fluidically coupled to the central body 111 and provide for fluid communication between an installed instrument or pressure relief valve and the interior of the central body 111. Instruments that may be installed on the one or more ports 109 may include any suitable instrument for use in fuel gas service, including but not limited to, flow meters, moisture meters, temperature measuring devices, and other instrumentation used to measure properties of a flowing fuel gas, as would be understood by a person having skill in the art with the benefit of the present disclosure. When not in use, the port 109 may be capped to prevent fuel gas from escaping the manifold body 110. In some embodiments, when fuel is being supplied to one or more fuel consuming assets through the fuel gas manifold system 100, the manifold pressure gauge 106 and/or one or more instruments coupled to the one or more ports 109 may be monitored. For example, the manifold pressure gauge 106 may be monitored to determine a pressure of fuel gas within the fuel gas manifold system 100 and the fuel gas source may be adjusted to reach a desired pressure or flow rate.
The manifold body 110 may also include one or more attachment points 115, commonly referred to as “picking eyes” or “hoist rings,” that are coupled to the central body 111. The one or more attachment points 115 may provide coupling of the manifold body 110 to a crane or hoist to facilitate movement of manifold body 110. In a particular embodiment, the central body 111 may have two attachment points 115, one at each end of the central body 111. In certain illustrative embodiments, the one or more attachment points 115 may be welded to the central body 111.
In some embodiments, a second manifold coupler 102b may be present at the end of manifold body 110 opposite the end having the manifold coupler 102a. The second manifold coupler 102b may be capped or otherwise sealed if only one fuel gas manifold system 100 is in use or may be used to couple a first fuel gas manifold system 100 to a second fuel gas manifold system 100, as is illustrated in
Each branch line take-off 112 may be coupled to a branch line valve 103. The branch line valves 103 may be positioned between the manifold body 110 and the branch line couplers 104 and may provide for fluid isolation between the manifold body 110 and the branch lines 105. For example, fuel gas flow to a particular branch line 105 may be shut off by closing a branch line valve 103 to accommodate coupling or decoupling of a fuel gas branch line 105 to a branch line coupler 104.
The branch line valves 103 may be any valve suitable for fuel gas service, as would be understood by a person having skill in the art with the benefit of this disclosure. Examples of branch line valves 103 include, but are not limited to gate valves, ball valves, globe valves, plug valves, and butterfly valves. In a particular embodiment, branch line valves 103 may be quarter turn ball valves manufactured by Balon.
In some embodiments, a branch line pressure gauge 107 and a branch line port 108 may be positioned between each branch line valve 103 and branch line coupler 104. The branch line pressure gauge 107 and branch line port 108 may be fluidically coupled to the corresponding branch line take-off 112, and therefore to the manifold body 110, when the corresponding branch line valve 103 is open. The branch line pressure gauges 107 may be any digital or analog pressure gauge suitable for use in fuel gas service, as would be understood by a person having skill in the art with the benefit of the present disclosure. The branch line ports 108 may be used for installation of instrumentation or a pressure relief valve that is fluidically coupled to each branch line 105. The branch line ports 108 may be fluidically coupled to the manifold body 110 and provide for fluid communication between an installed instrument or pressure relief valve and the interior of each branch line take-off 112. Instruments that may be installed on the branch line ports 108 may include any suitable instrument for use in fuel gas service, including but not limited to, flow meters, moisture meters, temperature measuring devices, and other instrumentation used to measure properties of a flowing fuel gas, as would be understood by a person having skill in the art with the benefit of the present disclosure. When not in use, the branch line ports 108 may be capped to prevent fuel gas from escaping the manifold body 110 and branch lines 105.
The branch line couplers 104 may include any coupler operable to allow for fluidic coupling between pipes, lines, or hoses, including but not limited to Dry-lock couplers, flanged couplers, screw couplers, “quick disconnect couplers” such as the NovaFlex coupler, as would be understood by one of skill in the art having the benefit of this disclosure. Likewise, manifold couplers 102a and 102b may include any coupler operable to allow for fluidic coupling between pipes, lines, or hoses, including but not limited to Dry-lock couplers, flanged couplers, screw couplers, “quick disconnect couplers” such as the NovaFlex coupler, as would be understood by one of skill in the art having the benefit of this disclosure.
If the manifold body 110 is not fluidically coupled to another manifold body 110, one of manifold couplers 102a or 102b may be sealed, for example by a valve, blind flange, cap, or other sealing apparatus as would be understood by one of skill in the art having the benefit of this disclosure. In certain illustrative embodiments, the manifold couplers 102a and 102b have a larger internal diameter than the branch line couplers 104. In some embodiments, the manifold couplers 102a and 102b may have the same internal diameter as each other and the branch line couplers 104 may have the same internal diameter as the other branch line couplers 104. In a particular embodiment, the manifold couplers 102a and 102b may have an ID to accommodate coupling to a hose or pipe having an ID of approximately between 2-4 inches, and the branch line couplers 104 may have an ID to accommodate coupling to a hose or pipe having an ID of approximately between 1-3 inches.
In certain illustrative embodiments, the fuel gas manifold 100 may be fluidically coupled to a fuel gas source 420 by a fuel gas feed line 101. The fuel gas manifold system 100 may also be fluidically coupled to the branch lines 105 which are in turn fluidically coupled to one or more fuel consuming assets 400. The fuel gas source 420 may be any source of fuel gas known in the art. Examples of fuel gas source 420 include tanks for storage of pressurized fuel gas, tanks for storage of liquified fuel gas, fuel gas wells such as fracking wells producing natural gas, and compressors fluidically coupled to fuel gas tanks or wells. The fuel gas source 420 may supply one or more gaseous fuels, including, but not limited to, compressed natural gas (CNG), liquefied natural gas (LNG), hydrogen, and propane. Additionally, the fuel gas source 420 may include treatment of fuel gases to make the fuel gas more suitable for use by the fuel consuming assets 400. In particular embodiments, fuel gas manifold system 100 may be coupled to a fuel gas source 420 that includes one or more alternative fuel offerings including, but not limited to: LNG, CNG, Hydrogen, Propane, and other gaseous fuels.
Fuel gas flows to the fuel consuming assets 400 from the fuel gas source 420, through the fuel gas feed line 101 to the manifold body 110. Fuel gas then flows through the manifold body 110 to one or more branch lines 105, and through the one or more branch lines 105 to one or more fuel consuming assets 500. In some embodiments, each branch line 105 may be coupled to two fuel consuming assets 400 by a branch line splitter 500 as is shown in
In certain illustrative embodiments, the manifold body 110 may be supplied with fuel gas through the fuel gas feed line 101 at a pressure of approximately between 50-1500 PSI. As would be understood by a person having ordinary skill in the art having the benefit of this disclosure, flow rate of fuel gas through the manifold system 100 may be a function of one or more of fuel gas supply pressure, fuel gas feed line 101 diameter, manifold body 110 diameter, branch line 105 diameter, the number of branch lines 105 connected to the manifold body 110, and the one or more fuel gas consuming assets' 400 demand for fuel gas. For reference, an abbreviated table providing maximum recommend fuel gas flow in standard cubic feet per minute (SCFM) for particular IDs and pressures is shown below in Table 1. As would be understood by a person having ordinary skill in the art having the benefit of this disclosure, Table 1 is not comprehensive for all possible fuel gas pressures or diameters of the manifold system 100 disclosed herein, and higher pressures and diameters from those listed may provide for higher maximum recommended fuel gas flow and likewise lower pressures and diameters from those listed may provide for lower maximum recommended fuel gas flow.
Capillary valves 503a and 503b may be used to isolate the branch splitter 500 from capillary lines 503a or 503b, respectively, to allow for coupling or decoupling of capillary lines 503a or 503b from capillary couplers 504a and 504b. As with branch line valves 103, capillary valves 503a and 503b may be any valve suitable for fuel gas service, as would be understood by a person having skill in the art with the benefit of this disclosure. Examples of capillary valves 503a and 503b include, but are not limited to, gate valves, ball valves, globe valves, plug valves, and butterfly valves. In certain embodiments, capillary valves 503a and 503b may be quarter turn ball valves.
The exemplary embodiment illustrated in
As with
As would be appreciated by those of ordinary skill in the art with the benefit of the present disclosure the methods and systems disclosed herein provide several advantages. For example, once the manifold system 100 has been connected, the manifold facilitates even fuel gas distribution between a plurality of fuel gas consuming assets 400, reducing problems of any particular fuel gas consuming asset experiencing fuel gas starvation. Moreover, the fuel gas manifold 100 allows for connection and disconnection of fuel gas consuming assets 400 during operation by use of valves 103, and/or 503 to isolate fuel gas flow to particular branch lines 105 or capillary lines 505. As would be appreciated by those of ordinary skill in the art, having the benefit of the present disclosure, this is not intended to be an exhaustive list of all advantages and benefits of the methods and systems disclosed herein and other advantages are apparent to those of ordinary skill in the art, having the benefit of the present disclosure.
As would be appreciated, numerous other various combinations of the features discussed above can be employed without departing from the scope of the present disclosure. While the subject of this specification has been described in connection with one or more exemplary embodiments, it is not intended to limit any claims to the particular forms set forth. On the contrary, any claims directed to the present disclosure are intended to cover such alternatives, modifications and equivalents as may be included within their spirit and scope. Accordingly, all changes and modifications that come within the spirit of the disclosure are to be considered within the scope of the disclosure.
