GAS HEATER / COOLER APPARATUSES AND METHODS

Abstract

Gas heater/cooler apparatuses and methods of manufacturing thereof are provided. A gas heater/cooler apparatus has a gas pipe configured to transport a fluid inside a heat transfer block. A fluid flow through a cooling pipe in the proximity of the gas pipe or pushed towards the gas pipe by a fan cools the fluid. An electric heater disposed inside the heat transfer block close to the gas pipe may heat the fluid flowing therein via radiated heat.

Description

BACKGROUND OF THE INVENTION

Embodiments of the subject matter disclosed herein generally relate to apparatuses and methods used in changing the temperature of fluid flowing through a pipe and, more particularly, to apparatuses and methods in which either heating and/or cooling may be performed with the same equipment.

The fossil fuels remain a main source of energy and, therefore, the interest in developing new production fields has increased parallel with the increase of demand. Since the availability of land-based production fields is limited, tapping the vast amounts of offshore reserves has become more imperative in spite of the technical challenges. Due to the limited space on a rig, the offshore oil and gas exploration and exploitation needs more compact equipment than the conventional land-based oil and gas equipment.

In conventional gas cooling equipment 1 as illustrated in FIG. 1, a container 10 houses a plurality of pipes 20 through which a cooling agent circulates. The cooling agent may be water. A fluid flow of oil or gas whose temperature is sought to be lowered is input through an inlet 30, and output through an outlet 40. In its passage from the inlet 30 to the outlet 40, the fluid flow surrounds the pipes 20. The cooling agent may be input into the container 10 through a coolant inlet 50 in an inlet plenum 60, and then split to flow through the pipes 20 by a tube sheet 70. Similarly, after circulating through the pipes 20, the cooling agent may pass through an output tube sheet into an output plenum 80, to be output via a coolant outlet 90. The output tube sheet is formed as a single piece with the tube sheet 70.

In the gas cooling equipment 1, the input plenum 60 and the output plenum 80 are located on the same side of the container 10, the pipes 20 having a U-shape to extend along the container 10. The pipes 20 may be supported inside the container by baffles 95. The cooling agent is typically brought back to an initial temperature and re-circulated.

The pipes 20 being surrounded by the flow of gas or oil leads to degradation of the pipe walls making possible leaks there-through that would yield contamination of both the flow of gas or oil and the cooling agent.

In processing extracted fossil fuel, cooling or heating the flow of gas or oil may become necessary. Conventionally, the heating equipment is separate from the cooling equipment. The presence of two separate equipments has the disadvantage of an increased cost and of an increased space requirement, which space may be scarce (e.g., on a rig operating offshore).

Additionally, the conventional use of two separate equipments limits the possibility to promptly adjust the temperature of the gas or oil flow.

Accordingly, it would be desirable to provide apparatuses and methods usable to either heat or cool a flow of gas or oil, thus, avoiding the afore-described problems and drawbacks.

BRIEF SUMMARY OF THE INVENTION

According to one exemplary embodiment, a gas heater/cooler apparatus includes a heat transfer block, a gas pipe, a coolant pipe and an electric heater. The gas pipe is configured to transport a fluid through an inside of the heat transfer block. The coolant pipe is configured to transport coolant agent through the inside of the heat transfer block, the coolant pipe being located in the proximity of the gas pipe to cool the fluid flowing therein via heat exchange with the cooling agent flowing through the coolant pipe. The electric heater is located inside the heat transfer block close to the gas pipe to heat the fluid flowing therein via radiated heat.

According to another exemplary embodiment, gas heater/cooler apparatus includes a heat transfer block, a gas pipe, a fan and an electric heater. The gas pipe is configured to transport a fluid through an inside of the heat transfer block. The fan is configured to push a flow of air towards the gas pipe. The electric heater is located inside the heat transfer block close to the gas pipe to heat the fluid flowing therein via radiated heat.

According to yet another exemplary embodiment, a method of manufacturing a gas heater/cooler apparatus is provided. The method includes mounting a gas pipe inside a heat transfer block configured to allow a coolant flow to pass there-through cooling a fluid flowing inside the gas pipe. The method further includes mounting an electric heater inside the heat transfer block and in the proximity of the gas pipe.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate one or more embodiments and, together with the description, explain these embodiments. In the drawings:

FIG. 1 is a schematic diagram of a conventional gas cooling equipment;

FIG. 2 is a schematic diagram of a heater/cooler apparatus according to an embodiment;

FIG. 3 is a flow diagram of a method of manufacturing a heater/cooler apparatus according to an embodiment;

FIG. 4 is a schematic diagram of a heater/cooler apparatus according to another embodiment;

FIG. 5 is a schematic diagram of a heater/cooler apparatus according to another embodiment;

FIG. 6 is a schematic diagram of a heater/cooler apparatus according to another embodiment; and

FIG. 7 is a schematic diagram of a heater/cooler apparatus according to another embodiment.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS OF THE INVENTION

The following description of the exemplary embodiments refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. The following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims. The following embodiments are discussed, for simplicity, with regard to the terminology and structure of a gas processing system. However, the embodiments to be discussed next are not limited to these systems, but may be applied to other systems that require a reduced size equipment capable to both heat or cool a fossil fuel (fluid) flow.

Reference throughout the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrases “in one embodiment” or “in an embodiment” in various places throughout the specification is not necessarily referring to the same embodiment. Further, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.

As discussed above with regard to FIG. 1, the prior art equipment has the disadvantage of being bulky because separate pieces of equipment are used for heating and for cooling, respectively. Additionally, exposure of the pipes carrying the cooling agent to the fluid flow leads in time to degradation of the pipes which may result in cross-contaminating leaks.

According to one embodiment illustrated in FIG. 2, a gas heater/cooler apparatus 100 includes a heat transfer block 110 inside which there is a pipe 120 carrying gas (or other fossil fuel, or fluid) whose temperature is sought to be controlled. The pipe 120 has a shape designed to increase exposure of a longer portion of the pipe 120 to temperature changing agents. For example, the pipe 120 may have a spiral shape (but its shape is not limited thereof). The pipe 120 is made, in an embodiment, from a material that is a good heat conductor, to spend a small amount of energy and time in modifying the temperature of the pipe 120 material. For example, the pipe 120 may be made of stainless steel.

A cooling agent is a fluid flow entering the heat transfer block 110 via an inlet 130 and exiting the heat transfer block via an outlet 140. The heating agent is an electric heater 150 located in the proximity of the pipe 120. Thus, the gas in the pipe 120 may be cooled by the fluid flow and/or may be heated due to heat radiated by the electric heater 150, while passing through the heat transfer block 110.

In another embodiment illustrated in FIG. 3, a method 200 of manufacturing a gas heater/cooler apparatus includes mounting a gas pipe inside a heat transfer block configured to allow a coolant flow to pass there-through, at S210. Further, the method 200 includes mounting an electric heater inside the heat transfer block and in the proximity of the gas pipe, at S220.

The method 200 may also include mounting temperature sensors at different locations along the gas pipe, and/or along the path of the coolant flow. Temperature sensors may be located before and after an area where heat exchange between gas in the gas pipe 120 and the fluid flow occurs, to measure a change of the temperature of the gas and a change of the temperature of the coolant.

The method 200 may further include mounting a fluid regulator on the path of the coolant flow, the fluid regulator being configured to modify the amount of coolant flow entering the heat transfer block. The fluid regulator may be connected to one or more temperature sensors configured to measure a temperature of the coolant and/or of the gas exiting the heat transfer block, to enable the fluid regulator to adjust the amount of coolant flow based on the temperature information received from the one or more sensors.

The method 200 may also include mounting a power supply configured to provide power to the electric heater and a switch configured to cut off the power supply based on temperature information received from one or more temperature sensors.

In another embodiment, the method 200 may include mounting the flow regulator, the power supply, the switch, and the one or more temperature sensors, and, then, connecting these components to a controller. The controller is configured to control the flow regulator and the power supply to adjust the amount of coolant and the power supplied to the electric heater based on the temperatures measured by the sensors, in order to achieve a target output temperature of the gas in the gas pipe.

The method 200 may also include mounting alarms in the apparatus. For example, a cooling agent temperature alarm may be connected to a coolant output temperature sensor located and configured to measure an output temperature of the coolant flow. The cooling agent temperature alarm may be configured to output an alarm signal when the output temperature has a value outside a predetermined temperature range. In another example, a switch may be connected to a coolant output temperature sensor located and configured to measure an output temperature of the fluid flowing inside the gas pipe. The switch may be interposed between the power supply and the electric heater, and be configured to cut off the power to the heater when the output temperature exceeds a predetermined value.

According to another exemplary embodiment, illustrated in FIG. 4, a gas heater/cooler apparatus 300 includes a heat transfer block 310 inside which a pipe 320 carrying gas whose temperature is sought to be controlled is immerged. The heat transfer block may be made of a casted piece of aluminum. The pipe 320 enters the heat transfer block 310 via an inlet 322 and exits the heat transfer block 310 via an outlet 324. Close to the inlet 322, inside or outside the heat transfer block 310, a first temperature sensor 326 may be located to measure the input temperature of the gas in the pipe 320. Close to the outlet 324, inside or outside the heat transfer block 310, a second temperature sensor 328 may be located to measure the output temperature of the gas in the pipe 320. For example, the input temperature of the gas in the pipe 320 may be about 250° C., and the output temperature of the gas may be about 150° C.

Another pipe 330, through which a cooling agent flows, is placed inside the heat transfer block 310 in the proximity of the pipe 320. The pipe 320 and the pipe 330 may have spiral shapes running substantially parallel to each other to maximize the heat exchange therebetween. The cooling agent may be mineral oil. The pipe 330 enters the heat transfer block 310 via an inlet 332 and exits the heat transfer block 310 via an outlet 334. Close to the inlet 332, a third temperature sensor 336 may be located inside or outside the heat transfer block 310, to measure the input temperature of the cooling agent in the pipe 330. Close to the outlet 334, a fourth temperature sensor 338 may be located inside or outside the heat transfer block 310, to measure the output temperature of the cooling agent in the pipe 330. For example, the input temperature of the cooling in the pipe 330 may be about 70° C., and the output temperature of the cooling agent may be about 75° C.

The heat transfer block may be made of a casted piece of aluminum or another material or environment.

A gas temperature alarm 329 and/or a cooling agent temperature alarm 339 may be associated with a respective temperature sensor located close to the outlets. The alarms are configured to output alarm signals when the output temperature of the gas or of the cooling agent respectively has a value outside a corresponding predetermined temperature interval or exceeds a corresponding upper or lower value. The alarm signal may be a visual or an audio indication or may trigger adjustment of the coolant flow and/or of the power supplied to the electric heater 340.

The pipes 320 and 330 are made, in an embodiment, from materials (or the same material) that are good heat conductors, to spend a small amount of energy and time in modifying the temperature of the pipes 320 and 330. For example, the pipes 320 and 330 may be made of stainless steel.

An electric heater 340 is located also in the proximity of the pipe 320, according to an embodiment, in a manner in which to optimize a heat transfer towards the pipe 320 while minimizing a heat transfer towards the pipe 330. Thus, inside the heat transfer block 310 the gas, the gas in the pipe 320 may be cooled due to the cooling agent in the pipe 330 having a lower temperature than the gas and/or may be heated due to heat radiated by the electric heater 340.

The gas heater/cooler apparatus 300 further includes a power supply 350 that provides power to the electric heater 340 and a flow regulator 360 located along a pipe through which the cooling agent enters the heat transfer block 310. The flow regulator 360 is configured to control the amount of cooling agent flowing along the pipe 330 inside the heat transfer block 310. The flow regulator may be an orifice in the coolant pipe wall, an area of the orifice being adjustable. For example, the cooling agent (mineral oil) flow may be about 28 l/min.

The temperature sensors 326, 328, 336, and 338, the power supply 350 and the flow regulator 360 may be connected to a controller 370. The controller 370 may send signals to the power supply 350 and to the flow regulator 360 based on the temperature values received from the temperature sensors 326, 328, 336, and 338 in order to achieve a targeted temperature of the gas exiting the heat transfer block 310.

Another schematic diagram of a gas heater/cooler apparatus 380 is illustrated in FIG. 5. In addition to elements already described relative to FIG. 4, the gas heater/cooler apparatus 380 includes a switch 382 interposed between the power supply 350 and the electric heater 340, the switch 382 being configured to cut off the power to the electric heater. For example, the power may be cut-off (1) when the output temperature of the gas or the coolant exceeds a predetermined value, (2) when a signal is received from an automatic controller or (3) when the switch is flipped between an open state and a close state by a command received via an interface 384. The mineral oil flow may be 28 l/min, the mineral oil temperature raising across the heater/cooler apparatus 380 from 70° C. to 75° C., and the gas flow may be 56 l/min the gas temperature dropping across the heater/cooler apparatus 380 from 250° C. to 150° C.

A layout of a heater/cooler apparatus 390 similar to the apparatuses 300 and 380 described above is illustrated in FIG. 6. The heater/cooler apparatus 390 stands on a mounting foot 392. The electric heater 340 may be lowered inside or raised outside the heat transfer block 310 using a lifting mechanism 394. The apparatus operation information (including temperature information) may be transmitted via a module 396. The heat transfer block 310 may be surrounded by a thermal insulating layer or casing 398. In FIG. 6, the gas pipe 320 and the coolant pipe 330 have helix shapes arranged on the same axis and running substantially parallel to each other.

According to another exemplary embodiment, illustrated in FIG. 7, a gas heater/cooler apparatus 400 includes a heat transfer block 410 inside which there is a pipe 420 carrying gas whose temperature is sought to be controlled. The pipe 420 enters the heat transfer block 410 via an inlet 422 and exits the heat transfer block 410 via an outlet 424. The pipe 420 is made, in an embodiment, from a material that is a good heat conductor, to spend a small amount of energy and time in modifying the temperature of the pipe 420. For example, the pipe 420 may be made of stainless steel. The pipe 420 may have spiral shape to maximize the heat exchange.

Close to the inlet 422, inside or outside the heat transfer block 410, a first temperature sensor 426 may be located to measure the input temperature of the gas in the pipe 420. Close to the outlet 424, inside or outside the heat transfer block 410, a second temperature sensor 428 may be located to measure the output temperature of the gas in the pipe 420.

A fan 430 pushes an air flow through the heat transfer block 410 towards the pipe 420. Here, air is mentioned as cooling agent. However, other gas mixtures may be used, cooled and re-circulated through the heat transfer block 410. The advantage of using air, even ambient air, with temperature between −40° C. to 50° C., is that, in this case, no re-circulating loop is necessary. The air flow pushed by the fan 430 towards the pipe 420 may pass through permeable walls (e.g., walls with holes to allow the air to pass there-through) or may be channeled through openings in the walls.

An electric heater 440 is located also in the proximity of the pipe 420. Thus, inside the heat transfer block 410 the gas, the gas in the pipe 420 may be cooled due to the air flow having a lower temperature than the gas and/or may be heated due to heat radiated by the electric heater 440.

The gas heater/cooler apparatus 400 further includes a first power supply 450 that provides power to the electric heater 440 and a second power supply 460 that provides power to the fan 430.

The temperature sensors 426, 428, and the power supplies 450 and 460 may be connected to a controller 470. The controller 470 may send signals to the power supplies 450 and 460 based on the temperature information received from the temperature sensors 426, and 428 in order to achieve a targeted temperature of the gas exiting the heat transfer block 410.

The disclosed exemplary embodiments provide apparatuses and methods of manufacturing thereof in which apparatuses either heating and/or cooling of a fossil fuel (fluid) flow may be performed. It should be understood that this description is not intended to limit the invention. On the contrary, the exemplary embodiments are intended to cover alternatives, modifications and equivalents, which are included in the spirit and scope of the invention as defined by the appended claims. Further, in the detailed description of the exemplary embodiments, numerous specific details are set forth in order to provide a comprehensive understanding of the claimed invention. However, one skilled in the art would understand that various embodiments may be practiced without such specific details.

Although the features and elements of the present exemplary embodiments are described in the embodiments in particular combinations, each feature or element can be used alone without the other features and elements of the embodiments or in various combinations with or without other features and elements disclosed herein.

This written description uses examples of the subject matter disclosed to enable any person skilled in the art to practice the same, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the subject matter is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims.

Claims

1. A gas heater/cooler apparatus, comprising:

a heat transfer block;

a gas pipe configured to transport a fluid inside of the heat transfer block;

a coolant pipe configured to transport a coolant agent inside of the heat transfer block, the coolant pipe being located in a proximity of the gas pipe to cool the fluid flowing therein via heat exchange with the cooling agent flowing through the coolant pipe; and

an electric heater located inside the heat transfer block close to the gas pipe to heat the fluid flowing therein via radiated heat.

2. The gas heater/cooler apparatus of claim 1, further comprising at least one of:

a temperature sensor located close to where the gas pipe exits the heat transfer block and configured to measure an output temperature of the fluid, and

a temperature sensor located close to where the coolant pipe exits the heat transfer block and configured to measure an output temperature of the coolant agent.

3. The gas heater/cooler apparatus of claim 1, further comprising:

one or more temperature sensors configured to measure temperatures at different locations along the gas pipe and/or the coolant pipe; and

a temperature information acquisition and transmission module configured to gather temperature information from the temperature sensors and transmit the gathered information.

4. The gas heater/cooler apparatus of claim 1, further comprising:

a temperature sensor located close to where the coolant pipe exits the heat transfer block and configured to measure an output temperature of the coolant agent; and

at least one of: a cooling agent temperature alarm connected to the temperature sensor and configured to output an alarm signal when the output temperature has a value outside a predetermined temperature range, and a coolant flow regulator connected to the temperature sensor and configured to adjust an amount of coolant agent transported in time through the coolant pipe based on a current value of the output temperature.

5. The gas heater/cooler apparatus of claim 1, further comprising:

a temperature sensor located close to where the gas pipe exits the heat transfer block and configured to measure an output temperature of the fluid; and

a gas temperature alarm connected to the temperature sensor and configured to output an alarm signal when the output temperature of the fluid has a value outside a predetermined temperature range.

6. The gas heater/cooler apparatus of claim 1, further comprising:

a temperature sensor located close to where the gas pipe exits the heat transfer block and configured to measure an output temperature of the fluid or close to where the coolant pipe exits the heat transfer block and configured to measure an output temperature of the coolant agent;

a power supply configured to provide power to the electric heater; and

a switch connected to the temperature sensor and interposed between the power supply and the electric heater, the switch being configured to cut off the power to the electric heater when the output temperature exceeds a predetermined value.

7. The gas heater/cooler apparatus of claim 1, further comprising:

one or more temperature sensors configured to measure temperatures at different locations along the gas pipe and/or the coolant pipe;

a coolant flow regulator configured to adjust an amount of coolant agent transported in time through the coolant pipe;

a power supply configured to provide power to the electric heater; and

a controller connected to temperature sensors, the coolant flow regulator and the power supply, the controller being configured to control the coolant flow regulator and the power supply based on temperature information received from the temperature sensors.

8. The gas heater/cooler apparatus of claim 1, wherein the gas pipe and the coolant pipe have co-axial helix shapes inside the heat transfer block.

9. A gas heater/cooler apparatus, comprising:

a heat transfer block;

a gas pipe configured to transport a fluid through an inside of the heat transfer block;

a fan configured to push a flow of air towards the gas pipe; and

an electric heater disposed inside the heat transfer block close to the gas pipe to heat the-a fluid flowing therein via radiated heat.

10. A method of manufacturing a gas heater/cooler apparatus, the method comprising:

mounting a gas pipe inside a heat transfer block configured to allow a coolant flow to pass there-through cooling a fluid flowing inside the gas pipe; and

mounting an electric heater inside the heat transfer block and in a proximity of the gas pipe.

11. The heater/cooler apparatus of claim 9, further comprising a temperature sensor located close to where the gas pipe exits the heat transfer block and configured to measure an output temperature of the fluid.

12. The gas heater/cooler of claim 9, further comprising:

one or more temperature sensors configured to measure temperatures at different locations along the gas pipe; and

a temperature information acquisition and transmission module configured to gather temperature information from the temperature sensors and transmit the gathered information.

13. The gas heater/cooler of claim 9, further comprising at least one of:

a cooling agent temperature alarm connected to the temperature sensor and configured to output an alarm signal when the output temperature has a value outside a predetermined temperature range, and

a coolant flow regulator connected to the temperature sensor and configured to adjust an amount of coolant agent transported based on a current value of the output temperature.

14. The gas heater/cooler of claim 9, further comprising:

a temperature sensor located close to where the gas pipe exits the heat transfer block and configured to measure an output temperature of the fluid; and

a gas temperature alarm connected to the temperature sensor and configured to output an alarm signal when the output temperature of the fluid has a value outside a predetermined temperature range.

15. The gas heater/cooler of claim 9, further comprising:

a temperature sensor located close to where the gas pipe exits the heat transfer block and configured to measure an output temperature of the fluid;

a power supply configured to provide power to the electric heater; and

a switch connected to the temperature sensor and interposed between the power supply and the electric heater, the switch being configured to cut off the power to the electric heater when the output temperature exceeds a predetermined value.

16. The gas heater/cooler of claim 9, further comprising:

one or more temperature sensors configured to measure temperatures at different locations;

a coolant flow regulator configured to adjust an amount of coolant agent transported in time;

a power supply configured to provide power to the electric heater; and

a controller connected to temperature sensors, the coolant flow regulator and the power supply, the controller being configured to control the coolant flow regulator and the power supply based on temperature information received from the temperature sensors.

17. The gas heater/cooler of claim 9, wherein the gas pipe has co-axial helix shapes inside the heat transfer block.

18. The method of claim 10, the method further comprising:

mounting temperature sensors at different locations along the gas pipe or along the past of the coolant flow.

19. The method of claim 10, the method further comprising:

mounting a fluid regulator on the path of the coolant flow, the fluid regulator being configured to modify the amount of coolant flow entering the heat transfer block.

20. The method of claim 10, the method further comprising:

mounting a power supply configured to provide power to the electric heater and a switch configured to cut off the power supply based on temperature information received from one or more temperature sensors.

21. The method of claim 10, the method further comprising:

mounting the flow regulator, the power supply, the switch, and the one or more temperature sensors, and connecting these components to a controller.

22. The method of claim 10, the method further comprising:

mounting alarms in the gas heater/cooler apparatus.