Abstract:
A modular compressor and condensation system is provided with standard sized piping modules, pumping modules and air cooler modules. The modules are designed for standardized shipment and assembly on site with significantly decreased time in start up compared to customized systems. The system may be assembled in the factory for complete testing with only a minimum level of testing necessary at the installation site.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority from Provisional Application No. 61/868,652 filed Aug. 22, 2013, the contents of which are hereby incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The invention involves modular compression and refrigeration systems. More particularly, it involves modular piping, pumping and air cooling components of compression and refrigeration systems. 
       FIELD OF THE INVENTION 
       [0003]    A gas compressor is a mechanical device that increases the pressure of a gas by reducing its volume. Compressors are similar to pumps: both increase the pressure on a fluid and both can transport the fluid through a pipe. As gases are compressible, the compressor also reduces the volume of a gas. Compression of a gas increases its temperature, which requires having some means to remove the resultant heat of compression. Depending upon the amount of compression that is desired, there may be staged compression in which the compressed gas is cooled between each stage of compression. Depending upon the type of compressor that is being used, this cooling may be by use of a cooling fan, a cooling lubricant or with some partial condensation and removal of liquid from the compressed gas in a vapor-liquid separator. Another aspect of compression is that liquids within the gas condense and then can be separated for treatment and subsequent use. 
         [0004]    Gas compressors are employed in a variety of applications where either higher pressures or lower volumes of gas are needed. In some of these applications, a standard sized compressor and associated equipment can be used. For example, in rail and heavy road transport vehicles, compressed air is used to operate vehicle brakes and various other vehicle systems. There are other applications that do not have standard sized requirements. For example, there are requirements for compressors in petroleum refineries, natural gas processing plants, petrochemical and chemical plants, and at operations where natural gas is extracted and then needs to be compressed before being transported in a pipeline. It has been customary to design compressor operations for each such application. However, this is a time consuming process and there are large financial incentives to minimize delays in startup. As unit sizes increase, the volume of gas to be compressed and number of pumps increases. It has now been found that it is feasible to modularize the components of a compressor and refrigeration system to effectively start up operations in a minimum amount of time. In prior installations of compressors, it can take as much as a year to provide all of the components. The present invention greatly reduces the time from the time of ordering a system to the installation of the system by modularizing several key subsystems. 
       SUMMARY OF THE INVENTION 
       [0005]    A modular system for compression of a gas as well as condensation of liquids from the gas is provided which comprises several modularized components. In particular there are at least one pipe rack module, at least one pumping module and at least one air cooler module. In a preferred configuration, the pipe rack module and pumping module are positioned parallel and the air cooler modules are positioned perpendicular to the pipe rack module and pumping module. The pipe rack module and the pumping module may be spaced apart and then the air cooler modules which often are longer in length may span the widths of those two modules as well as the gap between the modules. The air cooler modules will typically have four or more legs that are located in the corners of the modules or on one or more side walls that raise those modules above the surface of the surface of the module or ground below. In some arrangements, the air cooler modules legs will be in contact with only a portion of the module below with much of the air cooler module being over a gap between the pipe rack modules and/or pumping modules. There may be two or more air cooler modules for each pipe rack module and each pumping module. Each module has external dimensions that match the dimensions of a vehicle used to transport said modules. As needed, other components that may be found in compression and condensation systems may also be included as necessary. These other components may be designed for the particular system being deployed or may be off the shelf components. When necessary, there can be one or more separators to separate gases and liquids. Heat exchangers are provided as needed to heat or cool gas or liquid streams. The heat exchanger may be in the form of at least one cold box. At least one discharge drum may be provided. 
         [0006]    There is also provided a process for constructing a system for compressing a gas and separating liquids and gases. This process comprises providing at least one pumping module unit; at least one pipe rack module unit; providing at least one air cooler module unit mounted on top of the pumping module unit and the pipe rack module unit; and connecting the at least one pumping module unit, the at least one pipe rack module unit and the at least one air cooler module unit for operation to compress the gas. In some configurations, the at least one pumping module unit is approximately parallel to the at least one pipe rack module unit. The at least one air cooler module unit can be positioned above and perpendicular to the at least one pipe rack module unit and the at least one pumping module unit. While the air cooler module may be The pipe rack module unit and the air cooler module unit may have external dimensions that are equal to or less than current United States Department of Transportation maximum standard allowable shipping size for ground transportation or the current International Standards Organization&#39;s code regarding the maximum standard allowable shipping size for ground transportation, depending upon the destination for the system being installed. 
         [0007]    In other embodiments, a process is provided for rapid implementation of a condensing system. The process comprises providing at least one pumping module unit; providing at least one pipe rack module unit; providing at least one air cooler module unit mounted on top of the pumping module unit and the pipe rack module unit; and connecting the at least one pumping module unit, the at least one pipe rack module unit and the at least one air cooler module unit for operation to compress gas. 
         [0008]    The invention also comprises a rapid implementation of a gas compression and condensation system comprising assembling at least one pipe rack module; assembling at least one pumping module; providing at least one air cooler module; and assembling a gas compression and condensation system from these modules. The process further involves testing the gas compression and condensation system for operability. Then the system is disassembled and shipped on one or more vehicles to an installation site. Then the system can be assembled and receive final testing. Additional modules can be added as the volume of the gas increases or the capacity of the system necessitates. Other components are connected with the system as necessary for operation including heat exchangers, gas/liquid separators and vessels to hold liquids. 
     
    
     DESCRIPTION 
       [0009]    The invention provides a modular system to be used as a part of a compression system. In a condensing system there are several important sections that handle the cooling, separation, vapor handling and liquid handling functions. that includes many of the components in a compressor and refrigeration system. It has now been found that a number of these components can be preassembled modules. In that can be used in the of modularized pipe racks, pump skids and compressors and their layout in an efficient configuration so that air cooler units can be effectively mounted within the system. In an embodiment of the invention, there is a single compressor module, a pipe rack module, pump skid module and two air cooler units that form a basic embodiment of the invention. Other components of the system can be provided on a modular basis as well. It has been now found to be efficient to mount the air cooler units on top of the pipe rack and pump skid module. A vessel that is the appropriate size for condensate is connected to the system. 
         [0010]    In an embodiment of the invention, a two stage mixed refrigerant design is employed. Vapor from a cold box or exchanger goes to a knockout drum and then to the first stage inlet of a compressor. The first stage discharge is cooled by a set of heat exchangers where the refrigerant is partially condensed. The second stage cooler effluent then goes to a knock out drum. The liquid is pumped and the vapor goes to the second stage of the compressor. The second stage compressor outlet is cooled by a heat exchanger. The heat exchanger effluent is separated in a discharge drum for independent feeds (vapor and liquid) into the cold box. Vapor and liquid can be sent to the same cooler in the same line if the cooler is not a cold boxy There may be other heat exchangers in the loop that are integrated with other processes or unit operations where there is a benefit to the energy conservation. Similar configurations that are two stage or multiple stage modularized compression loops that require effluent cooling and have the need for modularization. 
         [0011]    One of the features of the modularization used herein is the use of pipe racks and process skids that in length are equal to the width of two air coolers. This means that the pipe racks and process skids may be laid out in a parallel manner and then the air coolers may be arranged in a perpendicular manner on top of the pipe rack and process skids. There is generally a gap between the pipe rack and process skids so that the air coolers fit appropriately on top of those modular components. The air cooler modules will typically have four or more legs that are located in the corners of the modules or on one or more side walls that raise those modules above the surface of the surface of the module or ground below. In some arrangements, the air cooler modules legs will be in contact with only a portion of the module below with much of the air cooler module being over a gap between the pipe rack modules and/or pumping modules. 
         [0012]    As the overall size of the unit changes, the number of pumps and the number of air coolers will change. The air coolers are set up so that they are in modules of two units together with a pump skid unit. In order to match the dimensions of the trucks that are used to transport the units, the air coolers are about 12 feet by 36 feet (3.658 m by 10.97 m) in width and length. The surface footprint of two air coolers is therefore 24×36 feet (7.315 m×10.97 m). An equal surface footprint may be achieved if two skids such as a process skid and a pump skid that each are 12×24 feet (3.658 m×7.315 m) in dimension would be placed in parallel configuration with a 12 feet gap between them. However, as noted above, there will be a larger spacing between the modules that rest on the ground and the air cooler modules will then be mostly above a gap between the modules but still supported by four or more legs resting on the module below. 
         [0013]    In another configuration of the modules, there may be process and pipe rack skids that are each 12×36 ft. (3.658 m by 10.97 m) in width and length and then three air coolers may be stacked on top where each of the air coolers is 12×36 ft. (3.658 m by 10.97 m) in width and length. 
         [0014]    The modules are designed to be of a size and shape that when packaged for shipment comply with current United States Department of Transportation regulations and the current International Standards Organization&#39;s code regarding the maximum standard allowable shipping size for ground transportation. 
         [0015]    Other equipment such as compressors, knock out drums, vessels for holding liquid do not need to be mounted below the coolers especially if they are too large for skid mounting. An advantage of the invention is that it is now feasible to have an inventory of all necessary piping and other equipment in a fabrication facility. It is then possible to assemble the piping racks in standard modules and mount the pumps as required. The system can then be pressure tested before each module is prepared for shipment to the site. Once the system is on site, the modules can be set in the desired configuration, assembled, pressure tested and then start up operation. An additional advantage is that the level of assembly skill required on site is generally reduced. Generally, a vessel is required for the condensate. However, from a manufacturing standpoint, the amount of time required to procure a needed vessel is much less than the standard equipment used in other parts of the system. 
         [0016]    The modular system can be employed in any system that has the need for a condenser, such as the overhead stream on a fractionator. As the volume of gas to be compressed, the system is designed to be expanded through the addition of additional modules. The modules are designed to fit on one or more trucks to improve their transportability. 
         [0017]    The pipe rack module, pumping module and air cooler modules are the main components that are modularized in this system. There are a number of other components that will be associated with or attached to the system. There will often be a discharge drum or vessel for holding liquid that has been condensed from the system. A number of heat exchangers may be mounted on a skid and provided to heating or cooling to the system as necessary. A gas/liquid separator may be provided. A smaller module may be provided for lubricating oil to be distributed to the mechanical sections of the system. 
       SPECIFIC EMBODIMENTS 
       [0018]    While the following is described in conjunction with specific embodiments, it will be understood that this description is intended to illustrate and not limit the scope of the preceding description and the appended claims. 
         [0019]    A first embodiment of the invention is a modular system for compression of a gas comprising at least one pipe rack module, at least one pumping module and at least one air cooler modules. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the pipe rack module and the pumping module are positioned parallel and the air cooler modules are positioned perpendicular to the pipe rack module and the pumping module. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the air cooler module is positioned on top of the pipe rack module and the pumping module. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph comprising at least two air cooler modules for each pipe rack module and each pumping module. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein each module has external dimensions that match the dimensions of a vehicle used to transport the modules. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph further comprising at least one separator to separate gas and liquid. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph further comprising an exchanger skid comprising a plurality of heat exchangers. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph further comprising at least one cold box. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph further comprising at least one discharge drum. 
         [0020]    A second embodiment of the invention is a process for constructing a system for compressing a gas and separating liquids and gases from the gas the process comprising a) providing at least one pumping module unit; b) providing at least one pipe rack module unit; c) providing at least one air cooler module unit mounted on top of the pumping module unit and the pipe rack module unit; and d) connecting the at least one pumping module unit, the at least one pipe rack module unit and the at least one air cooler module unit for operation to compress the gas. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein the at least one pumping module unit is approximately parallel to the at least one pipe rack module unit. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein the at least one air cooler module unit is positioned above and perpendicular to the at least one pipe rack module unit and the at least one pipe rack module unit. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein the pumping module unit, the pipe rack module unit and the air cooler module unit have external dimensions that are equal to or less than current United States Department of Transportation maximum standard allowable shipping size for ground transportation. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein the pumping module unit, the pipe rack module unit and the air cooler module unit have external dimensions that are equal to or less than the current International Standards Organization&#39;s code regarding the maximum standard allowable shipping size for ground transportation. 
         [0021]    A third embodiment of the invention is a process for rapid implementation of a gas compression and condensation system comprising a) assembling at least one pipe rack module; b) assembling at least one pumping module; c) providing at least one air cooler module; d) assembling a gas compression and condensation system comprising the at least one pipe rack module unit, the at least one pumping unit and the at least air cooler module; e) testing the gas compression and condensation system; f) disassembling the gas compression and condensation system; g) transporting the gas compression and condensation system on one or more vehicles to an installation site; and h) assembling the gas compression and condensation system. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the third embodiment in this paragraph further comprising adding additional modules as volume of the gas increases. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the third embodiment in this paragraph wherein at least one heat exchanger module is provided to heat or cool liquids or gases. 
         [0022]    Without further elaboration, it is believed that using the preceding description that one skilled in the art can utilize the present invention to its fullest extent and easily ascertain the essential characteristics of this invention, without departing from the spirit and scope thereof, to make various changes and modifications of the invention and to adapt it to various usages and conditions. The preceding preferred specific embodiments are, therefore, to be construed as merely illustrative, and not limiting the remainder of the disclosure in any way whatsoever, and that it is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims. 
         [0023]    In the foregoing, all temperatures are set forth in degrees Celsius and, all parts and percentages are by weight, unless otherwise indicated.