SPECIFICATIONMethod and system for distributing natural gasThis invention relates generally to a method and system for distributing natural gas from a supply terminal to one or more user terminals.
More specifically, it relates to a method and system for distributing natural gas to user terminals without the need for a pipeline, and which will assure delivery of the gas with effectively no service interruptions and in a manner that maximizes the amount of natural gas that can be moved per unit of labor.
Natural gas is one of the most desirable fuels, and extensive quantities of it are available from wells located around the world. In the past, natural gas was gathered from gas wells by a pipeline system and transported to a terminal facility or directly to users. More recently, methods and systems have been devised for moving large amounts of natural gas to a terminal facility by means other than pipelines, for subsequent distribution to users. Among such methods and systems are those employing liquefaction of the natural gas, such as the techniques disclosed inUnited States Patents 3,232,725 and 3,298,805, and the high pressure transport technique disclosed in United States Patent 4,139,019, the inventors of which are also inventors in this application.These newer techniques for moving natural gas from the gas well, and especially that of United States Patent 4,139,019, have opened up large numbers of so-called shut-in wells to the recovery of natural gas, thus greatly increasing the quantity of the fuel potentially available for use.
In our United States patent application Serial No. 011,683, filed February 12, 1979, we disclosed a method and system for assuring the optimum recovery of natural gas from gas wells, employing the high pressure transport technique of United States Patent 4,139,019. That invention further contributes to the availability of natural gas as a fuel.
In this time of energy shortage, efforts are being made to fully utilize all available natural gas.
Given the use of pipelines, liquefied natural gas techniques, and the new high pressure transport techniques developed by the present inventors, it is now possible to recover much larger quantities of natural gas from wells than was heretofore believed possible. There now remains the problem of adequately distributing the recovered gas to potential users, so that this now more abundant energy source can be more fully utilized.
Many potential users of natural gas are located where pipeline construction is very difficult and expensive, such as in established urban areas.
Other potential users are scattered in relatively small numbers across a large geographic area, and the economics required to support pipeline construction are simply not present. In the latter category of users will be found, for example, manufacturing plants, schools, hotels, and the like located in rural areas, nearly all of which could utilize natural gas for energy if it were available.
The situation also exists where there are in fact a sufficient number of users located so that pipeline construction might be feasible, but where capital financing will not be made available until an adequate market is proven to exist. In these instances, pipeline construction might well occur if the market could first be established, at least in part.
Currently, many potential users of natural gas falling in the noted categories are using propane, fuel oil, electricity and coal to meet their energy needs. In many instances, the use of natural gas would be more desirable if it could be made available. Natural gas is an especially clean fuel and, in older urban areas, significant improvements in air quality can be obtained by substituting it for coal or oil. And as natural gas becomes more available for the reasons noted earlier, it can be expected that in many cases it will prove more economical than propane or electricity, for example.
The problem which must be solved is how to effectively and efficiently distribute natural gas from a supply terminal to potential users, without the building of a pipeline network. Accompanying the need to transport natural gas to consumers is the need to do so in such a manner as to maintain a continuous and trouble-free supply. It is known that interruption of natural gas service, once an installation has become reliant upon it, can be both an inconvenience and a safety hazard. Given that natural gas demand can vary significantly from hour to hour and day to day, the distribution technique must be able to meet a varying demand, and at the same time be reliable and cost efficient.
The present invention provides a method and system for distributing natural gas which addresses and solves all of these problems.
The present invention provides the method for continuously distributing natural gas from a supply terminal to a user terminal, wherein said user terminal is connected with an off-loading manifold system, said method including the steps of:connecting first, movable separate pressure vessel means to said off-loading manifold system;;emptying natural gas from said first, movable separate pressure vessel means through said offloading manifold system, said natural gas being withdrawn by compressor means from said first separate pressure vessel means if the pressure of said natural gas within said first separate pressure vessel means does not exceed the pressure of natural gas found in said user terminal by an amount to assure an adequate flow of natural gas into said user terminal, and said emptying continuing at a regulated rate of flow chosen to maintain a preselected, preferred rate of supply to said user terminal;connecting a second separate pressure vessel means to said off-loading manifold system, at a time prior to when emptying of said first, movable separate pressure vessel means is complete;;switching from said first, movable separate pressure vessel means to said second separate pressure vessel means when said first, movable separate pressure vessel means reaches apreselected state of emptiness, without anysubstantial interruption in flow to said userterminal;emptying said second separate pressure vesselmeans in the same manner as said first separatepressure vessel means, while said first, movableseparate pressure vessel means is removed andreplaced;replacing said filled, first movable separatepressure vessel means with a full, movableseparate pressure vessel means, while saidsecond pressure vessel means is being emptied,and before completion of the emptying thereof;;andtransporting said empty, first movable separatepressure vessel means to said supply terminal,where it is filled, and is then returned to said userterminal and reconnected to said off-loadingmanifold system.
In the present invention, natural gas isdistributed from a supply terminal. The supplyterminal can be located on a pipeline connected toa natural gas field, or it can be a dockside facilityfor receiving natural gas transported to the dock ina liquefied state by large ships, a terminal to whichnatural gas has been transported by the highpressure technique of United States Patent4,139,019, or a similar installation. Thedistribution method of the invention begins at thesupply terminal, and is designed to supply one ormore user terminals located at a distance therefrom.
A preferred first step of the method is toanalyze the user terminal(s) to determine theamount of natural gas required over a given periodof time, the expected fluctations in demand, and other demand-related factors. Taking this data and integrating it with transport information such as the distance to be traveled, traffic conditions, the type and kinds of transport equipment available, the quantity and preferred flow rate of natural gas available at the supply terminal, and other factors, a distribution plan may be drawn. The distribution plan identifies the type and number of transport pressure vessel means required, the delivery scheduies which must be followed, and similar information.
The present invention draws upon the high pressure transport techniques described in UnitedStates Patent 4,139,019, modified to accommodate the demands for an efficient and effective natural gas distribution technique. It also draws upon some of the concepts described in ourUnited States patent application Serial No.
011,683, noted above, in particular as to the equipment for assuring automatic transfer between two different pressure vessel means so as to assure an uninterrupted flow of natural gas to the user terminal.
The system of the present invention includes at least two pressure vessel means, at least one of which is movable between the supply terminal and the user terminal being serviced. The other pressure vessel means can also be movable or, if desired, it can be permanently positioned at the user terminal assuming other factors in the distribution plan so allow. The movable pressure vessel means is loaded with natural gas at the supply terminal preferably in accordance with the principles set forth in United States Patent 4,139,019 and, where applicable, our earlierUnited States patent application Serial No.
011,683. The movable pressure vessel means is then transported to the user terminal, where offloading of the natural gas occurs.
The transporting steps of the present invention are preferably taken in accordance with the distribution plan, and the user terminal is preferably equipped with a novel arrangement of components designed to assure proper functioning of the invention. The system at the user terminal normally will include pressure regulating equipment, a safety controller valve arrangement, and a heater for the natural gas, along with associated flow control equipment.
Provisions are made for switching between connected pressure vessel means, and preferably the system will include an automatic switchover arrangement to ensure that the flow of natural gas to the user terminal will not be interrupted.
A principal advantage of the present invention as hereafter specifically described is the provision of an improved method and system for distributing natural gas from a supply terminal to a user terminal(s), wherein service disruptions are minimized and the maximum response to demand variations is assured.
Another advantage is the provision of a method and system for distributing natural gas which will minimize the per unit labor cost for transporting natural gas, and which assures an economical supply of natural gas to user facilities not located on a pipeline.
Yet another advantage is the provision of a distribution method and system which can be economically employed to establish and develop markets for the use of natural gas, preparatory to the building of a pipeline network to service the user facilities.
A further advantage is the provision of a method and system for distributing natural gas which minimizes personnel requirements and includes provisions to assure operating safety.
The invention will be illustrated by the following description of preferred embodiments, when taken in conjunction with the accompanying drawings, in which: FIG. 1 is a diagrammatic view of a first embodiment of the off-loading terminal of the invention, showing the apparatus of the system for off-loading natural gas to the user terminal;FIG. 2 is an enlarged, fragmentary diagrammatic view showing the loading and offloading manifold arrangement associated with the high pressure vessels;FIG. 3 is a diagrammatic view similar to FIG. 1, but showing a modified off-loading terminal incorporating a compressor arrangement for scavenging the natural gas from the pressure vessel means, the compressor arrangement including a bypass conduit having a flow control valve controlled by upstream pressure; andFIG. 4 is an enlarged, fragmentary diagrammatic view showing the automatic switchover off-loading arrangement of the invention.
In United States Patent 4,139,019 there is disclosed apparatus for safely loading a discrete batch of natural gas into pressure vessel means, normally under a pressure of about 138.46 to 173Kg/cm2 (2000 to 2500 psi). It is contemplated that the high pressure transport technique of this patent will be employed in the present invention.
Thus, all aspects involved in the loading of the pressure vessel means will not be described herein, but rather reference is made to UnitedStates Patent 4,139,019.
As is described in U.S. Patent 4,139,019, the pressure vessel means can take several different forms. For example, such can consist of a number of interconnected pressure vessels mounted on a truck for over-the-road movement, or upon a railroad car, or even a boat. For purposes of describing the present invention, the movable pressure vessel means is herein assumed to be a number of interconnected pressure vessels mounted for transport on a semitrailer, but it is understood that other arrangements are possible.
In the present distribution method and system, the natural gas is loaded in discrete batches into the movable pressure vessel means at a supply terminal. As mentioned earlier, the supply terminal can be a pipeline terminal, or some other terminal facility to which natural gas is supplied. The invention provides for distribution of the natural gas to one or more user terminals, and these can also assume different forms. For example, a user terminal can be the inlet of a manufacturing plant's pipeline system, the inlet pipe for the pipeline distribution system of a housing project or subdivision, the inlet for the natural gas energy system of a power plant or hospital, or any similar installation to which it is desired to supply natural gas.
Referring now to FIG. 1 of the drawings, an offloading terminal is indicated generally at 2, located adjacent a user terminal 4. The off-loading terminal 2 includes a manifold system 6 having two off-loading locations or stations 8 and 10, for receiving high pressure vessel means A and B to be unloaded. In the drawings the pressure vessel means A and B respectively comprise semitrailer vehicles 1 2 and 14 carrying high pressure vessels 16 and 18 thereon, and having motorized cabs 20 and 22 connected thereto. It is important in the present invention that at least one of the two high pressure vessel means A or B be movable, by train, watercraft or, as shown in the drawings, by truck, so that it can be utilized to transport discrete batches of natural gas from a supply terminal (not shown) to the user terminal 4.There must be at least two pressure vessel means A and B, in order to practice the invention; however, in many instances additional pressure vessel means will also be utilized.
Should it be desired to ulitize a stationary pressure vessel means at the user terminal 4, such can take many forms. In one form, the stationary pressure vessel means can simply be a parked semitrailer 12 or 14, which is not moved. Or it can be a large pressure tank, a series of interconnected tanks, a length of pipeline, or any other suitable arrangement designed to hold a sufficient quantity of natural gas. The stationary pressure vessel means must, of course, be filled with natural gas from time to time, and preferably be large enough to offer a reserve supply in case of inclement weather, equipment breakdown of the movable pressure vessel means or some other system components, or a like emergency situation.
The decision on whether or not to utilize a stationary pressure vessel means can include many factors, including the expected permanency of the user facility, and the amount of natural gas which must be transported to it. In some situations the use of only movable pressure vessel means will prove more desirable, and it is this arrangement which is illustrated in FIG. 1.
In accordance with the teachings of UnitedStates Patent 4,139,019 and our prior UnitedStates patent application Serial No. 011,683, the pressure vessels 1 6 and 18, comprising the pressure vessel means A and B, must be capable of safely confining a discrete batch of natural gas at pressures up to about 207.69 Kg/cm2 (3000 psi) and above. Usually, a number of cylindrical pressure vessels 1 6 and 1 8 will be mounted on each vehicle, all of which will be connected to a common manifold arrangement.Referring now toFIG. 2, the high pressure vessels 1 6 are all shown connected to a vessel manifold 24 by individual valves 26 provided with turning handles 28, and each including a rupture disk 30 or other suitable safety device to provide emergency pressure relief in case overpressurization should occur while the associated valve 26 is closed. While the illustrated valves 26 are manually operated, it is to be understood that automatically operated valves might instead be employed, if desired.
The vessel manifold 24 has a transfer conduit 32 connected thereto, the outer end of which carries a fitting 34. A loading conduit system 36 is connected to one side of the fitting 34, and an offloading conduit system 38 is connected to the other side thereof. The loading conduit system 36 includes a flow control valve 40, a bleed valve 42, and an inlet stub 44 disposed therebetween which carries one-half 46 of a coupling 48. A one-way check valve 50 is positioned between the flow control valve 40 and the fitting 34 to prevent backflow.
The off-loading conduit system 38 includes a flow control valve 52 and a bleed valve 54, between which is positioned a discharge stub 56 carrying one-half 58 of a coupling. The arrangement of the loading and off-loading conduit systems 36 and 38 are like those inUnited States Patent 4,139,019, and function in the same manner as described therein. Further, the pressure vessels 18 of the pressure vessel means B are fitted with comparable loading and off-loading conduit systems 36' and 38' including flow control valves 40' and 52', bleed valves 42' and 54', a check valve 50', and coupling halves 46' and 58'.
As noted in United States Patent 4,139,019, the purpose for the bleed valves 42, 42', 54 and 54' is to relieve pressure in the system before uncoupling occurs. It would be possible to eliminate the loading conduit system 36 and 36' and rely only on the off-loading conduit systems 38 and 38' to perform both loading and offloading functions. However, the separate loading conduit systems with their additional couplings and the check valves 50 and 50' provide additional safety, in that a ruptured loading line will not cause the high pressure vessels to exhaust, since the check valves would stop the flow. It may be desirable to add further relief devices to the system for additional backup safety purposes.
Returning now to FIG. 1, the off-loading manifold 6 includes a supply manifold 60 connected to supply natural gas to a feed conduit 62, which leads to the user terminal 4. The supply manifold 60 has supply conduits 66 and 68 connected to its opposite ends, which lead to the off-loading stations 8 and 10, respectively. Two cutoff valves 70 and 72 are positioned in the supply manifold 60, one on each side of the feed conduit 62, and serve to control natural gas flow from the off-loading stations 8 and 10. One-way check valves 74 and 76, respectively, are positioned in the supply conduits 66 and 68, and the conduits 66 and 68 respectively terminate in flexible or adjustable unloading lines 78 and 80 that have coupling halves 82 and 84 on their outer ends for mating with the coupling halves 58 and 58'.The check valves 74 and 76 prevent backflows, and between the check valves and the unloading lines 78 and 80 the supply conduits 66 and 68 each have a bleed valve 86 or 88 and a pressure relief valve 90 or 92, respectively, connected thereto. The bleed valves 86 and 88 are used to relieve pressure within the system after the associated cutoff valve 70 or 72 is closed, and before the coupling halves 82, 58 or 84, 58' are uncoupled.
The couplings used between the unloading lines 78 and 80 and the off-loading conduit systems 38 and 38' are a matter of choice, but preferably such will be of the quick connectdisconnect type. The pressure relief valves 90 and 92 are backup, the operating pressure therefor being set at a level to assure safety for the system and its operators.
The off-loading manifold system is identical in FIGS. 1 and 3 of the drawings, as are the arrangements of the high pressure vessel means A and B, and the off-loading conduit systems 38 and 38'. Thus, these elements of the system will not be further described herein.
Turning now to the distribution manifold system 64 of FIG. 1, such includes a distribution conduit 94 which is connected to the user terminal 4 through appropriate gauging equipment 96. The equipment 96 can include pressure measuring apparatus, a flow meter, or both thereof. The inlet of a main shutoff valve 98 is connected to the feed conduit 62 to control the flow of natural gas from the supply manifold 60, and the outlet of the shutoff valve 98 is connected with the distribution conduit 94.
The assumption in FIG. 1 is that the user terminal 4 will flow natural gas at a pressure sufficiently low to allow at essentially all times for the unaided off-loading of high pressure natural gas from the pressure vessel means A and B. That is, whereas the pressure in the pressure vessel means A and B will normally be in the 138.46 to 207.69 Kg/cm2 (2000 to 3000 psi) range, the pressure of the user terminal will usually be below about 6.923 Kg/cm2 (100 psi), and preferably in the range of between about 3.46 Kg/cm2 (50 psi) and about 13.85 Kg/cm2 (200 psi). Under these conditions, no mechanical compression of the natural gas is required to transfer it from the supply manifold 60 to the user terminal 4.But it is necessary in order to meet the objectives of the invention concerning efficiently meeting demand and at the same time conserving energy and providing a safe operating environment, that the flow rate of the natural gas be carefully controlled to conform to the distribution plan.
In order to control the pressure of the natural gas being supplied to the user facility 4 from the pressure vessel means A and B in FIG. 1, a flow regulating valve 100 is positioned in the distribution conduit 94, the regulating valve 100 being controlled by a controller 102 connected thereto and which includes a pressure tap line 104 connected with the distribution conduit 94 downstream of the regulating valve 1 00.
The pressure regulating valve 100 can be of any suitable design, of the type which in effect functions as a variable orifice. A suitable valve is the commerically available "Fisher D Globe StyleValve", with a "4100 Series Controller", configured in the pressure regulation arrangement. The pressure regulating valve 100 is necessary to carry out the method of the invention in part because when the pressure vessel means A and B are full, the differential pressure between the user terminal 4 and the pressure vessel means is usually so great that, if applied directly to the user terminal 4, it could create a safety hazzard, damage connected equipment, and cause other serious problems.The pressure regulating valve 100 compensates for these potential problems by opening and closing to keep the flow of natural gas to the user terminal 4 approximately constant at an acceptable pressure level, thus preventing either excessive pressures in the first part of the off-loading operation, or excessively slow offloading during the last portion. Further, the pressure regulating valve 100 accommodates variations in the demand for natural gas by the user terminal, assuring efficient operation.
A high pressure safety cutoff valve 108 is positioned between the regulating valve 100 and the user terminal 4, preferably near the user terminal. The valve 108 is operated by a controller 110, provided with a pressure tap line 11 2 that connects with the distribution conduit 94 upstream of the valve 108. The high pressure cutoff valve 108 is designed to shut down if the pressure in the distribution conduit 94 exceeds the safe off-loading pressure for the user terminal 4.
Usually, the natural gas transported to the offloading stations 8 and 10 in the pressure vessel means A and B will be relatively pure and free from moisture and liquid petroleum or the like.
Thus, installations are usually not required at a user terminal for removing these impurities. If they are needed, however, it is to be understood that a dehydrator and an oil-gas separator could be installed in the system of FIG. 1, preferably in the supply manifold 60 or the feed conduit 62, before the main shutoff valve 98.
The system of FIG. 1 also includes a heater 114, positioned after the pressure regulating valve 100. The heater 114 will normally be employed to heat the natural gas, so that the temperature thereof is sufficiently high before it enters the user terminal that low temperature embrittlement of equipment downstream of the heater 114 will be avoided. In some instances, the heater 114 can be eliminated, but usually its presence will be necessary for successful practice of the invention.
There are some user terminals which will operate at a pressure significantly above the preferred range of about 3.46 to about 13.846Kg/cm2 (50 to about 100 psi), say at or above the pressure of the natural gas in the pressure vessel means A and B, and this can cause difficulty in offloading natural gas from the pressure vessel means. In these instances, it will be necessary to add a compressor to the system, and such an arrangement is shown in FIG. 3. These components of the system which are the same inFIGS. 1 and 3 bear the same reference numbers.
Referring now to FIG. 3, a plurality of user facilities are shown at 4 and 4', equipped with gauging equipment 96 and 96', respectively, and connected with branch distribution conduits 1 22 and 124 that are in turn connected with a main distribution conduit 126. One-way check valves 1 32 and 1 34 are positioned in the branch distribution conduits 1 22 and 124, respectively, and downstream thereof are positioned high pressure safety cutoff valves 1 28 and 130, corresponding to the cutoff valve 108 in FIG. 1, and connected to operate in the same manner. A heater 114 is normally connected in the main distribution conduit 126, upstream of the branch distribution conduits 122 and 124 and, as in FIG.
1, it can be eliminated under certain operating conditions.
The multiple user terminal, branch distribution conduit system of FIG. 3 is of course illustrative only, in that many more user terminals might also be connected to a single distribution conduit 1 26, if desired. The same multiple arrangement can also be employed in FIG. 1, if desired.
The system of FIG. 3 includes a compressor 1 20 and, because of the presence thereof, the flow regulating valve 100 of FIG. 1 is not required in FIG. 3. The compressor 120 is connected in the main distribution conduit 126, between the main shutoff valve 98 and the heater 114, and the oneway check valve 148 is positioned upstream thereof. A bypass line 1 38 is connected around the compressor 120 between the inlet and outlet ends thereof, and contains a flow control dump valve 140 which is operated by a controller unit 142, the latter including a pressure tap line 144 which connects with the main distribution conduit 126 upstream of the bypass line 138 and the oneway check valve 148.
The compressor 120 is placed in operation to scavenge natural gas from the pressure vessels of the connected pressure vessel means A and B, and also functions to regulate the flow of the natural gas to the connected user terminals. It is intended in the invention that the off-loading operation will be substantially continuous, with changeover from one pressure vessel means to another occurring as the first empties, with no break in the flow of natural gas. However, it is recognized this might not always occur, for one reason or another, so that some time delay will be present after a pressure vessel means is emptied and before the next one is connected and placed in operation. In such an instance, the compressor bypass line arrangement of the invention comes into use.
Pressure within the feed conduit 62 will start to reduce as the pressure vessel means connected to the off-loading manifold system 6 empties. When this pressure falls below a predetermined value as set on the controller unit 142 and sensed by the pressure tap line 144, the normally closed dump valve 140 will be shifted to its open position, causing the bypass line 138 to begin operation and placing the compressor 120 in an easy idle mode. The compressor will go into an easy idle mode because when the dump valve 140 snaps open, the vacuum of the discharge of the compressor 1 20 is completely relieved, the oneway check valve 148 being chosen so that under such conditions it prevents any feedback of pressure from the pressure vessel means or the loading manifold system 6. The compressor 120 will operate in this easy idle mode, with minimum wear and using a minimum of energy, until the dump valve 140 isagain closed.
When pressure upstream of the check valve 148 is raised sufficiently, as for example when a full pressure vessel means is again connected to the system, such will be sensed by the controller unit tap line 144, and the dump valve 140 will be closed. The compressor 120 will then again be operational to supply natural gas under pressure to the user terminals, drawing it through the check valve 148. The bypass arrangement helps ensure that underpressurization of the off-loading manifold system 6 and the pressure vessel means will not occur, preventing the leakage of air into the system which might otherwise occur under a vacuum caused by the compressor 120.
As noted, it is preferred that the flow from the pressure vessel means into the distribution conduit be uninterrupted. This requires a substantially simultaneous switch from an emptying pressure vessel means to a pressure vessel means having an adequate supply of natural gas available. Usually, an operator can manually operate the control valves 70 and 72 of the off-loading manifold system 6 to change from an empty to a fuller pressure vessel means, with no significant interruption of natural gas flow.
However, it is preferable if this switchover can be made automatically, at a desired point in the emptying cycle for the first pressure vessel means.
This can assure a smoother, more efficient operation and, in addition, will safely accommodate those instances when an operator may not be available for or capable of a manual switchover.
Referring now to FIG. 4, there is shown an arrangement for effecting an automatic switchover from an empty pressure vessel means to a fuller one. In said FIG., a loading manifold 200 is shown connected with a feed conduit 202, and having supply conduits 204 and 206 connected to its opposite ends. The manifold 200 is provided with flow control valves 208 and 210, corresponding to the flow control valves 70 and 72, and the supply conduits have check valves 212 and 214, bleed valves 216 and 218, and pressure relief valves 220 and 222, respectively, connected thereto, corresponding to the check valves 74 and 76, bleed valves 86 and 88, and pressure relief valves 90 and 92 of FIG. 1. Offloading lines 224 and 226, respectively, are connected to the outer ends of the supply conduits 204 and 206.
A connecting conduit 228 extends between the supply conduits 204 and 206, and is connected with each thereof between the associated check valve 212 or 214, and the flow control valve 208 or 210. Centrally thereof, the connecting conduit 226 has a switchover control valve 230 therein, operated by a controller unit 232 provided with two pressure tap lines 234 and 236, which are connected to the connecting conduit 228 on opposite sides of the switchover valve 230. The pressure tap lines 234 and 236, respectively, connect to a selector valve 238, which is arranged to sense the lowest pressure of the two tap lines 234 and 236 and to permit flow only toward the controller unit 232.
The switchover control valve 230 is initially closed, and pressure vessel means are connected to both of the off-loading lines 224 and 226.
Thereafter, the shuttle check valve 238 senses the lowest of the two operating pressures which exist in the supply conduits 204 and 206 and, when the pressure in one of them falls below the setting of the controller unit 232, such is effective to open the switchover valve 230. Flow then is directed from the higher pressure supply conduit 204 or 206 to the lower pressure one, with the appropriate check valve 212 or 214 preventing any backflow into the just emptied pressure vessel means. Thus, the system is automatically switched from the emptying to the fuller pressure vessel means.
At some time after switchover occurs, the flow control valve 208 and 210 which normally supplies natural gas to the feed conduit 202 from the now being emptied pressure vessel means is opened, whereby the normal delivery of natural gas is established, and the other control valve 2Q8 or 210 is closed. The supply conduit 206 or 208 leading from the emptied pressure vessel means is then bled by operating its associated bleed valve, 216 or 218, and the fall in pressure in the associated pressure tap line 234 or 236 will be sensed by the controller unit 232 and the switchover valve 230 will close. The empty pressure vessel means is then replaced, and the system will thereafter continue in operation until the second pressure vessel means empties sufficiently, when the switchover cycle will again automatically occur.
The switchover arrangement of FIG. 4 helps assure a smooth transition from an empty to a full pressure vessel means, with no measurable interruption in the continuity of natural gas flow.
Thus, it helps to meet one of the goals of the invention. Further, because the actual switchover occurs automatically, the operator need not be overly attentive to the system and, indeed, is provided with a considerable time period during which to change pressure vessel means. This contributes to the safety of the overall system and, more importantly, makes it possible to accommodate widely varying demand situations that will occur from time to time.
Turning again to the method of the invention, if correctly practiced it will assure the minimum disruption of natural gas flow to the user terminal.
The first step of the method is to analyze the user demand to determine what the preferred rate of supply of natural gas thereto ought to be. To do this analysis, factors like the rate of use of natural gas by connected user equipment, variations and fluctuations expected in the weather, variations occurring during the work week and vacation -.
periods, and similar matters must be reviewed and evaluated. The technique for accomplishing this analysis are known in the industry.
Given the results of this review and evaluation, a maximum rate of supply for the user terminal is selected. This will commonly be in the range of from about 2 to 3 times the average consumption rate of the user system. It should also be noted that the preferred rate of supply can change over a period of time, and thus a periodic review is desirable to ensure a continued, adequate natural gas supply.
The next step of the method is to determine the preferred rate of production of natural gas from the supply terminal. The number of factors to be taken into account in this step will depend upon the nature of the supply terminal, and especially upon how natural gas is supplied to it. In some instances, the capacity of the supply terminal may be practically limitless. In others, the production may be limited.
Having selected a preferred rate of supply and a preferred rate of production, the next step in the method is to select the preferred number of separate pressure vessel means, and the mode of their operation required to satisfy the demand and accommodate the production capability of the supply terminal. In most instances, a separate pressure vessel means is defined as a vehicle of suitable design, movable from place to place, and which carries thereon one or more high pressure vessels arranged as described herein. The minimum number of separate pressure vessel means required to practice the invention is two; sometimes, however, one or several additional separate pressure vessel means may be required for continuity of supply to the user terminal, or to satisfy the conditions surrounding a given transport situation.At least one separate pressure vessel means must be movable, as has been noted earlier.
There are several factors which must be taken into account when selecting the number of separate pressure vessel means and their mode of operation. These include the holding capacity of the separate pressure vessel means at the selected operating pressure, which will usually be between about 138.46 and 207.69 Kg/cm2 (2000 psi and 3000 psi), the distance from the supply terminal to the user terminal(s), the rate at which off-loading will occur at the user terminal, the travel conditions and time required between the supply terminal and the user terminal, and similar factors. In each case, a production plan must be produced which will assure that the user facility is adequately and continuously supplied with natural gas.
The type of vehicles used in the movable separate pressure vessel means can be trucks, watercraft, aircraft, or possibly a combination of these. Usually however, transport will be on land, by truck. Considering for the moment the semitrailer mounted pressure vessels shown in the drawings, the minimum amount of equipment for practicing the present method would usually be two such semitrailers with their pressure vessels, and one motor cab to move them over the road.
For isolated areas and user facilities with a small demand for natural gas, and when short haul distances are present, this minimum system might well suffice. Further, as has been noted, it is possible that only one separate pressure vessel means would be movable and the other fixed; the necessary switchover to provide continuous gas flow is not affected with this arrangement, if the fixed, separate pressure vessel means itself is periodically filled with natural gas.
To determine the adequacy of the equipment, one must calculate the following:(1) The time required to fill a separate pressure vessel means; and(2) The cycle time required for an unloading operation, which includes:a. the time required to unhook a movable filled separate pressure vessel means from the supply terminal and ready it for travel;b. the travel time to and from the user terminal;c. the time required to unload at the user terminal, which is of course controlled by the rate at which the user terminal demands the natural gas; andd. the time required to connect an empty, movable separate pressure vessel means after it has been returned to the supply terminal.
If the off-loading cycle time is well within the filling time, with some margin for delays, then the minimum amount of equipment will suffice. If not, then normally more vehicles with pressure vessels thereon, each defining a movable separate pressure vessel means, will be required. Among ways in which the tractor-trailer system can be enlarged are the following which, again, are merely offered as examples:Alternate system A3 semitrailers with one motor cabAlternate system B4 semitrailers with two motor cabsThere are of course other variations which can be employed, such as four or six semitrailers with three or five motor cabs. In each situation, the goal is to minimize costs, while keeping the user terminal(s) supplied adequately with natural gas, and staying within the production capability of the supply terminal.
Once the data for the user terminal and the supply terminal have been analyzed, and the number of pressure vessel means and their mode of operation have been selected, the information is integrated into a distribution plan. The distribution plan must also include a selection of the offloading system to be employed at the user terminal, including a decision on the need for a compressor. With the distribution plan established, the next step of the method is to load a first, full pressure vessel means, and connect it to the user terminal. Then, the second pressure vessel means is loaded with a discrete batch of natural gas, and is connected to the user terminal and readied for a switchover. When the first pressure vessel means empties to a selected point, a switchover to the second pressure vessel means is made with no discernable interruption of natural gas flow, and the first pressure vessel means is then refilled with natural gas to the extent required by the distribution plan. During offloading, natural gas is moved from the connected pressure vessel means to the user terminal, the flow thereof being regulated to accommodate the demand of the user terminal, and the natural gas normally being heated during such movement.
When all of the separate pressure vessel means are movable, they are usually transported to the supply terminal for filling. If one or more of the separate pressure vessel means is stationary at the user terminal, it of course must be refilled periodically at the site of the user terminal, preferably by the use of a movable pressure vessel means.
After a switchover has occurred, the final step of the method is to replace the empty separate pressure vessel means with a full separate pressure vessel means, to ready the process for a new operating cycle.
In those instances when only two separate pressure vessel means are employed and one thereof is fixed at the terminal facility, the switchover from the first, empty, movable separate pressure vessel means is made in the usual manner, and the empty, movable separate pressure vessel means is then removed and transported to the supply terminal. After filling, it is returned to the user terminal and reconnected. If the cycle time is short compared to the holding capacity of the fixed pressure vessel means, this refilling operation can be repeated several or more times before the fixed separate pressure vessel means must itself be refilled.The time between filling operations of the fixed separate pressure vessel means can be extended if the duration of its connection to the user terminal is minimized, and this can sometimes be done by simply switching over to the movable separate pressure vessel means as soon as it is reconnected.
By increasing the number of movable separate pressure vessel means, it is possible to even further extend the time between fillings of the fixed separate pressure vessel means. In the instances just described, the fixed separate pressure vessel means is used essentially to maintain continuous flow to the user terminal.
It should be noted that the present invention utilizes the high pressure transport-technique ofUnited States Patent 4,139,019, which means that the pressure vessel means are not refrigerated, nor is the natural gas which is carried therein. Rather, the natural gas is transported in discrete batches at a pressure of at least 55.384Kg/cm2 (800 psi), preferably about 103.845Kg/cm2 (1500 psi), and usually in the range of from about 138.46 to 207.69 Kg/cm2 (2000 to 3000 psi). It is the transportation method of this patent which helps make possible the present invention, in part because this transportation technique for natural gas is both effective and economically sound.
As has been noted, the switchover step can be performed manually, but preferably it is accomplished automatically, utilizing the system of FIG. 4.
Obviously, many modifications and variations of the invention are possible. Further, it is evident the method and system as described herein meet the objects set forth hereinabove, and that the invention makes possible the distribution of natural gas in a continuous uninterrupted and adequate fashion to user facilities which are not connected with a pipeline.