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WO2015041660A1 - Appareil de production de vapeur et système et procédés de commande associés - Google Patents

Appareil de production de vapeur et système et procédés de commande associés Download PDF

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Publication number
WO2015041660A1
WO2015041660A1 PCT/US2013/060788 US2013060788W WO2015041660A1 WO 2015041660 A1 WO2015041660 A1 WO 2015041660A1 US 2013060788 W US2013060788 W US 2013060788W WO 2015041660 A1 WO2015041660 A1 WO 2015041660A1
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WO
WIPO (PCT)
Prior art keywords
steam
feedwater
control system
flow rate
water
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2013/060788
Other languages
English (en)
Inventor
Randall J. Davis
JR. Charles F. NOLL
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Skavis Corp
Original Assignee
Skavis Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US14/030,667 external-priority patent/US9383095B2/en
Priority claimed from US14/030,666 external-priority patent/US9310070B2/en
Priority claimed from US14/030,656 external-priority patent/US9303866B2/en
Priority claimed from US14/030,618 external-priority patent/US9303865B2/en
Application filed by Skavis Corp filed Critical Skavis Corp
Publication of WO2015041660A1 publication Critical patent/WO2015041660A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01K—STEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES
    • F01K13/00—General layout or general methods of operation of complete plants
    • F01K13/02—Controlling, e.g. stopping or starting

Definitions

  • the current disclosure relates to steam generation apparati and associated control systems. Particularly, the current disclosure relates to such steam generation apparati and associated control systems that are used for enhanced oil recovery.
  • Steam generation apparati are used in a host of industries including food preparation, cleaning, heating and power generation sectors.
  • Another industrial sector that uses steam generation apparati includes enhanced oil recovery projects where steam is injected into the reservoir through injection wells located in rock that has fluid communication with production wells.
  • the purpose of steam injection is to increase reservoir pressure and temperature to displace hydrocarbons toward a pumping well. This allows more oil to be recovered than was initially possible during the primary drilling and oil extraction phase of an oil well.
  • steam generation apparati require that a number of process variables and associated equipment be controlled during startup and continuous normal operation. Accordingly, a need exists for an apparatus that manages such variables efficiently during startup and continuous normal operation.
  • an apparatus for supplying a flow of at least one of water and steam to a desired destination or to a venting reservoir comprising a feedwater supply system, a steam generation system and a delivery system that includes a main steam header pipe that runs from the steam generation system to the desired location and a vent pipe that branches from the main steam header pipe to the venting reservoir. It further includes a plurality of instruments and devices that are in operative association with the feedwater supply system or delivery system configured for sensing physical parameters of at least one of water and steam for controlling the flow and a control system that includes an input device, output device and memory, said control system being in operative association or communication with said instruments and devices.
  • the method includes the following steps: determining whether it is permissible for the feedwater pump to run; and sending at least one of water and steam to the venting reservoir.
  • an apparatus for supplying a flow of at least one of water and steam to a desired destination at a desired injection pressure comprising a feedwater supply system that includes a feedwater pump and a first feedwater recirculation control loop that varies the feedwater flow rate based on the flow rate, a steam generation system and a delivery system that includes a main steam header pipe that runs from the steam generation system to the desired destination and a second control loop for controlling the feedwater flow rate based on the injection pressure of the steam or water mixture.
  • It further includes a plurality of instruments and devices that are in operative association with the feedwater supply system or delivery system configured for sensing physical parameters of the water or steam and for controlling the feedwater flow rate and the injection pressure of the steam or water and a control system that includes an input device, output device and memory, said control system being in operative association or communication with said instruments and devices.
  • the method includes the following steps: determining whether the injection pressure is within acceptable parameters; and adjusting the feedwater flow rate if the injection pressure is not within acceptable parameters.
  • an apparatus for supplying a flow of at least one of water and steam to a desired destination at a desired injection pressure or to a venting reservoir comprising a feedwater supply system that includes a feedwater pump, a steam generation system and a delivery system that includes a main steam header pipe that runs from the steam generation system to the desired destination and a vent pipe that branches from the main steam header pipe to the venting reservoir. It further includes a plurality of instruments and devices that are in operative association with the delivery system configured for sensing physical parameters of the water or steam and for controlling the pressure in the main steam header pipe and a control system that includes an input device, output device and memory, said control system being in operative association or communication with said instruments and devices.
  • the method includes the following steps: determining whether the pressure in the main steam header pipe is within acceptable parameters; and sending at least one of water and steam to the venting reservoir if the pressure in the main steam header pipe is not within acceptable parameters.
  • An apparatus for supplying at least one of water and steam to a desired destination at a desired steam quality comprising a feedwater system; a steam generation system; a delivery system that includes a main steam header pipe that runs from the steam generation system to the desired destination for supplying at least one of water and steam.
  • the apparatus further comprises a plurality of instruments and devices that are in operative association with the feedwater system, steam generating system, or delivery system configured for sensing physical parameters of water or steam; and a control system having an input device, output device and memory, said control system being in operative association or communication with said instruments and devices. Said control system being configured for performing the operation of determining the enthalpy of the feedwater.
  • a method of predicting or attaining the desired steam quality of at least one of water and steam supplied by an apparatus capable of producing at least one of water and steam of varying quality the apparatus including a feedwater supply system, a steam generation system and a delivery system, the method comprising the following steps: determining the feedwater enthalpy and flow rate; setting a desired value for the quality of at least one of water and steam; and estimating the enthalpy of the desired steam quality of at least one of water and steam.
  • FIGS. 1 A and IB are different perspective views of a trailer mounted unit of an
  • FIG. 1C is a simplified schematic of a feedwater supply system and a steam
  • FIGS. 2Ai, 2A 2 , 2Bi and 2B 2 provide legends so that the other detailed schematics of embodiments of this disclosure can be more readily understood. Specifically, they convey the meaning and function of certain components represented symbolically in the schematics including valves, flow elements, flow meters, level instruments, pumps, motors, blowers, fans, turbines, dampers, pressure instruments, strainers/filters, temperature instruments, controls, and miscellaneous items.
  • FIG. 2C is a detailed schematic of a feedwater supply system of an embodiment of a steam generating and supplying apparatus of the present disclosure.
  • FIG. 2D is a detailed schematic of a steam generating system of an embodiment of an apparatus of the present disclosure that receives feedwater from the supply system of FIG. 2C.
  • FIGS. 2Ei, 2E 2 and 2E 3 are segments of a detailed schematic of a steam and/or water delivery system of an embodiment of an apparatus of the present disclosure that receives steam and/or water from the steam generating system of FIG. 2D.
  • FIGS. 3A, 3B and 3C are segments of a detailed schematic of a burner of the steam generating system shown in FIG. 2D along with the associated inputs, outputs and control system.
  • FIG. 4 is a flowchart outlining the various steps of a method for starting up a steam generating apparatus according to one embodiment of the present disclosure.
  • FIG. 5A is a flowchart outlining the various steps of a method or routine for attaining a desired injection pressure that is supplied by steam generating apparatus according to one embodiment of the present disclosure.
  • FIG. 5B is a flowchart showing the various steps of a sub-process or subroutine for the step of determining whether the injection pressure at a desired location is within acceptable parameters as shown in FIG. 5A.
  • FIG. 5C is a flowchart of a method or routine similar to that disclosed in FIG. 5A
  • control system wherein a control system is used and various controls for the feedwater flow rate and the injection pressure are placed into automatic mode and the desired parameters for the flow rate and the injection pressure are inputted into the control system.
  • FIG. 6 contains a flowchart for maintaining the main steam header pipe pressure
  • valve that is configured to send steam and/or water to a venting reservoir when needed.
  • FIG. 7A shows a flowchart for a method or routine in generalized steps for predicting and attaining a desired steam quality made by a steam generating apparatus according to one embodiment of the present disclosure.
  • FIG. 7B shows a flowchart showing a sub-process or subroutine for the step of
  • FIG. 7C depicts a flowchart showing a sub-process or subroutine for calculating
  • boiler inefficiency that may be used to adjust the amount of heat calculated to be needed to be input to the feedwater as determined in a step of the process shown in FIG. 7A.
  • FIG. 7D shows a flowchart that illustrates the sub-process or subroutine and its
  • the steam generation apparatus includes a feedwater supply system, a steam generating system, a steam and water delivery system and a control system that is operatively associated and/or in communication with any or all of these systems. Also, various methods or protocols are disclosed for operating these various systems in several phases including startup and normal operation. It would be understood by one of skill in the art that the disclosed steam generation apparatus, control system and associated methods are described in but a few exemplary embodiments among many. No particular terminology or description should be considered limiting on the disclosure or the scope of any claims issuing therefrom.
  • EOR enhanced oil recovery
  • the intent is to reduce the viscosity of the bitumen to the point where gravity will pull it toward the producing well.
  • Locations where such steam injection is employed vary in certain embodiments.
  • the steam generating apparati disclosed herein may be mounted on portable platforms such as barges or truck trailers so that they can be transported to a site where oil and steam injection wells are located.
  • the steam generating apparatus is located permanently at the site.
  • the embodiments disclosed herein are not limited merely to oil recovery applications, which include both the Steam Flooding and Cyclic techniques as well as others, but it is contemplated that the embodiments discussed herein may be applied to other industrial sectors as well.
  • the quality of the steam which is the mass fraction in a saturated mixture that is vapor, produced by the embodiments disclosed herein may be varied from 0 to 100 percent. In many applications, the desired steam quality ranges from 50 to 100 percent and may be as high as 80 to 90 percent.
  • FIGS. 1 A and IB One embodiment of a steam generation and supply apparatus 100, which is at least partially portably mounted on a trailer platform, is disclosed and described in FIGS. 1 A and IB.
  • the steam generation and supply apparatus 100 includes three major systems including the feedwater supply system 110, the steam generating system 120, and the steam and water delivery system 130.
  • the feedwater supply system 110 includes a water tank (not shown), a filtration
  • water is supplied on site from a fresh water source such as a lake or municipal water system where it is stored in a water tank and then drawn out or pumped out by the booster pump 118 before being filtered for the removal of sediment and other impurities via the filtration device that could adversely affect the equipment of the apparatus. It is preferable if the water is free from impurities, that is to say, is on the level of water filtered by a reverse osmosis device and softened.
  • the feedwater pump is a positive displacement multi-plunger style of pump.
  • the steam generating system 120 includes a pipe in pipe (PIP) heat exchanger 122, a convection section that comprises an extended surface economizer type heat exchanger
  • the feedwater enters the PIP heat exchanger
  • the extended surface economizer 121 which includes fins or other types of extended surfaces for improving heat transfer that help to increase the water temperature further by supplying more surface area to facilitate heat transfer to the water.
  • the water then exits out of the extended surface economizer 121 back into PIP exchanger 122 past the incoming water in a manner already described, which cools the water back down again a slight amount which is advantageous as it is not desirable to overheat the water and have 100% steam quality in the boiler.
  • the water then enters the bare tube section 124 and then the radiant section 126 of the steam generator whose heat is created by the burning of fuel provided by the burner 128.
  • the bare tube section lacks fins as the combustion gases in the boiler unit in this area would be too high and would melt the fins. At this point, the majority of the water has been converted to steam.
  • the fuel rate supplied to the burner is monitored and controlled to adjust the amount of heat generated.
  • steam generation system or apparatus should be construed broadly herein to include any method or device that is used to heat water.
  • FIG. 1C the components of the feedwater supply system 110 and the steam generating system 120 and the manner in which they work together is shown in a simplified schematic format.
  • Water is drawn by the booster pump 118 from a preheated water supply (not shown) to the feedwater pump 111.
  • the feedwater pump 111 then raises the pressure and flow rate of the water before it reaches the steam generating system.
  • a feedwater flow rate control loop 113 is provided with a valve 115 so that the pressure and flow rate of the feedwater can be controlled by opening or closing the valve 115 which effectively changes the amount of water sent toward the steam generating system 120.
  • This control loop will be discussed in more detail later.
  • the feedwater then enters the PIP heat exchanger 122 into an outer pipe 123a that surrounds an inner pipe 123b, allowing the colder water that is entering the PIP heat exchanger 122 to run past warmer water found in the inner pipe 123b in an opposite direction.
  • this inner water has already been heated to a higher temperature by the extended surface economizer 121 of the steam generating system 120. Leaving the outer pipe, the water then enters the extended surface economizer 121 that includes a region having fins 125 and returns to the PIP heat exchanger 122 through the inner pipe 123b. The water then passes through the bare tube section 124.
  • the water then exits the bare tube section and passes back through the PIP heat exchanger 122 and then enters the pipe found in the radiant section 126, where the water is heated through radiation by a flame created by the burner 128 that has fuel supplied to it as well as air via the combustion air damper 127 and supply fan 129.
  • the damper actuator controls the position of the air damper 127 which comprises a series of louvers that move to an open position. This in turn, regulates the amount of air entering the burner 128.
  • the air flow is regulated by controlling the speed of the supply fan with a variable frequency drive that is run by the control system.
  • the water and steam delivery system 130 includes a steam quality measuring subsystem 132, a venting subsystem 134, a bleed-off or diverter subsystem 136, and a steam injection subsystem 138.
  • the steam quality measuring system 132 allows for a sample of the steam and water mixture that exits the steam generating system 120 to be cooled down and analyzed by methods or devices commonly known in the art to see what portion of the mixture is in fact steam.
  • the venting subsystem 134 provides an avenue for venting steam and/or water to atmosphere and/or a reservoir when certain parameters are not within acceptable limits both during startup and during normal operation.
  • the bleed-off system 136 allows a portion of the steam and water mixture to be separated from the mainline of the delivery system so that it can be fed to auxiliary equipment and/or recirculated to the feedwater preheater.
  • the steam injection subsystem 138 provides the steam/water mixture to an injection well at a desired pressure and quality. More details of how the delivery system 130 works will be given later.
  • a control system 140 is provided that can help ensure that the quality of the steam/water mixture as well as its temperature and pressure is within desired parameters as it is injected into an injection well.
  • the control system helps execute several algorithms or implements various routines, processes, and methods described herein that control operation of the apparatus 100 and that improve the efficiency as well as the safety and durability of the apparatus 100.
  • the control system includes a series of control units that are in communication with each other through the programmable logic controller (PLC) and certain components of the apparatus.
  • PLC programmable logic controller
  • control system could be provided by any other devices or methods known in the art or that will be devised in the art as is elaborated upon later herein.
  • control system may include a series of control units, instruments, control devices and other components that are communicatively connected to a programmable logic controller (PLC), the PLC may represent any PLC known in the art, a general -purpose processor with a firmware or other memory containing processing logic, a field-programmable gate array (“FPGA”), a distributed control system (“DCS”), or the like.
  • PLC programmable logic controller
  • FPGA field-programmable gate array
  • DCS distributed control system
  • the control system may further implement input devices, such as a touchscreens, keyboards, trackballs, mice, switches, knobs, and the like, and output devices, such as displays, dials, gauges, audible and visible alarm annunciators, and the like, that are in communication with the PLC.
  • input devices such as a touchscreens, keyboards, trackballs, mice, switches, knobs, and the like
  • output devices such as displays, dials, gauges, audible and visible alarm annunciators, and the like, that are in communication with the PLC.
  • a "memory” includes any non- transitory computer-readable medium accessible to the PLC or other processor of the control system and used to store data structures, program modules, and other processor- executable code or logic, and does not include transitory signals.
  • memory may include, but is not limited to, RAM, ROM, EPROM, EEPROM, flash memory or other solid-state memory technology, optical disk storage technology, hard disk devices ("HDD”) or other magnetic disk storage, other magnetic storage devices, and the like.
  • the control system could be provided by any other devices or methods known in the art or that will be devised in the art that may implement the routines, processes and methods described herein for controlling the operation of the apparatus 100 as well as improving the efficiency, safety, and durability of the apparatus, including a general purpose computer communicatively coupled to the control units, instruments, control devices, and other components of the apparatus and programmed to perform the routines, processes and methods described herein.
  • FIGS. 2Ai, 2A 2 , 2Bi and 2B 2 provide legends so that the other detailed schematics of embodiments of this disclosure can be more readily understood. Specifically, they convey the meaning and function of certain components represented symbolically in the schematics including valves, flow elements, flow meters, level instruments, pumps, motors, blowers, fans, turbines, dampers, pressure instruments, strainers/filters, temperature instruments, controls, and miscellaneous items.
  • instruments may refer to any component that is used to measure a physical parameter of water or steam such as flow rate, pressure and temperature.
  • the term “device” may refer to any component that manipulates the flow of water or steam. However, it is contemplated that either term may be interchanged with each other.
  • the context of how the term is used should relay the intended meaning to the reader of this disclosure and the claims.
  • FIG. 2C a detailed schematic depicting the design of an embodiment of the feedwater supply system 110 following the direction of flow from the main feedwater pump 111 to the steam generating system 120 is given.
  • the feedwater pump 111 includes a motor faceplate 202 that is in integral with the PLC and is displayed on the GUI or HMI of the control system and helps control the operation of the pump.
  • the motor faceplate 202 includes several inputs including a hand switch 204 signal that can be placed in an off or auto position, a feedwater pump vibration high alarm signal 206 that alarms and is hardwired in series with the pump starter contactor that can shut the motor off if the pump vibrates too much, and a feedwater drip oil tank level is not low signal 208 that allows the pump to start if sufficient drip oil is present. Also, a switch 209 is hardwired in series with the pump starter contactor and sends a low level alarm to the PLC that indicates whether the feedwater pump crankcase oil level is not low.
  • a feedwater pump run confirmation signal 210 is sent from the pump to the motor faceplate 202 once a turn pump on signal 211 has been sent to the pump 111 and the pump begins to run.
  • the pump can be turned off by a similar signal.
  • This flow rate control loop includes a recirculation feedwater flow rate control valve 218 (analogous to valve 115 of FIG. 1C), and a valve position measuring device 222 associated with the control valve 218 and associated control device 224. Also, feedwater flow control valve demand signal device 225 that is in communication with the PLC is provided.
  • an inlet feedwater pump pressure indicating instrument 226 and an associated control signal/alarm device 228 that can indicate if the feedwater inlet pump pressure is too low as this could damage the pump.
  • feedwater pump outlet pressure indicating instrument 230 Located downstream from the first outlet 214a is feedwater pump outlet pressure indicating instrument 230 as well as an associated control device 232.
  • feedwater flow indicating device 234 and an associated control device 236 that is in communication with the PLC via a software link to send an alarm 237 if the feedwater flow rate is too low as this could cause components of the steam generating system 120 to overheat or be otherwise damaged.
  • the alarm goes to the burner management system (BMS) as a burner run permissive condition, if the flow rate is too low then the burner is shut down.
  • the control signal devices 232 and 236 are in communication with the feedwater recirculation control valve 218 as well as other controls associated with the delivery system 130 as will be described in more detail later for allowing control of the feedwater flow rate. The methods associated with the control of the feedwater flow rate will be elaborated upon later herein.
  • FIG. 2D shows a detailed schematic of the steam generating system 120. It receives water from the feedwater supply system just described and then includes a temperature indicating instrument 238 and an associated control device 240 for measuring the temperature of the water as it exits the feed pump 111 before it enters the PIP heat exchanger section 122 and for giving an alarm 240 if the temperature is too high. If the temperature exceeds the maximum operating temperature for the feed pump 111, control device 241 will communicate with the burner management system to trip the burner. The water then proceeds through the PIP heat exchanger section 122 and exits as previously described in relation to FIGS. 1A and IB and then exits where its temperature and pressure are measured using pressure transmitting instrument 242 and temperature sensor instrument 244, that each have control devices 246, 248.
  • a temperature indicating instrument 250 in the form of a thermocouple or resistance temperature detector measures the temperature of the flue gases exiting the extended surface economizer 121. Its associated control device 252 performs two functions. An alarm is generated via the PLC as an indication of excessive ash buildup. The second but primary function of the temperature control device 252 is as an input to the steam quality algorithm which will be elaborated upon later. The water then exits the extended surface economizer and flows back through the PIP heat exchanger as previously described.
  • the temperature of the water as it enters and exits the PIP heat exchanger is again measured by temperature measuring instruments 254, 256 to make sure that its temperature is within acceptable parameters as it enters and exits the PIP heat exchanger respectively. If not, the associated alarm devices 258, 260 of the PLC are notified. [0048] The water then flows through the bare tube section of the system 124 and exits toward the radiant section 126 where its pressure and temperature are measured by instruments 262, 264 respectively and monitored by their associated control devices 266, 268 respectively. If these values are outside of acceptable parameters, an alarm signal is generated from the PLC. The water then enters the radiant section 126 where it is heated even further to turn the majority of the water into steam.
  • the temperature of the pipe/water in the radiant section is measured by a temperature measuring instrument 270 to see if its temperature exceeds a maximum value.
  • the associated control device 272 signals and relays it to the PLC and triggers an alarm 272 if the maximum operating threshold value is exceeded. If the temperature continues to rise above the setpoint established in temperature control device 273, the burner will be stopped to prevent possible damage to the radiant section 126 of the system 120.
  • its target quality is usually in the 80 to 90 percent range where it heads toward the delivery system 130.
  • the steam and water delivery system 130 will now be described with reference to FIG. 2Ei, 2E 2 and 2E 3 where it is illustrated by another detailed schematic. Focusing for now on FIG. 2Ei, the steam/water mixture travels to a steam separator 278 that is part of the steam quality measuring subsystem 132 that takes a portion of the water from the mixture and sends it to a sample cooler 280 where it is cooled and its conductivity is measured and compared to the conductivity of the incoming feedwater. This allows the quality of the steam/water mixture to be calculated. This is done manually on a periodic basis using equipment and methods commonly known in the art such as a conductivity measurement instrument.
  • This actual value is then compared to a theoretical value that is calculated using an algorithm programmed into the PLC to be elaborated upon later that predicts and helps attain a desired steam quality based on measurements taken and controlled by the control system.
  • An adjustment is then made by entering a correction coefficient into the program done manually by the user each time the steam quality is measured to correct for predictive error in the algorithm or other inefficiencies in the apparatus.
  • This is done using a GUI (graphical user interface) or HMI (human-machine interface) such as a touchscreen as is well known in the art but other devices and methods could be used such as a keyboard, mouse, etc.
  • GUI graphical user interface
  • HMI human-machine interface
  • the steam quality measuring subsystem 132 provides an intermittent slip stream of the main flow path and the majority of the steam/water mixture proceeds to flow toward the venting subsystem 134 (see FIGS. 2Ei, 2E 2 and 2E 3 ) down the main steam header supply pipe 285 that includes first and second pressure safety valves 282 and 284 respectively, that vent to atmosphere if a pressure surge occurs that exceeds certain thresholds. Later, the steam/water mixture arrives at a vent pipe 286 that includes a pressure control valve 288 that can be selectively opened when desired in conjunction with the closing of other valves in the delivery system 130 in order to vent at least one of water and steam to a tank or reservoir as will be discussed in more detail later herein.
  • valve position indicating device 290 that is associated with this valve 288 as well as a valve position demand signaling device 292 as well as a control device 293 within the PLC that is in communication with device 292. Both the valve position indicating device 290 and its associated controller 29 las well as the control device 293 communicate with the PLC so that it knows when to open or close the valve and at what position the valve actually is located.
  • a flow indicating instrument 294 (see FIG. 2Ei) that is part of the steam injection subsystem 138 that includes an associated control device 295 that measures the flow of the steam/water mixture to make sure that it is not too high or too low and sends that signal to the PLC.
  • a main steam header pressure measuring device 298 (see FIG. 2E 2 ) that includes an associated control device 281 that communicates with the PLC to show whether the pressure is too high or too low.
  • control signal device 281 is in communication via the PLC creating a valve position demand signal 283 that opens or closes the main header pressure control valve 296 (see FIG.
  • Another temperature measurement instrument 251 that is part of the steam injection subsystem 138 is found along the main steam header pipe 285 that indicates through an associated control device 253 whether the temperature of the steam/water mixture is still within an acceptable high and low range. If the temperature continues to rise to a very high level, the PLC will send a signal 255 to the burner management system to turn off the burner.
  • the last measurement device found along the main steam header pipe is pressure transmitting instrument 297 (see FIG. 2E 3 ) that includes an associated control device 299 that is in communication with the PLC and feedwater recirculation flow control valve 218 as alluded to above with reference to FIG. 2C.
  • This valve 218 and main steam pressure control valve 296 work together to modify the feedwater flow rate and injection pressure, which directly influence each other, to provide the desired pressure of the steam/water mixture to the injection well while also maintaining a consistent pressure in the steam generating system 120. This cooperation between these valves and the PLC will be discussed more thoroughly later.
  • Branching off the main steam header pipe 285 is the supply line 267 (see FIG. 2E 2 ) that diverts part of the steam/water mixture to the bleed-off subsystem 136 for supplying auxiliary equipment with steam at a reduced pressure.
  • a pressure control or flash valve 269 is provided that reduces the pressure by approximately 90%.
  • Associated actual valve indicating device 207 and its associated controller 215, and valve position demand signaling device 213 as well as pressure control device 217 are provided in similar fashion as has been described for other pressure and flow control valves.
  • a steam pressure measuring instrument 219 transmits a signal to the PLC which, through an algorithm or routine, sends a signal to the pressure control device 217 to the pressure control or flash valve 269 to maintain pressure.
  • a steam separator 221 removes the water from the mixture and sends it to the feedwater preheater for the sake of conservation of energy to begin to warm up the feedwater.
  • the remaining steam is sent to the oil burner 128 for atomizing the fuel, to the feedwater preheater to conserve energy and warm up the feedwater, and to the warm the fuel of the oil heater when heavy oil is being used.
  • 4 niA corresponds to a signal for closing a device or minimizing a readout while a 20 mA signal corresponds to a signal for opening a device or for maximizing a readout and for analog applications, anything between these values is calibrated to create a proportional reading or control of a device.
  • valve operations could be designed to operate in the opposite direction with the same control signal.
  • FIGS. 3A, 3B and 3C show in a segmented fashion a detailed schematic of the inputs and outputs and related control system associated with burner unit 128 that is designed to use multiple fuels including natural gas, #2 oil (diesel) and/or #6 oil (heavy oil) and/or any other gaseous or liquid fuel (best seen in FIG. 3A is a typical schematic of such a burner).
  • gas may be sent to the burner with its flow rate controlled by flow rate control valve 300 (see FIG. 3B).
  • the flow rate may be monitored using flow transmitting instrument signal 303 conveyed to the PLC.
  • Natural gas supply instrument 302 transmits its signal to the PLC to alarm if conditions or measurements are abnormally low or high.
  • Both the valve and the flow measuring instrument are in communication with control device 304. If not enough gas is being sent to the ignition system, then a demand signal 306 is increased, which in turn causes the valve to open.
  • other fuels can be used separately or in tandem with each other and be controlled in like manner to what has just been described so that the amount of fuel, and therefore, energy might be calculated in conjunction with the air flow rate.
  • the air flow rate is measured using a flow element 308 (see top of FIG. 3 A). If more air is needed, then a control signal 310 is sent to the fan or blower 129 by the controller 312, which in turn increases the rate of rotation of the fan (see top of FIG. 3B).
  • the air flow could be adjusted using devices or methods known in the art suitable for this application.
  • An Atomizing media such as steam that is received from the bleed-off system as has been described or compressed air is sent to the burner to mix with oil to atomize the oil and reduce its particle size to improve its combustion efficiency in the furnace (see FIG. 3C).
  • Propane or natural gas is also supplied for creating the pilot light for the burner. Excess oil not needed by the burner is returned to the oil tank (see bottom of FIG. 3 A).
  • other methods of atomizing the liquid fuels known in the art are suitable for this application.
  • control system may be able to sense when the feedwater rate is increased or decreased and may adjust the burn rate accordingly. That is to say, the fuel and air rates would also being increased to compensate for the increased feedwater flow rate in an attempt to maintain the desired steam quality that is made by the steam generating system.
  • a startup algorithm or routine 400 may be implemented by the control system and executed to perform the following method for starting the apparatus.
  • the following conditions should be satisfied before the feedwater pump 111 start command is issued and the run contact is energized.
  • the motor trip alarm should have been reset (step 402).
  • One of the booster pumps that provides flow to the feedwater pump should be running (step 404) which is proven if the feedwater pump inlet pressure is not too low (step 406).
  • the hand switch of the feedwater pump should be in the auto position (step 402).
  • the feedwater pump outlet pressure must not be too high
  • the feedwater pump outlet temperature must not be too high (step 408)
  • the feedwater pump vibration switch must be reset
  • the feedwater pump drip oil tank level must not be too low (step 410).
  • the air instrument pressure must not be too low (step 412) or instruments must be otherwise energized.
  • the feedwater pump crankcase oil level must not be too low (step 414).
  • these conditions may vary depending on the selection of the pump and the overall design of the system. Accordingly, the algorithm or routine and associated method in its broadest interpretation may reduce all these conditions into a go or no go situation, that is to say, is it permissible for the feedwater pump to run (step 413). If so, then the algorithm or routine 400 or method should proceed to the next step.
  • valves, actuators and other devices should be supplied with enough air or hydraulic pressure, enough electricity or mechanical force, or other form of energy depending on the device to work properly. If at least minimum of these conditions is satisfied for these embodiments, then it is permissible for the pump to be energized.
  • a signal is sent to the feedwater pump to turn it on and the starter contact sends a signal back to the controller confirming that pump is in fact running. If this contact is not made when the run confirmation timer expires, a feedwater pump failed to start alarm is annunciated and the run contact is de-energized. If the pump inlet pressure switch opens, the feedwater pump will trip and a feedwater pump low inlet pressure alarm is annunciated. If the feedwater outlet pressure exceeds the high limit, the feedwater pump will trip and a feedwater pump outlet pressure high alarm is annunciated. If the feedwater outlet temperature exceeds the high limit, the feedwater pump will trip and a feedwater pump outlet temperature high alarm is annunciated. Any one of these alarms or warnings can lead to a shutdown of the feedwater pump after the pump has been turned on.
  • the feedwater pump will trip and an instrument low air pressure alarm or other similar type of alarm will be annunciated. If the pump vibration switch opens, the feedwater pump high vibration alarm will be annunciated and since the switch is also hardwired in series with the pump starter contactor, the feedwater pump will trip. Likewise, if the feedwater pump crankcase oil level switch opens, the feedwater pump low crankcase oil level alarm will be annunciated and since the switch is also hardwired in series with the pump starter contactor, the feedwater pump will trip. Again, any one of these alarms or warnings can lead to a shutdown of the feedwater pump after it has been turned on.
  • feedwater pump drip oil tank level switch opens, a feedwater pump drip oil tank low level alarm will be annunciated and a one hour timer will start. In order to stop the running of this timer, the operator needs to reset the alarm by pushing the reset button after refilling the drip oil tank. If the feedwater pump drip oil tank low level switch stays open for more than one continuous hour, the feedwater pump will trip. Of course, this can occur at any time during the operation of the pump.
  • the start routine 400, method or associated algorithm proceeds to the next step as follows.
  • the startup valve 288 is opened an appropriate amount to vent steam and water directly from the main steam header pipe 285 to the vent tank or reservoir (step 415) until it has been determined that the steam/water mixture is suitable (step 416) to be sent toward the injection well or other desired destination (step 418).
  • the main header pressure control valve 296 is closed an appropriate amount or entirely until the desired parameters have been achieved. This can all be done dependent on parameters input by a user or that were previously programmed into the controller.
  • another method or routine 500 that can be implemented by the control system and executed during normal operation includes the following steps.
  • the injection pressure at the injection well or other desired location is determined to be within acceptable parameters (step 502). If not, then the feedwater flow rate is adjusted (step 504) as well as the burn rate (step 506) of the burner of the steam generating system. Then, it is determined whether the feedwater flow rate and pump discharge pressure are within acceptable parameters (step 508). If not, then the feedwater flow rate is adjusted (step 510). This method was alluded to above with respect to the maintenance of the injection pressure using the recirculation feedwater flow rate control valve 218.
  • determining whether the injection pressure is within acceptable parameters, for adjusting the feedwater flow rate and for adjusting the burn rate is determined whether the injection pressure is within acceptable parameters, for adjusting the feedwater flow rate and for adjusting the burn rate.
  • a desired setting for the injection steam pressure is placed into the computer such as by the user via an input device or preprogrammed into the PLC. The injection steam pressure is then measured. If the injection steam pressure is too low as compared to the desired setting (step 512), then the recirculation feedwater flow rate control valve is closed an
  • step 514 If the injection steam pressure is too high as compared to the desired setting (step 516), then the recirculation feedwater flow rate control valve is opened an appropriate amount (step 518).
  • This can be automated using the PLC since all the necessary components are communicating with the PLC and therefore with each other. This can be considered the first control loop 520 for maintaining the desired main steam header pressure.
  • steps 522 and 524 require that the burn rate be raised or lowered respectively to match the increase or decrease in the flow rate in an effort to maintain the desired steam quality.
  • FIG. 5B There can also be a secondary control loop 526 that is also depicted by FIG. 5B based on the feedwater flow rate.
  • step 528 measuring the feedwater flow rate, inputting a maximum value for the flow rate into the control system, which may be done in any manner including manually or by programming, and comparing the feedwater flow rate to the maximum value for the flow rate. If the feedwater flow rate is above the threshold value (step 528), then the second control loop takes precedence over the first control loop and the flow rate is decreased (step 530) even if the desired injection steam pressure has not been reached. On the other hand, if the flow rate is too low (step 532), then the flow rate may be increased (step 534) as long as the pump discharge pressure is not too high (step 533).
  • feedwater flow rate or to the injection steam pressure controller can be placed in manual or automatic mode. This yields four separate scenarios with the typical scenario being the one where both controls are placed in automatic mode (step 536).
  • feedwater flow rate until the desired pressure has been reached. This may involve the steps of inputting the desired injection pressure range into the control system (step 538). Then, the injection pressure and feedwater flow rate are measured (step 540). This continues until the feedwater flow rate or the injection pressure are not within desired ranges (step 542). Then, the recirculation feedwater flow rate control valve is opened or closed as necessary to obtain the desired injection pressure range (step 544).
  • the output of the feedwater flow rate controller is at and remains at 0% until the flow rate approaches the high flow limit, such as when it exceeds the design conditions of the steam generator, at which time its output is greater than the output of the injection steam pressure controller and controls the recirculation feedwater flow rate.
  • the high feedwater flow rate limit is sometimes automatically set when the injection steam pressure controller is placed into automatic mode to avoid an operator forgetting to set the appropriate limit.
  • these control loops can only be put into automatic if the feedwater pump is running. If the feedwater pump stops for any reason including those related to the conditions necessary to start the pump discussed with reference to FIG. 4 above, both the feedwater flow rate controller and injection steam pressure controller are placed into manual mode and the output is placed to 100% so at least a minimal amount of water flows to the steam generating system helping to keep its components from overheating.
  • a setpoint for any value whether it be flow rate, pressure or temperature disclosed herein may include a range or single setpoint so the term range or setpoint should be considered equivalents of each other.
  • step 546 of FIG. 5C provides position feedback from the feedwater flow rate control valve 218 (see step 546 of FIG. 5C). If the actual position deviates more than 5% from the valve position demand signal 225 (step 548), a feedwater flow rate control valve position deviation alarm is annunciated to alert that there may be a problem with the valve (step 550).
  • steps of measuring a valve's position, comparing it to a desired position, and annunciating an alarm if the deviation is too great may be used in conjunction with any valve that includes the appropriate instruments and controls.
  • both the feedwater flow rate controller and the injection steam pressure controller are both placed in manual mode so they need to track each other.
  • the output buttons on the injection steam pressure controller are not visible to the operator when both controllers are in manual mode. Consequently, the operator only has access to manipulate the output of the feedwater flow rate controller (shown as 236 in FIG. 2C) and the logic of the PLC tracks this and matches it on the injection steam pressure controller (shown as pressure controller 299 in FIG. 2E 3 ).
  • the feedwater flow rate controller is in automatic mode and the injection steam pressure controller is placed in manual mode.
  • the recirculation feedwater flow rate control valve is always opened or closed to the higher of either controller output. If the output of the injection steam pressure controller is set to 100%, then the output of the feedwater flow rate controller has no effect, since the control valve will always stay at 100%.
  • the setting for the injection steam pressure controller has to be 0%>.
  • the feedwater flow rate controller is put into manual mode and the injection steam pressure controller is placed into automatic mode.
  • the result is the same as the second scenario except that the output of the feedwater flow rate controller must be set to 0% in order for the injection steam pressure controller to be exclusively in control.
  • the first scenario is the one typically used and involves placing both the feedwater flow rate controller and the injection steam pressure controller into automatic mode.
  • the second scenario is discouraged as it does not take advantage of the control system and its logic.
  • FIG. 6 depicts the steps of another routine 600 or method that can be implemented and executed by the control system.
  • This routine 600 is well suited once the startup routine has been accomplished and normal operation has ensued.
  • the main header pressure control valve 296 is opened and the startup valve 288 is closed an appropriate amount to maintain the main steam header pressure at an operator selected or preprogrammed level. Also, excess steam pressure that may arise during some sort of event, excursion or surge can be vented using the vent or startup valve 288.
  • the main steam header pressure 298 is controlled by a backpressure
  • step 612 in FIG. 6 it is determined whether the pressure in the main steam header pipe or line is within acceptable parameters.
  • a possible sub-process or subroutine for this may include the following steps.
  • a desired pressure is input into the main steam header pressure controller 287 (step 604 in FIG. 6) by any method including manually or by programming.
  • This controller can only be put into automatic mode (step 602) if the feedwater pump 111 is running and the burner 128 is released for modulation, that is to say, it is in normal operation mode.
  • the pressure is then measured and compared to the desired value (step 614).
  • the steam and/or water mixture is sent to the venting reservoir (step 616). If either the feedwater pump stops (step 606) or the burner is shut off (step 608), this controller is automatically switched to manual (step 610) and the output is pulsed to zero and backpressure control valve 296 closes so that some pressure is maintained within the steam generation system. Once more, the same conditions that have been discussed as necessary to start the feedwater pump could also cause the pump to stop if they are not satisfied. Also, a position transmitter 287 provides position feedback from the main steam header pressure control valve 296. If the actual valve position deviates more than 5% from the valve position demand signal 283, a main steam header pressure control valve position deviation alarm is annunciated.
  • the main steam header pipe may be provided with pressure safety valves 282, 284.
  • This method may also include the step of determining whether the pressure in the main steam header pipe is greater than the designed release pressure of one of the safety valves (step 618). If so, then one of the pressure safety valves opens. It should be noted that this may be done without any signal from the control system as such valves are usually constructed with a mechanical spring that keeps the valve closed until a setpoint steam pressure overcomes the spring pressure opening the valve (step 620).
  • the pressure setting for the vent pressure control valve or startup valve 288 is set at a threshold value by any suitable method including manually or via a program so that its value is slightly higher than main steam header pressure controller 281 setting. If the pressure exceeds this threshold value, then the vent pressure control valve 288 opens up an appropriate amount to allow excess steam pressure to escape to the venting reservoir.
  • the valve provides both the functions of an excess steam pressure relief valve when there is a surge or excursion in the main steam header pressure or injection steam pressure during startup and normal operation.
  • the controller associated with the startup valve 288 is automatically placed in automatic mode by the PLC logic when the feedwater pump is started.
  • this controller 293 is automatically switched to manual and the output is pulsed to zero and the startup valve 288 is closed as it is desired to maintain some pressure and water in the steam generation system to help prevent overheating.
  • a position transmitter 290 tells the control system the position of the valve 288 and if the actual position deviates more than 5% from the valve position demand signal 292, a startup or vent valve position deviation alarm is annunciated.
  • a process steam control valve 269 is used to reduce the steam pressure from the main steam header pressure to a suitable pressure for the process steam that is sent to the fuel oil heater, feedwater heater, burner atomizing steam and soot blower (not shown in the figures).
  • the following method and associated algorithm may be employed during normal operation. First, a desired pressure is placed in the process steam pressure controller 217. The pressure is then measured using pressure measuring device 219. If the pressure is not within acceptable parameters, then the valve is opened or closed as needed to place the pressure in the desired range.
  • this controller can only be placed in automatic mode if the feedwater pump is running and the burner has been released for modulation, that is to say, it has been cleared by the control system for normal operation. If the feedwater pump stops or the burner is shut off, this controller is automatically switched to manual and the output is pulsed to zero, and the valve is closed, as it is desired to maintain some water pressure in the steam generation and delivery systems.
  • a valve position transmitter 207 provides position feedback from the process steam pressure control valve 269. If the actual valve position deviates more than 5% from the valve position demand signal 213, a process steam pressure control valve position deviation alarm is annunciated.
  • routine 700 (see FIG. 7A), algorithm or method that can be implemented by the control system provides the following process for adjusting the burner firing rate to achieve a desired steam quality being sent to the injection well or other desired destination from the steam generating system.
  • the temperature of the water supplied by the feedwater system to the steam generation system as well as its flow rate and enthalpy are determined (step 714) by any device or method known in the art or that will be devised in the art. This step may be achieved using sub-steps of a sub-process or subroutine including the following.
  • the feedwater enthalpy is calculated by subtracting a value of thirty-two from the measured temperature in degrees F to get the feedwater enthalpy in BTU/lb (step 704). If the temperature's electronic signal quality is bad, then the temperature is assumed to be about 200 degrees F and the feedwater enthalpy is estimated to be 168 BTU/lb (step 706). It is contemplated that the enthalpy of the water could be estimated some other way such as using a table since the system is capable of measuring the temperature and pressure of the water.
  • the current steam header vapor and liquid enthalpies associated with the main steam header pressure are retrieved from look-up tables that are based on ASME steam tables and are stored in a database.
  • the tables cover a pressure range from 0 to 1800 psig with an enthalpy value for every 100 psi increment (step 718 of FIG. 7B).
  • the program may determine if the pressure is located between those listed in the table (step 720 of FIG.
  • step 7B may automatically interpolate for pressures found between these 100 psi listed increments (step 722).
  • similar programs known in the art may be used to determine the steam vapor and steam liquid enthalpies.
  • the pressure of the steam/water mixture is measured as it exits the steam generation system in a manner that has already been described.
  • the desired steam quality could be set by any known method or device known in the art or that will be devised in the art (step 712 of FIG. 7A) such as by preprogramming without the need of a user to input a value into the control system.
  • the amount of heat that must be generated and put into the water by the steam generating system is affected by the efficiency of the steam generating system, especially that of the boiler which includes the radiant section, bare tube section and the extended surface economizer section.
  • the boiler efficiency can be estimated as follows as best seen in FIG. 7C. First, the flue gas oxygen level signal and content are measured as has been previously described to determine if it is within an acceptable range (step 726). In one embodiment, the transmitted signal to the control system from 274 will be between 3.8 and 21.0 mA. If it is within this range, then the actual corresponding oxygen content is used in the calculation involving the boiler efficiency (step 728). If it is outside this range, then the flue gas oxygen content is assumed to be 3% (step 730).
  • the stack temperature signal is measured, and if its signal is within acceptable parameters (step 732), the actual temperature provided by the thermocouple or other measuring instrument is used in the calculation (step 734). In one embodiment, this range is anything that falls within these signal limits. If the measured temperature is outside the permissible range, then a temperature of 480 degrees F is assumed (step 736). Also, the type of fuel burned in the burner is considered (step 738). If natural gas is used as fuel, then an equation is derived from a matrix of efficiency number obtained from running a boiler heat balance program for various flue gas oxygen values and stack temperatures (step 740). The calculation may be made using the equation as follows: Boiler
  • step 744 If the calculated boiler efficiency number is greater than 95%, then the algorithm assumes that the boiler efficiency unit is 95%. If the calculated boiler efficiency number is less than 60%, then the algorithm assumes that the boiler efficiency is 60%) (step 746). Otherwise, the boiler efficiency is set to the calculated value found between 60 and 95% (step 748).
  • Adjusted Gross Heat Input Rate 1000 * Gross Heat Input Rate / Gas Higher Heating Value * Natural Gas Load Factor.
  • the Natural Gas Load Factor is stored in a database and converts from SCFH (standard cubic feet per hour) to a percent (dimensionless number) of the burner load (see step 758).
  • step 766 a similar step can be used when #6 oil is being used.
  • Adjusted Gross Heat Input Rate 1000/60 * Gross Heat Input Rate / #6 Oil Higher Heating Value * #6 Oil Load Factor
  • this factor is stored in a database and converts gpm to a percent of the burner load (step 768). This factor is often fixed at 32.26 (step 770).
  • the firing rate (step 754 of FIG. 7A) until the stack temperature and flue gas oxygen content, (and as a result the calculated boiler efficiency) change to match the required burner heat input necessary to match the desired steam quality.
  • the actual sampled steam quality may be compared to the predicted or desired steam quality. Any difference can be used to create a correction factor to compensate for inefficiencies in the system and error in the algorithm. So, if it is predicted that the steam quality would be 90% but it is in fact 88%, then a correction factor can be entered in the control system for adjusting for this 2% error. This would increase the burn rate by an appropriate amount to obtain the desired 90% steam quality.
  • control system may use the measured steam flow in main steam
  • header pipe to estimate what the current quality of the steam is.
  • the feedwater flow rate is measured and the steam is sampled to determine its quality and a curve is generated throughout the operating range plotting pressure differential across the steam flow element versus quality as measured. From this curve, an estimated steam quality is displayed on the GUI or HMI and allows the operator to have an estimation of whether the steam quality is within desired parameters. If there is a difference between the estimate and actual tested steam quality, then an adjustment may be made to the burn rate.
  • a correction coefficient can be entered into the control system to help correct for predictive error with respect to this algorithm so that it is more accurate and adjust the burner rate as needed. This error may be a result of or related to energy losses within the system and is typical with such systems. Nevertheless, it is recommended that the operator periodically check the actual steam quality using quantitative steam quality measuring instruments. This process could also be automated so that the algorithm self corrects itself on regular intervals.
  • this process may be changed depending on the amount of accuracy needed for a particular application. Therefore, one or more of the variables just described may be omitted or substituted for or an additional variable may even be added depending on the situation. It is contemplated that this algorithm and associated process could be thus varied as long as some sort of model is used that takes into consideration the heat balance of the inputs and outputs of the steam generating system.
  • the flow rates of the fuels and air may be linked so that their individual control is rendered unnecessary. For example, a mechanical control may link the fuel flow rate to the air flow rate such as the use of linkages or this could be done electronically.
  • the GUI or HMI of the control system may provide graphical information on the following process parameters including, the radiant section tube metal temperature 270, the main steam header temperature 251, feedwater pump outlet pressure 230, feedwater pump outlet temperature 238, extended surface economizer feedwater inlet pressure 242, extended surface economizer feedwater inlet temperature 244, extended surface economizer feedwater outlet temperature 254, bare tube section feedwater inlet temperature 256, radiant section feedwater inlet pressure 262, radiant section feedwater inlet temperature 264, and stack temperature 250
  • more or less parameters could be displayed and/or available for input by a user through the GUI or HMI as desired depending on the application.
  • a control system that is used with the apparatus to implement any of the methods discussed herein may include an input device that may include any number of devices or methods currently used or that will be devised in the art such as a keyboard, a mouse, a touchscreen, voice recognition, etc.
  • an input device may include any number of devices or methods currently used or that will be devised in the art such as a keyboard, a mouse, a touchscreen, voice recognition, etc.
  • output devices may be used that includes those currently used or that will be devised in the art such as a display screen, flashing lights or other visual displays or cues, audible alarms, etc.
  • control systems may be employed including a PLC, a distributed control system (DCS), a gate array logic system, a mechanical system including those that use mechanical linkages, a hard wired logic system, a microprocessor, a microcontroller, a PC that includes customized software that is configured to execute an algorithm and/or associated method, etc.
  • any of the routines, algorithms, methods or processes described herein may be accomplished absent a formal control system such as may be the case when one or more operators are acting in concert.
  • the algorithm, processor-executable code or instructions may be stored in the PLC or in the memory of the control system for execution on the PLC or the processor to perform the operation, routine, process or method.
  • the display language can be English or any other desired language.
  • the feedwater pump motor may be made by TECO WESTINGHOUSE and have the following specifications: one hundred horsepower, 480 VAC with three phase at 60 Hz, 1200 RPM and it may be totally enclosed and fan cooled.
  • the pump itself may be made by NATIONAL OILWELL under model # 1100-3M and it may include the following specifications: a design or preferred allowable pressure output of 1742 psig, a maximum allowable pressure output of 2295 psig, a output temperature of 200 degrees F, a design or preferred allowable output flow rate of 48 gallons per minute and a maximum allowable output flow rate of 57 gallons per minute.
  • the steam generator is cable of producing a heat output of 25.0 MMBTU per hour, includes a design pressure of 1760 psig and is designed, fabricated and stamped in accordance with ASME Boiler and Pressure Vessel Code Section I, Latest Edition.
  • the steam separator that is used in conjunction with the bleed-off subsystem may be made by SPIRAX SARCO under model # 4 inch SC4 Special. It may be made using SA-106 GR. B steel, maximum allowable working conditions of 300 psig and 650 degrees F, and the associated inlet and outlet connections are made using 4 inch Class 300 RF flanges.
  • a separate steam separator may be used in conjunction with the steam quality measuring subsystem that is installed in or as a side stream of the main steam header supply pipe.
  • a device known in the art as a sample cooler is used to cool the steam sample to enable steam sample analysis.
  • the steam quality measuring subsystem may be supplied with a shell design pressure of 285 psig, a cooling water design flow rate of 5 gallons per minute, and a stainless steel coil design pressure of 3500 psig.
  • the outputs from the delivery system are as follows: the normal injection pressure to a steam injection well is 1500 psig, the maximum desirable design pressure is 1760 psig, the normal temperature is 598 degrees F, the maximum desirable design temperature is 619 degrees F, the normal flow rate is 24,000 lb per hour, the maximum allowable flow rate is 24,314 lb per hour and the desired steam quality may range from 0 to 90% but is in fact often within 80-90%.
  • the output to the blowdown tank or venting reservoir includes a design pressure of 300 psig, a design temperature of 619 degrees F, and a design flow rate of 24,000 lb per hour.
  • the output of condensed water to the feedwater heater includes a design pressure of 250 psig, design temperature of 406 degrees F, and a design flow rate of 2,100 lbs per hour.
  • the output of steam to the fuel oil heater includes a design pressure of 150 psig, a design temperature of 375 degrees F, and a design flow rate of 200 lb per hour.
  • the output of steam to the feedwater heater includes a design pressure of 150 psig, a design temperature of 375 degrees F, and a design flow rate of 3,040 lb per hour.
  • the output of atomizing steam to the oil burner includes a design pressure of 150 psig, a design temperature of 375 degrees F, and a design flow rate of 200 lb per hour.
  • control system and the present disclose of certain embodiments are not to be construed to any system, inputs, or outputs or values disclosed herein but is suitable for many different combinations of equipment and for various design parameters, operating conditions and specifications. Thus, the claims should not be limited to any specific embodiment disclosed herein.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Control Of Steam Boilers And Waste-Gas Boilers (AREA)

Abstract

La présente invention concerne des appareils de production de vapeur et d'alimentation en vapeur ainsi que des systèmes de commande associés. La présente invention se rapporte en particulier à des appareils de production de vapeur et d'alimentation en vapeur ainsi qu'à des systèmes de commande associés qui sont utilisés pour une récupération d'huile améliorée. Certains modes de réalisation comprennent des procédés et des systèmes de commande associés liés au démarrage ainsi qu'à la commande d'un collecteur à pression de vapeur principal ou au maintien d'une qualité de vapeur souhaitée pour de tels systèmes de production de vapeur durant un fonctionnement normal.
PCT/US2013/060788 2013-09-18 2013-09-20 Appareil de production de vapeur et système et procédés de commande associés Ceased WO2015041660A1 (fr)

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US14/030,667 US9383095B2 (en) 2013-09-18 2013-09-18 Steam generation apparatus and associated control system and methods for providing desired steam quality
US14/030,656 2013-09-18
US14/030,618 2013-09-18
US14/030,666 US9310070B2 (en) 2013-09-18 2013-09-18 Steam generation apparatus and associated control system and methods for providing venting
US14/030,666 2013-09-18
US14/030,656 US9303866B2 (en) 2013-09-18 2013-09-18 Steam generation apparatus and associated control system and methods for providing a desired injection pressure
US14/030,667 2013-09-18
US14/030,618 US9303865B2 (en) 2013-09-18 2013-09-18 Steam generation apparatus and associated control system and methods for startup

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CN109114539A (zh) * 2018-08-27 2019-01-01 清华大学 一种锅炉系统及其失电保护方法
CN109114539B (zh) * 2018-08-27 2023-11-07 清华大学 一种锅炉系统及其失电保护方法
CN111247602A (zh) * 2018-09-28 2020-06-05 原子能技术科学研究设计院股份公司 用于把核电厂紧急情况之后转入安全状态的方法和系统
CN111247602B (zh) * 2018-09-28 2023-11-03 原子能技术科学研究设计院股份公司 用于把核电厂紧急情况之后转入安全状态的方法和系统

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