CN110769915A

CN110769915A - Method and system for solid particle removal

Info

Publication number: CN110769915A
Application number: CN201880019068.0A
Authority: CN
Inventors: 克里斯·丹顿; 费德里可·卡洛斯·雷斯奥
Original assignee: Calandra Resources
Current assignee: Calandra Resources
Priority date: 2017-01-18
Filing date: 2018-01-17
Publication date: 2020-02-07
Also published as: EP3570958A4; EP3570958A1

Abstract

The present invention relates to a system and method for separating a solid particulate component from a fluid. The present invention uses mechanical filtration, solids decantation, and a novel combination of real and imagination. The invention comprises a spherical vessel with a tangential inlet to introduce fluid, and a fluid discharge and filter arranged on the centerline of the interior of the vessel. The combination of pressurized fluid and solid particles enters the present invention at the tangential inlet and will move primarily in a circular path around the interior of the vessel. The path of the fluid and the solid particle mixture in the circular path will cause a larger mass of particles to settle at the lower region of the vessel. The smaller mass particles may be entrained in the exhaust fluid flow, toward the filter element, where they are removed from the exhaust fluid.

Description

Method and system for solid particle removal

Cross reference to related applications

This application requests the benefit of U.S. provisional application No. 62/618,325 filed on 17.1.2018; U.S. provisional application No. 62/618,325 requests the benefit of 62/447,749 filed on 18/1/2017; U.S. provisional application nos. 62/618,325 and 62/447,749 are incorporated by reference in their entirety.

Technical Field

The present invention relates to separators used in oil and gas well completion and production operations, and more particularly to generally spherical separators particularly suitable for use in separating solid materials from high pressure, high velocity fluid streams encountered at hydrocarbon well heads (wellheads) or equivalents.

Background

For over 100 years, the extraction of oil and gas from underground locations rich in hydrocarbons has been mainly carried out by: spalling, drilling or otherwise in vertical holes in the earth's surface to reach (access) oil and gas rich areas. These hydrocarbons have played a key role in economic and technological advances throughout modern civilization, and provide energy, transportation fuels, and chemical precursors to fertilizers, materials, pharmaceuticals, and myriad other chemicals and technologies.

However, extracting hydrocarbons has become more difficult and technical due to the need for drill bits to reach deeper and more difficult reservoirs and to deliver larger quantities of hydrocarbons from each reservoir. Advanced methods to increase extraction include chemical means such as surfactants and solvents in injector wells, and steam assisted gravity drainage or SAGD, to name two of several examples. In addition, many wells use horizontal drilling techniques, wherein after thousands of feet have been drilled vertically to reach a rich zone, a drilled well bore (well bore) or hole is further drilled substantially horizontally, developing a well bore or hole in the horizontal zone.

Additional methods include mechanical and chemical techniques, such as hydraulic fracturing. Hydraulic fracturing or fracturing (fracking) involves the injection of large volumes of a mixture of high pressure fluids and solid particles into wells, opening existing fractures and fissures, and possibly even creating new fractures and fissures, thereby increasing the volume of oil or gas from each well or allowing existing wells to be produced for longer periods of time.

Typically, these oil, or gas wells, which may be enhanced by hydraulic fracturing, produce not only gas and oil, but also water, other liquid impurities, and particulate solids, collectively referred to as fluid streams. The source of the undesirable solid contaminants may be from the hydrocarbon-rich rock formation (formation) itself, or from added materials such as frac proppants, e.g., ceramic spheres or sand. The size of the solids will vary from high diameter particles and particle aggregates, which may be nominally greater than 0.1 inch in diameter, to very small diameter particles and particle aggregates, which may be less than 0.005 inch in diameter. Proppants are typically used in conjunction with large volumes and pressures of additive-containing fluids to enlarge existing fractures in the formation and to "prop open" the fractures. The purpose of the liquid additive is to increase, among other things, the viscosity of the fluid so that it will better transport the proppant to the end of the fracture. Once the fracturing process is complete, at least a portion of the additive-containing liquid or gas or combination will be returned to the wellhead through the wellbore, often at high pressure. Whether the material is from a hydrocarbon-rich rock formation or from a solid material (such as various types of proppants), they are referred to herein as "sand" or a "solid particulate component" unless otherwise specified.

The combination of the solid particulate component with the fluid stream, particularly at high pressures, will cause surface corrosion or deterioration in oil and gas well components (e.g., wellheads, valves, fittings, etc.). Corrosion caused by the presence of solid particulate components in the fluid stream can cause equipment damage, including system failure. System failures can cause significant property and even human life loss. Furthermore, these solid particulate components also contaminate further processing and can cause significant equipment degradation in a short time.

In general, sand separation systems exist to separate solid and solid particulate components from a liquid stream or from a gas stream or from a combination of liquid and gas streams (and will be referred to as a fluid stream to describe any combination of gas, oil, water, and solids). The system may be spherical, cylindrical or conical, or a combination of cylindrical and conical, with the most common orientation being with the long axis of the system in the vertical direction. The size of the conventional fluid and solids separation system is selected to allow the fluid stream to undergo a velocity drop large enough to facilitate solids removal before the fluid stream exits the (exit) separator. In some separator systems, impingement plates may be added in-situ (intertally) for high velocity solids and fluids to impinge.

Historically, these primarily cylindrical or conical separator systems have been effective when the inlet (inlet) fluid stream has a generally low velocity and relatively low fluid flow rate. Additionally, the fluid stream often has a low proportion of solid particles to the total volume of the fluid, and the solid particle components are approximately the same size. In the case of particle addition (e.g. for hydraulic fracturing), the particle diameter is selected to be appropriate for a given well. At higher fluid velocities and larger distributions of solids sizes, these conventional separators significantly lose the efficiency of solids separation. These systems are not suitable for high velocity fluid streams containing large quantities of variable sized sand and water compositions most often encountered at or near the wellhead. The higher the velocity of the incoming (entraining) fluid and the smaller the solid size, the greater the relative drag on the moving fluid and particles. In this high velocity, small particle size environment, a standard separator will not function effectively and will not remove a large portion of the solids.

In order for a conical or cylindrical sand separator to operate safely at pressures in excess of 10000psi, the wall thickness of the separator may be, for example, more than 3 inches thick of steel. As a result, the size, weight, materials, and cost of such systems become impractical, unmanageable, and costly.

There is a need in the industry for a system that: the system can efficiently separate a wide range of solid particle sizes from a high volume high velocity stream in a small and light package, made of less expensive materials. The separator system of this invention addresses these historical shortcomings.

Disclosure of Invention

We describe a vessel, the interior of which (interior) and associated piping connections (tubing), piping connections (piping), flanges, fittings and filters are used to separate solids from a fluid stream. The fluid may be various liquids or various gases or a combination of liquids and gases. The container and its associated subsystems are installed in relatively close proximity to the oil or gas well outlet (known as the wellhead) and are therefore exposed to the maximum pressure of the well or close to it. The invention is constructed to utilize a combination of real (real) and apparent (apparent) mechanical forces, including gravity and centrifugal forces, and from time to time and if desired, mechanical filtration to separate solid particulate components from fluids. The aforementioned forces, separator means and, if desired, mechanical filtration will cause larger solids to settle and remain at the bottom of the interior volume of the vessel, and the filter will also remove some of the remaining smaller particles, if used, and will cause the discharge fluid to be substantially free of solid particles. The presence or absence of subsequent mechanical filters should not typically be limiting, and those skilled in the art will recognize that most of the filtering occurs within the shell (enclosure) of the sphere. The combination of separation techniques allows the system to handle a wide range of solid sizes, a wide range of fluid compositions, and the efficiency of the separation will be less sensitive to fluid velocity.

The solid particle separator has a predominantly spherical inner volume. The outer portion (exteror) may also be spherical, but may be other geometric shapes as warranted by the particular use, by manufacturing techniques, and one skilled in the art will recognize no effect on the inner surface, function or volume. Further, the interior may be of the following geometry: smooth, regular, and wider in approximately the central region and narrower at non-equatorial regions, including geometries such as elliptical and smooth biconic shapes. Furthermore, all diameter transitions are smooth and regular. The usual location for installation and use is at or near the wellhead of an oil or gas well, but this should not be limiting as the separation effect is independent of the layout.

The solids separator may be installed as a single separator, or any number of separator systems may be used, with two in parallel as a conventional configuration, but many arrangements of separators may be used, and the particular arrangement of separators is not limiting and will be appreciated by those skilled in the art. The inlet ports are arranged about a horizontal plane and are conventionally located slightly above the equator or mid-plane (midplane) of the sphere of the separator and tangential to the interior surface of the sphere. This allows the inlet fluid and solids mixture to travel in a roughly disc-shaped flow pattern (flow pattern) upon entering the interior region of the separator. The angular velocity of the mixture is determined in part by: the inside diameter of the inner region at the inlet level, and the velocity and also the viscosity of any incoming fluid.

Although the invention is generally described as being positioned behind a hydrocarbon wellhead, the wellhead may mean any source of fluid, including an oil well, a gas well, a mechanical pump out circuit, or any source of fluid that may be input to the device.

Particles entering the sphere primarily tangentially will experience various real and apparent forces including, but not limited to:

gravity, since the particle will only have a horizontal velocity, the weight of the particle will cause it to move out of the horizontal plane generally and begin to move to the lower portion of the sphere;

centrifugal forces, since the fluid and particles entering the sphere generally tangentially will have the angular velocity of the particles, which will cause a centrifugal force that will move the particles to the wall of the sphere; as the initial plane of rotation is primarily above the horizontal mid-plane, the particles will be caused to slide down following the expanding slope of the wall, either while the particles are in contact with the internal (inner) spherical surface or after the particles are in contact with the internal spherical surface; and

coriolis forces because angular movement in the horizontal plane can cause an apparent force to be exerted on the particle, which will affect the particle in a downward direction.

Those skilled in the art will recognize that the name and description of the forces and the amount of each acting on the particles is in no way limiting on the scope of the invention.

The solids separator system includes a predominantly spherical interior volume, which is alternatively known as an ellipsoid of revolution with a single focal point (ellipsoid of revolution), but which may also be an ellipsoid of revolution with two focal points, or an ellipsoid of revolution with a non-ellipsoidal shape, or a combination of smooth conical features with ellipsoidal or spherical features. When the interior is described as spherical, it will be recognized by those skilled in the art that it ranges in shape from spherical to ellipsoidal to ovoid volumes, with the general feature that the center is larger than the pole.

The solids removed from the fluid may be: natural sand from the formation, or fractured sand, or fractured proppants (in the form of, for example, ceramic particles), or drill cuttings (or other solid particulate components), which have been added as part of the development of the well, or which naturally occur in the area prior to drilling, or a combination of both. Further, these solid particulate components may be single particles, or may be aggregated into composite particles connected by chemical means, electrostatic means, combinations, or other means. This configuration of solid material is entrained in the fluid, as hereinafter referred to as the solid particulate component, and those skilled in the art will recognize that these descriptions should not be limiting, and that any entrained solid particulates or solid aggregates will be referred to as particulates or collectively as particulates. Also in this case, fluid refers to liquids encountered at the well (such as water, oil, or other liquids), and refers to gases (such as naturally occurring methane, added carbon dioxide, or other non-liquid, non-solid materials). The fluid may also be referred to as a sublimating material.

Once the fluid and solids (in the form of particles or aggregates of particles, or in the form of other configurations of solid material entrained in the fluid stream) emerge from the wellhead, they enter the separator via an inlet (entrance) port or conduit positioned slightly above the mid-plane of the interior sphere volume and positioned tangentially to the interior surface of the sphere volume.

Once the high pressure fluid and particles are introduced tangentially into the volume of the separator, the fluid and particles are in a predominantly circular path. The force will cause the solid particles to move in a generally radially outward and downward direction.

Particles that become proximate to the interior surface of the separator will migrate to the lower section of the sphere due to one or more effects of the force exerted on the particles.

Some particles may remain entrained in the fluid flow and may be separated from the exhaust fluid by means of an additional filter through which all of the exhaust fluid traverses.

The fluid outlet is substantially at the central top of the separation device. The moving fluid and any entrained solids will exit the sphere through the exit. The solids (acted upon by the fluid and moved by the fluid to the center of the sphere) will be filtered with a dedicated filter, either inside the sphere (internal) or outside the sphere (external), with the preferred embodiment having a filter outside the sphere. The fluid (carrying the still entrained solid particles) will impinge on the filter and be transported through the filter.

Generally, the filter is cylindrically constructed with the long axis arranged in line with the fluid flow direction. Typically, the fluid is transported across the surface of the filter device. The fluid may be carried either outwardly from the inner surface or carried and moved inwardly from the outer surface. The filter may be positioned in various locations without altering the operation of the invention or altering the invention. The filter may be contained within the interior and typically more or less arranged on a polar axis extending from one interior surface to the interior of the sphere of the spherical separator, or further contained in a structure having an inner diameter greater than the outer diameter of the filter element and operating outside the separator. Further, the separator may be used with or without a filter element.

The input port, which is most often arranged slightly above the mid-plane and positioned tangentially to the interior surface, allows a flow of high pressure, high velocity material to be introduced into the interior volume of the separator. This allows the high pressure combination of fluid and solid to be launched in a trajectory slightly above the mid-plane. However, the input may be at the midplane or below the midplane.

Various techniques common to metal fabrication may be used to join the segments of the separator device, including using welding techniques to permanently join portions of a sphere that has been forged, machined, or otherwise constructed. Additionally, the separator may be constructed using bolts, flanges, etc. to join various portions of the separator body. Furthermore, if the device is manufactured in two sections, those two sections can be connected by using threads. Those skilled in the art will recognize that the method of attaching the separator, if any, will not limit its use, operation or function. Further, if a filter is to be attached, it may be attached using a threaded mating member, but one skilled in the art will recognize that the filter may be secured using one or more of several means including threads, bolts, flanges, mounts, retainers, etc., and this is not a limitation of the present invention.

The present invention is designed in materials and techniques to allow its use at wells, wellheads, and other fluid and pressure sources. The present invention can be used at pressures from several hundred psi to pressures in excess of 20000 psi. In addition, the device may be sized to best accommodate the range of pressures, viscosities, and solids encountered. The internal volume can range from a size of less than 10 cubic feet to a size of greater than 40 cubic feet. The particular dimensions will be selected to function optimally under the introduction pressure and composition. In addition, the inlet port size is selected to accommodate the incoming pressure and composition in addition to the existing fitting, tubing and piping dimensions encountered at the point of use. Common sizes for the inlet port size range from less than 0.5 inches to greater than 5 inches. The inlet port offset may also be selected to best accommodate the pressure, viscosity, chemistry and solids encountered at the point of use. Common offsets may be less than 0.5 inches and greater than 10 inches. Both the lower and upper ports may be a range of sizes to accommodate pressure, flow, solids content, and other parameters. Common port sizes may range from less than 1 inch to greater than 8 inches.

The present invention can be used in parallel to increase throughput (throughput) or effectively reduce pressure in each unit, and can be used in series with the same apparatus or differently sized apparatus to maximize filtration efficiency, and this is not a limitation.

Drawings

The features of the invention believed to be novel are set forth with particularity in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:

figure 1 schematically shows the invention with a single sphere.

Figure 2 schematically illustrates the invention with two separators operating in parallel attached to a single wellhead and multiple valves.

Figure 3 shows a side view of the separator with the inlet both above the central plane and tangential to the interior of the vessel.

FIG. 4 is an additional view of an access port showing its tangential entry and position above the mid-plane of the separator, the separator including an input flange with a through hole and a central open port.

FIG. 5 is a top-bottom cross-sectional view of the separator, with the ports shown entering generally tangentially to the interior region.

FIG. 6 is a schematic illustration of the particle path within the separator.

Fig. 7 shows a chamfer or chamfer to facilitate joining the portions of the ball together using a butt weld.

Fig. 8 shows an ideal plot of angular momentum versus radial distance from the center of the chamber.

Fig. 9 shows a detail of the filter unit.

FIG. 10 is a detail of a cross section of the separator, including the location of the recovered sand.

FIG. 11 is a schematic of the potential real and apparent forces on a sample particle, including gravity, centrifugal force, and Coriolis force.

Figure 12 shows a separator, two outer filters and a plurality of valves.

Detailed Description

While the present invention has been particularly shown and described with reference to preferred and alternative embodiments, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.

The apparatus of this invention is designed to separate the particulate solid component from the high pressure, high velocity fluid stream. As used herein, fluid and fluids are understood to be the non-solid portions of the material entering the separator and may include liquid and return fluids (like water, brine, solvents, surfactants, and hydrocarbons) and may be vent gases (like naturally occurring natural gas) or added gases added to the well in either the liquid or gas phase, such as fracturing or return additives or adjuvants or other materials, and all such variations are contemplated as being found within the operating specifications of the present invention. As used herein, solid particulate components are understood to be solid phase materials and aggregates entrained by the movement of fluid entering the separator. The fluid includes water, chemicals, gases, and solids. The apparatus is designed to handle high flow, high velocity and high pressure fluid and solids streams while maintaining effectiveness in the separation of solid particles. During continuous operation, the composition of the fluid entering the separator may change from a fluid containing a predominantly liquid-based component with minimal gaseous components, and then to a fluid stream comprising a predominantly gaseous fluid with lower amounts of liquid entrained in the fluid transport.

At high pressures or high fluid flow rates, or both, the solid particulate component is entrained in the fluid stream and generally travels with the flow of the high pressure and high velocity fluid. The particles may have an overall velocity that is less than or greater than the average fluid flow velocity. This flow of untreated and unseparated fluids and solids can cause a great deal of damage and corrosion on the interior surfaces of the equipment. The ordinarily skilled artisan will recognize that a substantial portion of the entrained solids are fractured proppants and naturally occurring formation particulates, and it is contemplated that all such variations of particulate compositions are found within the operating environment of the present invention. The present invention may operate at all pressures conventionally encountered at a well, but if future well pressures are found to be greater, it is expected that the present invention will operate at greater pressures. In addition, the device is also expected to operate at lower pressures. There is a general relationship between the introduction pressure and the size of the vessel.

This invention comprises a vessel having a generally spherical inner region or cavity into which the vessel will admit a high pressure and high velocity stream of fluid and solid particles. In the examples, the vessel is known as a separator. Unlike other solid particle separators, this device does not use any baffles or deflector plates or other additional devices to reduce fluid and particle velocity. This separator uses natural fluid flow and principles associated with angular momentum and other real and apparent forces to separate particles from the fluid flow.

Referring to fig. 1-12, the present invention includes a solid particulate component removal device that separates solid material from a fluid stream, referred to herein as a separator, installed adjacent to and downstream of a wellhead, and upstream of other support equipment, such as a throttle manifold or other in-line equipment. The solid particulate component separator causes solid particulates and particulate aggregates to migrate to a substantially lower region in the separator apparatus, the solid particulates and particulate aggregates being derived from a fluid stream, the fluid stream comprising a high pressure high velocity fluid stream. Particles with a mass greater than a threshold amount are collected in the bottom of the device, and the collected particles can be removed or extracted by means of a removal port, valve, device or architecture (schema) typically on the bottom of the device. Any particles remaining entrained in the fluid stream may be separated by means of a mechanical filter external to the body of the separator.

Throughout this invention, the valves are generally included in pairs to effectively isolate sections of the device, to modify the filter elements, to modify the separator device to remove sand and other particulates, and to facilitate the aforementioned modifications and other changes without causing the well to be shut in or shut off, or for high pressure fluids or solids to exit the system in an uncontrolled manner, although they should in no way be construed as limiting on the invention and are simply included as one non-limiting embodiment.

Fig. 1 shows a separator device 10, the separator device 10 comprising an inlet port flange or connection surface 11, an inlet pipe or conduit 12 with a penetration into a sphere 13. In addition, a solids removal or outlet (outlet) line and port flange 14 and a fluid discharge flange 15.

Following primarily the wellhead and associated hardware, the solid particulate component separator removes a large mass range of solids, including those removed by means of mechanical and apparent forces, higher angular momentum and gravity, and those lighter solids removed by mechanical filtration.

Figure 2 schematically shows a plurality of separators used in parallel and a plurality of connecting and isolating valves. Two separators are indicated, but one skilled in the art will recognize that any number of separators may be used. The introduction of fluids and solids through inlet 20 and through manifold 21 allows the use of multiple separators. The separators may be isolated by valves 22 and 22', 23 and 23' and also 24 and 24', all of which may shut down incoming or outgoing material for ease of repair, adjustment or replacement, and further may isolate the separators, allowing for maintenance or use and replacement of the separators. The port 13 is generally at the midplane 25 or above the midplane 25. It will also be appreciated that any effective number of separators may be arranged in series, in parallel, or in a combination of series and parallel, and that the particular number in use is not limiting, and that the valves, fittings and flanges are simply one embodiment and should not be construed as limiting.

Before the fluid enters the separator, there may be a plurality of valves, manifolds and associated equipment conventionally found at the wellhead, including a manifold 21, a valve 22, a discharge valve 23 and a discharge manifold 25, which are shown schematically. It should be recognized by those of ordinary skill in the art that any associated equipment other than the invention herein is included or omitted without altering the invention or its use. Valve 22 serves to direct or control the flow of fluid to the separator. Those of ordinary skill in the art will recognize that valves 22 and 22 'are representative in nature and that additional wellhead equipment is conventionally present between the wellhead and the separator, and that valves 22 and 22' are not intended to represent a complete installation, but merely illustrate that the separator may be isolated as desired.

Solids can be removed by opening valves 24 and 24', most commonly when valves 22 and 22' and 23' are closed, to allow solids removal without an associated high well pressure. In addition, fig. 2 shows upper filter isolation valves 27 and 27', an outer filter 28, and lower filter isolation valves 29 and 29'. The inclusion of an external filter is one embodiment and should not be construed as limiting as the invention may be used with or without a filter and the filter, if used, may be internal or external.

Fig. 3 shows an inlet port flange 11 which allows a source of fluid and solids to be connected to the interior of the separator via an inlet line 12 and to penetrate into the interior of the separator via an inlet line aperture 13. The separated solid material may be removed through the separator ball opening 32 and continue past the bolt surface 33. Separator sphere 34 has both an interior surface 35 and an exterior surface 36. The separator has a mid-plane 37 with the inlet port members 11, 12 and 13 at or generally above the mid-plane 37. The upper bolt surface 38 is the surface on which additional manifolds and other equipment through which pressurized fluid may be exhausted are mounted. Particular mounting configurations may include machined mounting surfaces and bolt holes, piping and flange systems, or other methods of attachment, and should not be construed as limiting.

Further, the separator includes a high pressure, high fluid volume vessel. The separator includes an outer surface 36 and an inner surface 35, and the inner surface 35 may be spherical, approximately spherical, elliptical, oval, or other geometric shape, wherein the area near or around the midplane has a larger diameter than the area closer to the upper and lower port penetrations. Those skilled in the art will recognize that the surface geometry does not materially affect the separator function. The required penetrations include: inlet port systems 11, 12 and 13 (to introduce high pressure high volume fluid and solid particulate components into the separator), fluid discharge bolt surfaces 38 and fluid discharge penetrations 39, and collected particulate extraction ports 32 and mounting surfaces 33. Other penetrations may include, but are not limited to, a pressure sensing port, a fluid velocity sensing port, and a particle level detection port, none of which are important to the operation of the separator.

The separator vessel 34 is constructed from and by the following such materials: the materials and processes will provide suitable structural integrity to withstand the expected pressure ranges and exceed those pressures at the wellhead without the need for systems or equipment (such as chokes and other devices) to reduce the induced pressures that are often encountered on and significantly limit the use of other types of separators and which can damage the well. The separator input systems 11, 12 and 13 are generally tubular and generally horizontal with respect to the mid-plane of the separator. The separator input is more or less tangential to the interior of the sphere. The separator input is arranged substantially at or above the median plane 37 of the separator. The input tubular structure 12 extends from the body of the separator 34 to a distance that will allow for convenient connection to associated well hardware. The input end 11 has a sufficient diameter to allow sufficient flow velocity and material velocity within the separator to effect separation. The inside diameter of the pipe 12 may range from a fraction of an inch to several inches, with a 2 inch inside diameter being a common size.

The solids removal penetration 32 at the lower section of the separator allows for removal and disposal of the solid particulate component after a suitable amount has been collected. The solids collected may comprise dry particles, or may comprise solids and liquids, slurries or other collected materials prior to extraction. The collected solid material refers to those particles that have generally rested in the lower portion of the separator and are not in general motion, although it will be clear to those skilled in the art that some degree of solids motion is possible and does not alter the operation of the apparatus. Alternatively, the lower portion of the vessel may comprise an architecture for continuous or semi-continuous removal of solids from the separator. It will be apparent to those skilled in the art that the present invention remains generally unchanged in any embodiment, and is not limiting.

One preferred embodiment has the following dimensions, but those skilled in the art will recognize that the dimensions may be varied without adversely changing the functionality of the separator. Further, a representative embodiment is described, but it should not be a limiting factor, as other sizes will work equally well. The inlet port 11 from fig. 3 is about 3 inches above the horizontal midplane. The outer radius is approximately 23 inches and the inner radius is approximately 20 inches. The initial surface of the fluid inlet was 26 inches from the centerline. The separator is approximately 50 inches high, on a central vertical axis, from surface 33 to surface 38, including the build area for the fittings. The central bore (bore) of the inlet pipe is about 19 inches from the midplane. The upper fixed surface construction area is about 14 inches in diameter and the lower fixed construction area is about 8 inches in diameter.

The separator has materials and bonding techniques suitable to withstand the pressures encountered at the wellhead. The nominal wall thickness is about 3 inches, but this is not a limitation, and the separator may be constructed with a wall thickness to correspond to the particular pressure encountered at the point of use. The wall thickness will need to be in the range of available sources, production and manufacturing. Well pressures will range from a maximum generally known as the shut-off pressure to zero, and may range from below 500psi to over 20000 psi. The vessel wall thickness, coupling specifications, fasteners and fittings will be sized to accommodate the particular pressure, and those skilled in the art will recognize that accommodating changes in pressure will not alter the separator or operation of the invention, and that different points of use will correspond to different operating pressures.

Fig. 4 provides an additional illustration of the exterior of the separator vessel, attracting attention to the tangentially arranged inlet system, which comprises a connecting surface 40 with a connecting point 42 through the interior 41 of the inlet conduit, which connecting surface 40 is arranged substantially above the mid-plane 37 of the separator. This is but one embodiment of a large number of connection architectures and should not be viewed as limiting. The location and placement of the fluid inlet offset is determined by the separator size, fluid properties, pressure, and viscosity of a given well and is not limiting. The fluid and solid particulate components are transported from the wellhead to the separator vessel by conventionally used equipment, piping connections and equipment. The separator may be supported directly on the valves, manifolds and fixtures below the separator, or may be supported by a bracket, by legs structurally attached to the separator, or by chains or cables supporting the separator, or by other support means. As will be appreciated by those skilled in the art, the method of support does not alter the function of the separator. The separator may be on a moving carriage or other system designed to be transported from station to station and installed in a moving environment as a trailer or track, and those skilled in the art will recognize that this is not a functional limitation of the present invention. One of ordinary skill in the art will appreciate that the securing and mounting does not alter or add to the elements of operation. The fluid is essentially (essentiaily) directed from the wellhead to the separator. Manifolds, tubular structures, and valves, as well as other systems encountered at well sites, may also be brought online or integrated with the separator, and those skilled in the art will appreciate that these components do not alter the operation of the separator. The solid particles are removed through a port 33 at the lower portion of the vessel. During operation, the extraction zone is sealed to allow the separator to operate at normal operating pressures encountered at the wellhead.

The collected particles can be removed through an opening to allow solids to be extracted when pressure is isolated from the ball by valve 22 and through port 32. The upper region of the ball includes a mounting system and mounting surface 38 to maintain and support the filtration system and fluid drain port 39. After the fluid and solid particles have entered the separator through the port 11 and have been acted upon by the separator, the solid material is mainly stationary in the lower region, waiting to be collected and removed through the opening 32. The lighter particles remaining entrained in the fluid are removed by the filter element, which may be positioned either inside or outside the sphere. The filter element is arranged to be removed for cleaning, maintenance and replacement. Container fittings and fixtures for use with filters include threaded openings that allow installation and removal using threads or clamps or bolts or other securing mechanisms. Those skilled in the art will recognize that the particular means for attaching the filter is not important to separator performance, and that a wide range of securing systems may be used without altering the inventive concept.

Fig. 5 shows a top-bottom view cross-section of the vessel more or less above the mid-plane, highlighting the tangential inlet port flange 30, the inlet pipe 31 and the separator penetration 13, which are arranged mainly above the horizontal mid-plane. The solid particulate component entering the separator will contact the inner surface of the separator, for example, in or around region 50. The particles will generally move in the path 51.

Figure 6 shows a generalized section of the separator. During such transport, the particles 60 will both move around the sphere and will generally move to a larger radius of the sphere. Because the particles 60 are generally introduced above the mid-plane, the particles will move to a region of larger inner diameter. When the particles first move to a larger vessel diameter by traveling along the expanded wall diameter 62, the particles 60 will travel in direction 61, contacting the vessel interior surface 35, until the particles are generally at the mid-plane, which is the region of maximum vessel diameter. As the particles 60 move to the larger diameter region, the momentum of the particles will decrease and additional forces, including but not necessarily limited to gravity, will help move the particles to the generally lower region of the separator. As the particles move to the lower region of the separator, progressively less energy from the moving fluid is imparted to the particles. Eventually, most of the particles will become more or less stationary and collect at the lower region of the separator.

Fig. 7 schematically shows two halves of a sphere with a weld bevel 70 arranged generally at the mid-plane of the separator, including one half from the side of the upper chamber half 71 and one half from the weld bevel of the lower chamber portion 72. For production, the vessel includes two or more sections that are welded or bolted or otherwise joined to provide an essentially featureless vessel interior. Although fig. 7 schematically indicates two halves 71 and 72 and a weld bevel 70, those skilled in the art will recognize that more than two pieces may be assembled to create a separator vessel, and that methods other than welding may suitably join subsystems, including but not limited to bolting, threading, friction-fitting, press-fitting, riveting, or other suitable joinery methods. Further, the method of manufacturing may include constructing from a substantially single piece of material. The method of fabrication is not limiting and those skilled in the art will recognize that the present invention is independent of the method of construction and the method of fabrication.

Fig. 8 shows a velocity profile where there is a region a of low angular velocity for the fluid and particles near the center of the chamber, a region B of greater angular velocity as the particles are less near the center of the separator, a region C of reduced angular velocity and a region D of maximum angular velocity.

Generally, the greater the radial position of the solid particles, the greater the angular velocity and the greater the angular momentum of the individual solid particles. Minor deviations from this general concept do not alter the operation of the separator and those skilled in the art will recognize that these changes do not alter the operation of the separator and are not limiting. The angular velocity will be determined by: the inside diameter of the sphere, the pressure differential between the inlet pressure and the vessel pressure, the velocity of the incoming fluid and solid particulate component, and the viscosity of the mixture of fluid and particulate. Perturbations to parameters including the diameter, inlet pressure, fluid velocity, and pressure differential will be apparent to those skilled in the art without limitation and without altering the inventive concept. The angular velocity will generally cause all portions of the fluid and particles to be subjected to forces including centrifugal forces, which will generally cause migration to a larger radius trajectory that is closer to the wall of the inner sphere. Furthermore, since the inlet is above the horizontal mid-plane, the particulate solids will move lower in the chamber due to gravity and because of other apparent and real forces. As the particles fall due to the effect of gravity, the diameter of the inside of the sphere will increase as the inlet is above the mid-plane, and the fluid velocity will decrease, and this in turn will increase the likelihood of the particles settling at the bottom of the chamber. Substantially no particles entrained by the fluid will migrate to the lower region of the sphere and will collect. Particles of smaller mass will remain entrained by the fluid flow and those particles that are not separated by other forces including gravity and centrifugal forces may be mechanically separated by the mechanical filter.

Furthermore, fig. 8 also shows: the angular velocity is lower for small radii and higher for large radii. A lower angular velocity is found towards the middle of the chamber.

FIG. 9 illustrates one embodiment of a mechanical filter element. Details of the filter include connecting threads 90, outer screen 91, end manifold 92 and inner frame 93.

Fig. 10 shows the interior of the container 100 as including an interior surface that is continuous in nature, spherical in nature, and uninterrupted in nature. Fig. 10 also shows fluid inlet orifices 101 on the interior surface of the separator. The interior surface includes a regular surface and openings for functionality. The openings include, but are not limited to, a fluid inlet, a material removal system aperture 102, and an exhaust fluid penetration 103 to allow material to exit the separator. Other penetrations may exist, including but not limited to pressure sensors, fluid velocity sensors, additional inlets, additional solids removal ports, and additional filter mounts. Those skilled in the art will recognize that the additional port opening will not substantially affect the separator function. Fig. 10 also shows a schematic view of the collected solid particulate component 104 generally at the bottom of the separator. The figure also shows an outer surface 105, which outer surface 105 may be spherical, but may also be of other geometries. The figure also shows a possible particle movement path 106, indicating, among other movements, the path to the lower part of the separator. Various coupling and connection methods 107 may be used, but are not limiting as to the functionality of the invention. The exit for fluid 108 is essentially at the top of the device and may be parallel to the midplane to allow connection to subsequent equipment.

Fig. 11 shows a representative particle 60 proximate the interior surface 34 with indicated representative actual and apparent forces, including gravitational, coriolis, centrifugal, and centripetal forces. During operation, the high pressure fluid and the solid particulate component enter the separator interior tangentially, generally above the horizontal mid-plane, and begin a generally circular and essentially disk-like (discotic) path in the separator interior, the path resulting from the essentially spherical shape of the separator interior. The particles 60 will follow the trajectory 61 under the influence of the inner surface 34 of the separator and the previously named forces. This more or less disk-like trajectory is substantially parallel to the device midplane and more or less parallel to the local surface of the earth. The rotational motion of the particles causes angular momentum as illustrated in fig. 8 to be imparted to the particles and the fluid. Forces including gravity and apparent force centrifugation and coriolis forces are schematically indicated to represent some of the potential effects on the solid particulate component. In this case, the particles have a mass m, and the weight is the mass and the gravitational constantgThe product of (a). In this schematic illustration, F_gIs due to gravity-induced forces and is generally a negative product of mass and gravity constant ormg，F_ωIs the centrifugal force and is the vector multiplication product of the squares of the mass and velocity vectors divided by the radial distance ormv²/r, where the bold case represents vector quantity (vector quantity), and F_cIs the Coriolis force and is the vector cross product of the angular velocity vector ω and the linear velocity v, increasing with a negative value twice the mass (-2)m) Or-2 m (ω x v), where x is the vector cross product.

While the present invention has been particularly shown and described with reference to preferred and alternative embodiments, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention. For example, the fixture and fittings supporting the container may be changed without changing the invention. The filter element mounts and fittings also do not change the basic inventive properties.

Cited references

U.S. Pat. No. 3, 8,623,2212014, 1 month, 7 days Boyd

US 7,785,4002010 year 8, 31 th, Worley

6.6.6.6.6. 6,752,8602004 Hoydal

Morgan 11/13/US 6,315,8132001

Odom 4 month 10 days in US 6,214,0922001

US 6,162,2842000 Mitchel 12/19/78

US 5,928,5191999 Homan 7/27/month

Farion of 27 days 10 months in US 5,827,3571998

US 3,008,5381961 Glasgow at 11 months and 14 days.

Claims

1. An apparatus for separating solid particles from a moving fluid, comprising:

a) a container, comprising:

i) an inner surface comprising a generally spherical inner region that allows a moving fluid stream to be introduced therein, the fluid stream comprising a solid particulate component;

ii) an inlet port in the vessel allowing introduction of the fluid stream;

iii) an outlet port in the vessel allowing the fluid stream to be discharged; and

iv) a discharge port in a lower region of the vessel, the discharge port allowing removal of the solid particulate component.

2. The apparatus of claim 1, further comprising a filter positioned within the vessel, at or near the outlet port, wherein the filter removes at least a portion of any remaining solid particulate component in the effluent fluid stream.

3. The apparatus of claim 1, wherein the inner surface is a regular symmetrical shape, comprising a substantially spherical region.

4. The apparatus of claim 1, wherein the inlet port enters the vessel tangentially to the inner surface.

5. The apparatus of claim 1, wherein the inlet port enters the vessel at or above an interior mid-plane of the vessel.

6. The apparatus of claim 1, wherein the inlet port is located at a higher offset than a mid-plane of the vessel to create or enhance the direction of the fluid flow along the inner surface.

7. The apparatus of claim 1, wherein the apparatus is arranged near a wellhead to:

allowing the fluid flow to be efficiently introduced through the inlet port,

collecting a solid particulate component in a bottom region of the vessel;

allowing removal of solid particulate components through the outlet port,

filtering additional particles from the exhaust fluid stream by means of an exhaust stream filter, and

allowing installation, securing and use near the wellhead.

8. The apparatus of claim 1, wherein the outlet port allows for substantial attachment of a filter assembly by bolts, screws, welding, clamping tubing, piping, or other fixture and flow containing means.

9. The apparatus of claim 1, wherein the container has a bottom.

10. The apparatus of claim 8, wherein the removal port is disposed at the bottom of the separator.

11. The apparatus of claim 1, wherein the filter is removable and attached proximate to the outlet port.

12. The apparatus of claim 1, wherein the filter is contained in the housing.

13. The solid particle container of claim 1, wherein:

a) the fluid stream has a pressure in a range of 500psi to 15000 psi;

b) the container has an internal volume in the range of 10 to 40 cubic feet;

c) the f inlet port has a diameter in the range of 0.5 inches to 5.0 inches;

d) the inlet port has a plane offset to a horizontal mid-plane of the vessel in a range of 0.5 inches to 10 inches;

e) the inlet port enters the interior of the vessel tangentially to the interior surface of the vessel;

f) the outlet port has a diameter in the range of 1 to 8 inches; and is

g) The discharge port has a diameter in the range of 1 to 8 inches.

14. An improved method of separating a solid particulate component from a high pressure, high velocity fluid stream, the method comprising providing a vessel having a spherical wall surrounding a center point and defining an interior surface, the vessel further having:

a) arranging a fluid inlet above the mid-plane of the vessel and such that fluid enters the vessel tangentially;

b) disposing a solid particulate component removal port substantially at the bottom of the vessel;

c) disposing a filter securing system substantially at a top of the container; and

d) a system for supporting the solid particulate component container is disposed at the point of use.