Insertable nozzle for directing or diffusing flow into a separator vessel

Abstract

A system connected to a wellbore includes a separator, an inlet nozzle, and an outlet nozzle. The separator includes a main body defining an interior chamber, an inlet port, and an outlet port. The inlet nozzle includes an inlet tubular body that extends through the inlet port into the interior chamber, a plurality of cutouts disposed along the inlet tubular body that permits fluid communication between the inlet tubular body and the interior chamber, and an inlet end plate fixed to a distal end of the inlet tubular body. The outlet nozzle includes an outlet tubular body that extends through the outlet port into the interior chamber, a plurality of outlet apertures disposed along the outlet tubular body that permits fluid communication between the outlet tubular body and the interior chamber, and an outlet end plate fixed to a distal end of the outlet tubular body.

Description

TITLE INSERTABLE NOZZLE FOR DIRECTING OR DIFFUSING FLOW INTO A SEPARATOR VESSELCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims benefit under 35 U.S.C. § 119(e) to U.S. Provisional Application No. 63 / 673,510, filed July 19, 2024, entitled “INSERTABLE NOZZLE FOR DIRECTING OR DIFFUSING FLOW INTO A SEPARATOR VESSEL,” the entire disclosure of which is herein incorporated by reference.TECHNICAL FIELD

[0002] The present disclosure relates to separators, gas production units, and methods for separating gas from liquid, sand, and debris being produced from oil and gas wells and more particularly to such devices used to facilitate the production of natural gas and emissions-free or near emissions-free energy for use in the production of LNG (liquid natural gas), CNG (compressed natural gas), electricity, hydrogen, and oxygen.BACKGROUND

[0003] In separators, gas production units, and methods for separating gas from liquid, sand, and debris being produced from oil and gas wells, an insertable inlet nozzle may be employed for directing or diffusing flow into a vapor-liquid separator vessel. Many vaporliquid separators have permanently affixed internal structures called diffusers that spread out and decelerate incoming fluid so as to achieve better vapor-liquid separation performance. A vertically oriented cylindrical separator vessel is described in commonly owned U.S.Patent Application Publication No. 20220154568 A1, entitled APPARATUS AND METHOD FOR HARNESSING ENERGY FROM A WELLBORE TO PERFORM MULTIPLE FUNCTIONS WHILE REDUCING EMISSIONS, filed on September 9, 2021 , which claims priority to and the benefit of U.S. Provisional Application No. 63 / 089,777, entitled SEPARATOR FOR GAS PRODUCTION UNITS, filed on October 9, 2020, each of which is herein incorporated by reference. The diffusers in the vertically oriented cylindrical separator vessel are generally able to utilize the entire horizontal cross-section of the vessel and thus achieve better performance (e.g., deceleration and even distribution of incoming fluid).However, since the inlet flow in a separator is highly erosive, it is advantageous to use an inlet nozzle rather than a diffuser, since either device functions as a wear item, and a removable inlet nozzle is far more easily and inexpensively replaced than a permanently affixed diffuser.

[0004] Existing inlet nozzle designs feature a length of pipe with a semicircular, downward-facing cutout and a flat deflection plate affixed to one end. This configuration guides the incoming fluid flow horizontally through the length of the pipe. Upon reaching the end, the fluid impinges on the deflection plate, causing it to drop straight down into the interior of the separator.

[0005] During early flowback tests of existing inlet nozzles, significant quantities of gas were present in the separator’s drain, indicating poor separation of vapor bubbles from bulk liquid within the vessel. Additionally, turbulence within the vessel at all phases of production and flowback compromised the ability for instrumentation to work properly within the vessel. Computational fluid dynamics (CFD) simulations of the separator vessel revealed that the inlet nozzle was only deflecting incoming fluid slightly downward, causing an erosive jet to impinge on the vessel wall, and aggravating the entrainment of vapor bubbles into the drain. In turn, turbulence is apparent within the vessel making level control difficult. It is thus apparent that an alternative inlet nozzle and baffling system design is necessary.SUMMARY

[0006] In a first embodiment, the present disclosure describes a system connected to a wellbore that includes a separator, an inlet nozzle, and an outlet nozzle. The separator includes a main body defining an interior chamber, an inlet port, and an outlet port. The inlet nozzle is removable from the inlet port and directs a first fluid from the wellbore into the interior chamber. The inlet nozzle includes an inlet tubular body that extends through the inlet port into the interior chamber, a plurality of cutouts disposed along the inlet tubular body that permits fluid communication between the inlet tubular body and the interior chamber, and an inlet end plate fixed to a distal end of the inlet tubular body. The outlet nozzle is removable from the outlet port and directs a second fluid out of the interior chamber. The outlet nozzle includes an outlet tubular body that extends through the outlet port into the interior chamber, a plurality of outlet apertures disposed along the outlet tubular body that permits fluid communication between the outlet tubular body and the interior chamber, and an outlet end plate fixed to a distal end of the outlet tubular body.

[0007] In one aspect of the first embodiment, the inlet nozzle further includes a plurality of slots extending in an axial direction along the inlet tubular body that permits fluid communication between the interior chamber and the inlet tubular body.

[0008] In another aspect of the first embodiment, which may be combined with one or more previously recited aspects of the first embodiment, the inlet nozzle further includes a plurality of inlet apertures disposed along the inlet tubular body opposite of the plurality ofcutouts that permits fluid communication between the interior chamber and the inlet tubular body.

[0009] In another aspect of the first embodiment, which may be combined with one or more previously recited aspects of the first embodiment, the inlet nozzle further includes a plurality of deflection plates configured to disrupt a flow of the first fluid entering the interior chamber through the inlet tubular body. Each deflection plate is fixed to a radial edge of a different cutout of the plurality of cutouts.

[0010] In another aspect of the first embodiment, which may be combined with one or more previously recited aspects of the first embodiment, a first deflection plate of the plurality of deflection plates includes a first height and a second deflection plate of the plurality of deflection plates includes a second, different height.

[0011] In another aspect of the first embodiment, which may be combined with one or more previously recited aspects of the first embodiment, the plurality of cutouts are disposed along a lower side of the inlet tubular body, thereby directing the first fluid to exit the inlet tubular body in a downward direction.

[0012] In another aspect of the first embodiment, which may be combined with one or more previously recited aspects of the first embodiment, a first cutout of the plurality of cutouts includes a first width and a second cutout of the plurality of cutouts includes a second, different width.

[0013] In another aspect of the first embodiment, which may be combined with one or more previously recited aspects of the first embodiment, the inlet nozzle further includes an inlet flange fixed to a proximal end of the inlet tubular body, and the outlet nozzle further includes an outlet flange fixed to a proximal end of the outlet tubular body. In addition, the inlet flange is removably attached to the inlet port, and the outlet flange is removably attached to the outlet port.

[0014] In a second embodiment, the present disclosure describes a system connected to a wellbore that includes a separator and an inlet nozzle. The separator includes a main body defining an interior chamber, an inlet port, and an outlet port. The inlet nozzle is removable from the inlet port and directs a first fluid from the wellbore into the interior chamber. The inlet nozzle includes an inlet tubular body that extends through the inlet port into the interior chamber, a plurality of cutouts disposed along the inlet tubular body that permits fluid communication between the inlet tubular body and the interior chamber, an inlet end plate fixed to a distal end of the inlet tubular body, and a plurality of deflection platesthat disrupts a flow of the first fluid entering the interior chamber through the inlet tubular body. Each deflection plate is fixed to a radial edge of a different cutout of the plurality of cutouts, and a first deflection plate of the plurality of deflection plates includes a first height and a second deflection plate of the plurality of deflection plates includes a second, different height.

[0015] In one aspect of the second embodiment, the system further includes an outlet nozzle that is removable from the outlet port and directs a second fluid out of the interior chamber. The outlet nozzle includes an outlet tubular body that extends through the outlet port into the interior chamber, a plurality of outlet apertures disposed along the outlet tubular body that permits fluid communication between the outlet tubular body and the interior chamber, and an outlet end plate fixed to a distal end of the outlet tubular body.

[0016] In another aspect of the second embodiment, which may be combined with one or more previously recited aspects of the second embodiment, the inlet nozzle further includes a plurality of slots extending in an axial direction along the inlet tubular body that permits fluid communication between the interior chamber and the inlet tubular body.

[0017] In another aspect of the second embodiment, which may be combined with one or more previously recited aspects of the second embodiment, the inlet nozzle further includes a plurality of inlet apertures disposed along the inlet tubular body opposite of the plurality of cutouts that permits fluid communication between the interior chamber and the inlet tubular body.

[0018] In another aspect of the second embodiment, which may be combined with one or more previously recited aspects of the second embodiment, the plurality of cutouts are disposed along a lower side of the inlet tubular body, thereby directing the first fluid to exit the inlet tubular body in a downward direction.

[0019] In another aspect of the second embodiment, which may be combined with one or more previously recited aspects of the second embodiment, a first cutout of the plurality of cutouts includes a first width and a second cutout of the plurality of cutouts includes a second, different width.

[0020] In another aspect of the second embodiment, which may be combined with one or more previously recited aspects of the second embodiment, the inlet nozzle further includes an inlet flange fixed to a proximal end of the inlet tubular body, and the outlet nozzle further includes an outlet flange fixed to a proximal end of the outlet tubular body. In addition,the inlet flange is removably attached to the inlet port, and the outlet flange is removably attached to the outlet port.

[0021] In a third embodiment, the present disclosure describes an inlet nozzle that directs a fluid from a first location to a second location. The inlet nozzle includes an inlet tubular body, a plurality of cutouts disposed along the inlet tubular body that permits fluid communication between the inlet tubular body and the second location, an inlet end plate fixed to a distal end of the inlet tubular body, and a plurality of deflection plates that disrupts a flow of the fluid entering the second location through the inlet tubular body. Each deflection plate is fixed to a radial edge of a different cutout of the plurality of cutouts, and a first deflection plate of the plurality of deflection plates includes a first height and a second deflection plate of the plurality of deflection plates includes a second, different height.

[0022] In one aspect of the third embodiment, the inlet nozzle further includes a plurality of slots extending in an axial direction along the inlet tubular body that permits fluid communication between the second location and the inlet tubular body.

[0023] In another aspect of the third embodiment, which may be combined with one or more previously recited aspects of the third embodiment, the inlet nozzle further includes a plurality of inlet apertures disposed along the inlet tubular body opposite of the plurality of cutouts that permits fluid communication between the second location and the inlet tubular body.

[0024] In another aspect of the third embodiment, which may be combined with one or more previously recited aspects of the third embodiment, the plurality of cutouts are disposed along a lower side of the inlet tubular body, thereby directing the first fluid to exit the inlet tubular body in a downward direction.

[0025] In another aspect of the third embodiment, which may be combined with one or more previously recited aspects of the third embodiment, a first cutout of the plurality of cutouts includes a first width and a second cutout of the plurality of cutouts includes a second, different width.

[0026] These and other features and characteristics of the present disclosure, as well as the methods of operation and functions of the related elements of structure and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. It is to be expresslyunderstood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of any of the aspects disclosed herein.BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In the description, for purposes of explanation and not limitation, specific details are set forth, such as particular aspects, procedures, techniques, etc. to provide a thorough understanding of the present technology. However, it will be apparent to one skilled in the art that the present technology may be practiced in other aspects that depart from these specific details.

[0028] The accompanying drawings, where like reference numerals refer to identical or functionally similar elements throughout the separate views, together with the detailed description below, are incorporated in and form part of the specification, and serve to further illustrate aspects of concepts that include the claimed disclosure and explain various principles and advantages of those aspects.

[0029] The apparatuses and systems disclosed herein have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the various aspects of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

[0030] FIG. 1 is a perspective view of a separator according to one or more embodiments of the present disclosure.

[0031] FIG. 2 is a perspective view of the main body of the separator of FIG. 1 according to one or more embodiments of the present disclosure.

[0032] FIG. 3 is a cross-sectional view of an inlet nozzle according to one or more embodiments of the present disclosure.

[0033] FIG. 4 is a section view of the inlet nozzle of FIG. 3 taken along section line 4 — 4 according to one or more embodiments of the present disclosure.

[0034] FIG. 5 is a perspective view a deflection plate of the inlet nozzle of FIG. 3 according to one or more embodiments of the present disclosure.

[0035] FIG. 6 is a perspective view of an inlet nozzle according to one or more embodiments of the present disclosure.

[0036] FIG. 7 is a cross-sectional view of an inlet nozzle according to one or more embodiments of the present disclosure.

[0037] FIG. 8 is a perspective view of an outlet nozzle according to one or more embodiments of the present disclosure.

[0038] FIG. 9 is a cross-sectional view of an outlet nozzle according to one or more embodiments of the present disclosure.

[0039] FIG. 10 is a section view of the outlet nozzle of FIG. 9 taken along section line 10 — 10 according to one or more embodiments of the present disclosure.

[0040] FIG. 11 is a schematic diagram of a system according to one or more embodiments of the present disclosure.

[0041] FIG. 12 is a schematic diagram of a system according to one or more embodiments of the present disclosure.

[0042] FIGS. 13A-D are CFD models showing vortexes formed within a separator employing varying inlet nozzles.

[0043] FIG. 14 is a schematic diagram illustrating a gas production facility according to one or more embodiments of the present disclosure.DESCRIPTION

[0044] Numerous specific details are set forth to provide a thorough understanding of the overall structure, function, manufacture, and use of the aspects as described in the disclosure and illustrated in the accompanying drawings. Well-known operations, components, and elements have not been described in detail so as not to obscure the aspects described in the specification. The reader will understand that the aspects described and illustrated herein are non-limiting examples, and thus it can be appreciated that the specific structural and functional details disclosed herein may be representative and illustrative. Variations and changes thereto may be made without departing from the scope of the claims.

[0045] In the following description, it is to be understood that such terms as “forward,” “rearward,” “left,” “right,” “above,” “below,” “upward,” “downward,” and the like are words of convenience and are not to be construed as limiting terms.

[0046] Embodiments of inlet and outlet nozzles according to the present disclosure may be constructed from a straight length of pipe. This feature may enable the nozzles to be easily inserted and removed from the separator vessel. Since the nozzles are wear components that may need regular replacement, they should be designed for easy and cost- effective fabrication.

[0047] In various embodiments, the inlet nozzle according to the present disclosure may include multiple semicircular, downward-facing cutouts that are intended to divide the incoming flow in multiple directions. The most upstream cutout functions similarly to a single cutout configuration, deflecting a portion of the incoming fluid slightly downward while maintaining most of its forward momentum. The most downstream cutout is intended to do the opposite: a portion of the incoming flow impinges on the inlet nozzle's end plate and exits the cutout in a backwards and downward direction. The intermediate cutouts are intended to direct a portion of the incoming flow in an intermediate direction (e.g., substantially downward). Two axial slots facing upwards at an oblique angle are intended to allow vapor bubbles to escape the inlet nozzle in an upwards direction.

[0048] In one embodiment, the inlet nozzle according to the present disclosure may include three semicircular, downward-facing cutouts that are intended to divide the incoming flow in three directions. The first (most upstream) cutout functions similarly to a single cutout configuration, deflecting a portion of the incoming fluid slightly downward while maintaining most of its forward momentum. The last (most downstream) cutout is intended to do the opposite: a portion of the incoming flow impinges on the inlet nozzle’s end plate and exits the cutout in a backward and downward direction. The middle cutout is intended to direct a third portion of the incoming flow in an intermediate direction (e.g., substantially downward). Two axial slots facing upwards at an oblique angle are intended to allow vapor bubbles to escape the inlet nozzle in an upwards direction.

[0049] CFD simulations of the inlet nozzle performance (for a dispersed-bubble flow regime at the inlet) show that fluid exits through the upstream and downstream cutouts in roughly equal portions and in the directions intended; these two streams collide below the inlet nozzle, dissipating some of the fluid’s kinetic energy. An eddy generated by the last cutout causes a small portion of the fluid to re-enter the inlet nozzle through the intermediate cutout(s). Overall, the CFD simulations of the inlet nozzle predict satisfactory performance, which was confirmed by subsequent field testing.

[0050] Referring to FIGS. 1 and 2, embodiments of the present disclosure are directed to a sand and liquid separator 100 (hereinafter “separator 100”) particularly adapted for useat natural gas wells. The main body 102 of the separator 100 is generally a hollow vessel which defines an interior chamber 122. In the embodiment shown in FIGS. 1 and 2, the main body 102 is constructed of an upper vessel section and a lower vessel section, which together define a continuous interior chamber 122. However, it is to be understood that the main body 102 could be constructed from any number of sections, including one continuous, unitary section. The main body 102 is preferably constructed from a strong, rigid material such as steel designed, configured, or rated to operate at an incoming pressure of fluid flowing directly or indirectly (e.g., through a choke) from a wellbore 3003 (e.g., FIG. 14). In some embodiments, the separator 100 may be rated, designed, or configured for, or be capable of, operating at pressures greater than approximately 1 ,500 psig, or greater than approximately 2,500 psig, or greater than approximately 5,000 psig. In some embodiments, the separator 100 may be rated, designed, or configured for, or be capable of, operating at pressures as high as or greater than an unregulated pressure at which fluid flows from the wellbore. For example, unregulated pressure at the wellhead of Marcellus Shale formation wells may be approximately 5,000 psig, and unregulated pressure at the wellhead of Utica Shale formation wells may be approximately 10,000 psig. In other embodiments, the separator 100 may be rated, designed, or configured for, or be capable of, operating at regulated pressures. For example, the pressure of a Utica Shale formation well may be regulated down from approximately 10,000 psig at the wellhead to approximately 5,000 psig before being fed to the separator 100. Such a pressure regulation, which may be utilized to prevent damage to or failure of the various components of the separator 100 described herein, may be achieved by a choke or other device disposed inline between the wellbore and the separator 100. In some embodiments, the separator 100 and the various components thereof may be designed to meet various industry standards for pressure vessels or pressure and / or technical limitations associated with instrumentation described herein. As those of ordinary skill in the art will appreciate, modifications to existing instruments and other system components (e.g., the main body 102 of the separator 100) can be made to accommodate the high pressures of formations such as the Utica Shale formation without the need of equipment to regulate the pressure down from that coming out of the wellbore. As those of ordinary skill in the art will appreciate, the separator 100 can be oriented horizontally rather than vertically.

[0051] In addition, the disclosed separator 100 allows for separation of liquid, sand, and debris from the gas stream at pressures available at the wellbore, prior to gas pressure reduction. It is advantageous to maintain high pressure of the gas removed of liquid, sand, and debris, as this pressurized stream of gas may be used for the production of compressed natural gas (CNG), liquefied natural gas (LNG), electricity, hydrogen and / or oxygen. Theseproducts may be produced individually or simultaneously in any combination without compression and free of emissions, with or without also providing natural gas to a pipeline.

[0052] In embodiments in which the main body 102 is constructed of multiple sections, the various sections may be connected to one another using any suitable fastening method or device, such as mechanical fasteners (e.g., bolts or rivets), a welded joint, or the like. The connection between the various sections should be sufficiently tight to prevent the escape of high pressure fluid and other materials from the interior chamber 122 to the outside environment. The main body 102 may be supported in a generally vertical position by a frame 104.

[0053] A plurality of inlets and outlets (e.g., in the form of connecting ports and / or flanges) may be provided in the main body 102 to facilitate flow of liquid, sand, and other debris through the separator 100. An inlet (e.g., inlet port 124 provided in the main body 102) may allow flow into the interior chamber 122 from a first location (e.g., a wellbore 3003). The inlet port 124 may be fluidly connected to the first location by an inlet nozzle 200. That is, a pipe fluidly connected to the first location may be attached to an inlet nozzle 200 that is attached to the inlet port 124. Flow to the inlet nozzle 200 may be regulated by one or more valves or the like. As shown in FIG. 3, the inlet nozzle 200 may include an inlet tubular body 202 extending into the interior chamber 122 through the inlet port 124, with a terminal end of the inlet tubular body 202 being partially or fully obstructed by a baffle or inlet end plate 204. Fluid including gas, liquid, sand, and / or other debris entering the interior chamber 122 enters the inlet nozzle 200 through an inlet opening 206 (e.g., in the direction of arrow A), travels through the inlet tubular body 202, and any solid and / or liquid contaminants carried by the fluid may be deflected by the inlet end plate 204 toward a bottom of the interior chamber 122 (e.g., in the direction of arrow B). Such contaminants may include, for example, sand, water, oil, rock, and metal fragments.

[0054] An outlet (e.g., liquid, sand, and debris outlet port 106) may be provided at or near a lower portion of the interior chamber 122. The outlet port 106 may be fluidly connected to a valve 108 which may be periodically and / or continuously opened and closed to drain liquid and solid contaminants collected at the bottom of the interior chamber 122. The valve 108 may be mounted remotely from the separator 100 by rigid or flexible pipe. The valve 108 may feed into a waste holding tank, also via rigid or flexible pipe, for holding contaminants removed from the fluid until the contaminants can be safely processed for disposal. The downstream processing equipment may include, for example, one or more separation components used to separate the different constituents of the liquid, sand, and / or debris output from the separator 100.

[0055] The valve 108 may be a dump valve, and more particularly a hardened dump valve. It should be noted, however, that any desired type of valve may be used to output liquid, sand, and / or debris from the lower portion of the interior chamber 122. The valve 108 may be a piston valve, a ball valve, a butterfly valve, a gate valve, a choke valve, a needle valve or the like suitable for operation at pressures up to, for example, 5,000 psig. The valve 108 may include an electrical, hydraulic, or pneumatic actuator such as an electric motor, solenoid, hydraulic actuator, pneumatic actuator, or combinations thereof such that opening and closing of the valve 108 can be performed automatically by an electronic control circuit. As such, the valve 108 may be an electronically controlled valve. In certain embodiments, the valve 108 may include a fast-acting electrically actuated linear valve actuator used to rapidly transition the valve 108 between open and closed positions and / or to one or more intermediate positions between the open and closed positions. The valve actuator may be capable of transitioning the valve 108 between a fully open position and a fully closed position in less than 2.0 seconds, more particularly less than 1.0 second, or more particularly less than 0.5 seconds.

[0056] In some embodiments, two or more valves 108 may be provided in parallel to one another due to the critical nature of this component. If one valve 108 fails, leaks, erodes or is nonoperational (e.g., undergoing maintenance), a second valve 108 may be used to operate the separator 100. Each valve 108 of the two or more valves 108 may be identical so that fewer maintenance components and spare parts are needed to perform maintenance and repairs on the valves 108. The valves 108 may be coupled to independent strainers (or junk catchers), respectively, provided upstream of the valves 108 to capture debris. The valves 108 may feed into the same waste holding tank, or into different waste holding tanks. The valves 108 may be electronically controlled and connected to the control circuit. The valves 108 may be electronically controlled by the control circuit to provide a fixed flow rate (e.g., 150 barrels of water per hour), rather than controlled to maintain a certain level of liquid in the interior chamber 122 of the vessel. As those of ordinary skill in the art will appreciate, this method of operation may be employed, e.g., where little to no gas is present.

[0057] In some embodiments, a plurality of bridle ports 120a-120f may be provided in the upper vessel section of the main body 102 and may be configured to connect to a bridle 130. The bridle 130 may include a tube 110 and a plurality of connecting flanges. As illustrated, the tube 110 may be a vertical tube 110 (e.g., the tube axis is oriented vertically). Each of the connecting flanges may connect to a corresponding one of the bridle ports 120a- 120f, such that fluid can flow freely between the tube 110 and any of the bridle ports 120a- 120f via the connecting flanges.

[0058] Because fluid can flow freely between the interior chamber 122 and the bridle 130 via the bridle ports 120a-120f, a liquid level in the tube 110 of the bridle 130 selfequalizes with a liquid level in the interior chamber 122. As such, the liquid level in the interior chamber 122 may be ascertained by measuring the liquid level in the bridle 130. The bridle 130 also helps to protect the instruments from gas bubbles in the interior chamber 122, which can cause the instruments to record inaccurate readings.

[0059] As shown in the accompanying drawings, a representative embodiment of the separator 100 includes six bridle ports 120a-120f and six corresponding connecting flanges. As those of ordinary skill in the art will appreciate, the bridle 130 may include more than six bridle ports or a lesser number. The bridle port third from the top 120c may correspond to a high liquid level within the interior chamber 122, and the lowermost bridle port 120f may correspond to a low liquid level within the interior chamber 122. During operation, the valve 108 may be periodically and / or continuously opened and closed, or modulated between an opened and closed position, to maintain the liquid level within the interior chamber 122 at a desired level, for example between the bridle port third from the top 120c and the lowermost bridle port 120f. The two intermediate bridle ports 120d, 120e between the bridle port third from the top 120c and the lowermost bridle port 120f may facilitate equalization of the liquid level in the interior chamber 122 with the liquid level in the bridle 130. The uppermost bridle port 120a prevents the formation of a gas pocket from forming at the top of the bridle 130 and allowing a liquid level sensor 112 to take measurements along the entire length of the bridle 130 and vessel. The bridle ports 120a-120f may be spaced vertically apart from one another and be of sufficient cross-sectional area to ensure that the liquid level within the bridle 130 can rapidly equalize with the liquid level in the interior chamber 122. That is, the bridle ports 120a-120f allow sufficient liquid flow into the bridle 130 to minimize time delay in equalization of the liquid level within the bridle 130 to the liquid level in the interior chamber 122. It is to be understood that the separator 100 may include more or fewer bridle ports, and a corresponding number of connecting flanges, than are shown in the drawings in order to reduce liquid level equalization time in the bridle 130. Moreover, the bridle ports 120a-120f may have increased cross-sectional area in order to reduce liquid level equalization time in the bridle 130. The bridle 130 may include a cleanout valve that may be used to evacuate sand or other particulate material that may become trapped in the bridle 130.

[0060] In some embodiments, the separator 100 may not include a bridle 130 at all. For example, the separator 100 may include a liquid level sensor 112 inserted directly into an upper portion of the interior chamber 122 of the separator 100 to determine the liquid level in the separator 100. The liquid level sensor 112 may be a guided wave radar sensor, asdescribed above. In still other embodiments, the separator 100 may include both a bridle 130 with a first liquid level sensor 112 disposed therein and a second liquid level sensor 112 disposed in the interior chamber 122 to provide redundant measurements of the liquid level in the separator 100.

[0061] With continued reference to FIGS. 1 and 2, a gas outlet (e.g., gas outlet port 126) may be provided in the main body 102 through which gas may flow out of the separator 100 to downstream components of the facility, such as a line heater or molecular dryer. The gas outlet port 126 may be fluidly connected to the downstream components, for example, by an outlet nozzle 300. Accordingly, the outlet nozzle 300 may connect the gas outlet port 126 to a rigid or flexible pipe connected to the downstream components. The gas outlet port 126 may be located vertically above the uppermost bridle port 120a, and therefore above the intended liquid level of the interior chamber 122, such that no liquid flows out of the gas outlet port 126 during normal operation. In some embodiments, a mist extractor may be provided within the interior chamber 122 below the gas outlet port 126 to prevent very fine water droplets / aerosols from reaching the gas outlet port 126 and exiting the separator 100. In some embodiments, a diffuser may be provided within the interior chamber 122 to allow gas to more easily travel upward within the interior chamber 122.

[0062] In some embodiments, the gas outlet port 126 and the outlet nozzle 300 may extend through a top of the main body 102 of the separator 100, thereby enabling a maximum length between upper and lower limits of the liquid level within the separator 100. In other embodiments, the gas outlet port 126 and the outlet nozzle 300 may extend through a side wall of the main body 102 of the separator 100 (e.g., FIG. 11).

[0063] An upper sensor port 114 may be provided in the main body 102 of the separator 100 and may receive an upper limit sensor, such as a limit switch, float switch, thermal dispersion switch, or the like. The upper sensor port 114 may be located vertically above the uppermost bridle port 120a and vertically below the gas outlet port 126. In some embodiments, the upper limit sensor may be located above an uppermost point at which the liquid level sensor 112 can detect liquid. The upper limit sensor may be used to detect the presence of liquid, and may thus serve as an auxiliary device, in addition to the liquid level sensor 112, for determining if the liquid level is above a predetermined high point in the interior chamber 122. The upper limit sensor may be in electronic communication with a control circuit, and the control circuit may be programmed or configured to initiate a shutdown procedure if liquid is detected by the upper limit sensor.

[0064] Similarly, a lower sensor port 116 may be provided in the main body 102 of the separator 100 and may receive a lower limit sensor, such as a limit switch, float switch, thermal dispersion switch, or the like. The lower sensor port 116 may be located vertically below the lowermost bridle port 120f and vertically above the inlet port 124. In some embodiments, a lower limit sensor may be located below a lowermost point at which the liquid level sensor 112 can detect liquid. The lower limit sensor may be used to detect the presence of liquid, and may thus serve as an auxiliary device, in addition to the liquid level sensor 112, for determining if the liquid level is below a predetermined low point in the interior chamber 122. The lower limit sensor may be in electronic communication with a control circuit, and the control circuit may be programmed or configured to initiate a shutdown procedure if liquid is not detected by the lower limit sensor.

[0065] A relief valve 118 may be provided at or near the top of the upper vessel section of the main body 102 and may be configured to open at a predetermined pressure to allow pressurized gases to escape from the interior chamber 122. The pressure at which the relief valve 118 is configured to open may be selected to prevent damage to the separator 100 and / or downstream components from excess gas pressure. For example, the relief valve 118 may be configured to open if the pressure in the interior chamber 122 exceeds the maximum operating pressure of the separator 100, for example approximately 5,000 psig. The relief valve 118 may be passive, e.g., having a spring that deflects at a predetermined crack pressure or may be actively controlled by a control circuit.

[0066] The relative vertical locations of the various ports may optimize performance of the separator 100. For example, the inlet port 124 may be located below the bridle ports 120a-120f, with the inlet end plate 204 of the inlet nozzle 200 directing inflow downward, so that contaminants do not flow toward and become trapped in the bridle 130. The inlet port 124 may also be located below the gas outlet port 126 so that less dense gas rises above relatively more dense water, such that only the gas exits the separator 100 via the gas outlet port 126. Moreover, the gas outlet port 126 may be located at the top of the main body 102, and therefore above the intended liquid level within the separator 100, again to prevent water from exiting through the gas outlet port 126. The liquid, sand, and debris outlet port 106 may be positioned as near to the base of the separator 100 as is reasonably practical so that liquid and contaminants cannot collect below the liquid, sand, and debris outlet port 106. The upper sensor port 114 may be located above the uppermost bridle port 120a and the lower sensor port 116 may be provided below the lowermost bridle port 120f, such that the upper and lower limit sensors may serve as fail safe devices in the event that the liquid level sensor 112 fails to detect and account for the liquid level being outside the intended range.

[0067] It should be noted that an increased vertical length of the bridle 130 may provide additional reaction time for the valve 108 to release the liquid, sand, and debris from the main body 102 of the separator 100. In some embodiments, the length of the bridle 130 and the probe length of the liquid level sensor 112 may be selected such that the liquid level sensor 112 has a probe length of approximately 80 inches and a targeted liquid level (e.g., a midpoint length of the bridle 130) of approximately 55 inches.

[0068] FIG. 3 illustrates an inlet nozzle 200 according to one or more embodiments of the present disclosure. The inlet nozzle 200 may be removably coupled with an inlet port 124 of a separator 100 and configured to direct a first fluid received from a first location (e.g., a wellbore 3003) to a second location (e.g., an interior chamber 122 of the separator 100). The inlet nozzle 200 may include an inlet tubular body 202 configured to extend through the inlet port 124 into the interior chamber 122. In the non-limiting example of FIG. 3, the inlet tubular body 202 is elongated along a longitudinal axis of the inlet nozzle 200 and presents opposed first and second longitudinal sides.

[0069] The inlet nozzle 200 may include a plurality of cutouts 210 disposed along the inlet tubular body 202. The plurality of cutouts 210 is configured to permit fluid communication between the inlet tubular body 202 and the interior chamber 122. In the nonlimiting example of FIG. 3, the plurality of cutouts 210 may be disposed along a first longitudinal side 211 (e.g., a lower side) of the inlet tubular body 202. The plurality of cutouts 210 thereby directs the first fluid to exit the inlet tubular body 202 in a first direction (e.g., a downward direction).

[0070] In one or more embodiments, the plurality of cutouts 210 may include a first cutout 210 having a first width and one or more additional cutouts 210 having widths different than the first width. In one example, and as depicted in FIG. 3, the plurality of cutouts 210 of the inlet nozzle 200 is arranged such that the cutouts 210 increase in width as subsequent cutouts 210 approach the distal end of the inlet tubular body 202. Alternatively, in another example (e.g., FIG. 7), the plurality of cutouts 210 of the inlet nozzle 200 may be arranged such that the cutouts 210 decrease in width as subsequent cutouts 210 approach the distal end of the inlet tubular body 202.

[0071] The inlet nozzle 200 may further include a plurality of slots 214 extending in an axial direction along the inlet tubular body 202. The plurality of slots 214 is configured to permit fluid communication between the interior chamber 122 and the inlet tubular body 202. In one or more embodiments, the plurality of slots may be disposed along a second longitudinal side 213 (e.g., an upper side) of the inlet tubular body 202 so as to permit aportion of the first fluid (e.g., vapor bubbles) to exit the inlet nozzle 200 in a second direction (e.g., upwards direction) that is different than the first direction. FIG. 4 depicts a section view of the inlet nozzle 200 of FIG. 3 taken along section line 4 — 4. In the non-limiting embodiment of FIG. 4, the inlet nozzle 200 includes two slots 214 and the arrangement of the two slots 214 creates an oblique angle. However, the angle between the two slots 214 may be greater than or less than the angle depicted in FIG. 4.

[0072] The inlet nozzle 200 may further include a plurality of deflection plates 212 configured to disrupt a flow of the first fluid entering the interior chamber 122 through the inlet tubular body 202. FIG. 5 depicts a deflection plate 212 of the plurality of deflection plates 212 according to one or more embodiments of the present disclosure. Each deflection plate 212 of the plurality of deflection plates 212 may be fixed to a radial edge of a different cutout 210 of the plurality of cutouts 210. In addition, each deflection plate 212 may be oriented substantially perpendicular to the longitudinal axis of the inlet nozzle 200. In one or more embodiments, each deflection plate 212 spans only a portion of the interior crosssection of the inlet tubular body 202 such that a gap remains between a distal edge of each deflection plate 212 and the opposite interior wall of the inlet tubular body 202.

[0073] In one or more embodiments, and as depicted in FIG. 3, each deflection plate 212 of the plurality of deflection plates 212 may have a same height 228, and thus, span a same distance within the interior of the inlet tubular body 202. Alternatively, the plurality of deflection plates 212 may include one or more deflection plates 212 having different heights 228. That is, in one or more embodiments, the plurality of deflection plates 212 may include a first deflection plate 212 having a first height 228 and one or more additional deflection plates 212 having heights 228 different than the first height 228. In one example (e.g., FIG. 7), the plurality of deflection plates 212 of the inlet nozzle 200 is arranged such that the deflection plates 212 increase in height 228 as subsequent deflection plates 212 approach the distal end of the inlet tubular body 202. In another example, the plurality of deflection plates 212 of the inlet nozzle 200 may be arranged such that the deflection plates 212 decrease in height 228 as subsequent deflection plates 212 approach the distal end of the inlet tubular body 202.

[0074] In one or more embodiments, the inlet nozzle 200 includes an inlet end plate 204 fixed to the distal end of the inlet tubular body 202. In one or more embodiments, the inlet end plate 204 is configured to seal the distal end of the inlet tubular body 202 such that no fluid is permitted to pass through the distal end of the inlet tubular body 202.

[0075] The inlet nozzle 200 may further include a first inlet flange 216 fixed to a proximal end of the inlet tubular body 202. In one or more embodiments, the first inlet flange 216 includes a central bore through which the inlet tubular body 202 extends. The first inlet flange 216 is configured to be removably attached to the inlet port 124. The inlet nozzle 200 may further include a second inlet flange 218 fixed to the proximal end of the inlet tubular body 202. The second inlet flange 218 is configured to be removably attached to a pipe fluidly connected with the first location (e.g., a wellbore 3003).

[0076] The first inlet flange 216 includes a plurality of first inlet flange openings 220. Accordingly, mechanical fasteners (e.g., bolts) may extend through the plurality of first inlet flange openings 220 of the first inlet flange 216 to secure the inlet nozzle 200 to the inlet port 124. Similarly, the second inlet flange 218 includes a plurality of second inlet flange openings 222, and mechanical fasteners may extend through the plurality of second inlet flange openings 222 of the second inlet flange 218 to secure the inlet nozzle 200 to a pipe that is fluidly connected with the first location.

[0077] FIGS. 6 and 7 illustrate an inlet nozzle 400 according to one or more additional embodiments of the present disclosure. Components shown or described in FIGS. 3-5 have not been redescribed for purposes of readability and have the same description and purpose as outlined above.

[0078] In one or more embodiments, the inlet nozzle 400 includes a plurality of inlet apertures 424 configured to permit fluid communication between the inlet tubular body 402 and the interior chamber 122 of a separator 100. In one or more embodiments, the plurality of inlet apertures 424 is disposed along the second longitudinal side 213 (e.g., an upper side) of the inlet tubular body 202 opposite of the plurality of cutouts 410. In this way, the plurality of inlet apertures 424 directs a portion of the first fluid (e.g., vapor bubbles) to exit the inlet nozzle 400 in a direction that is different than or opposite the first direction.

[0079] FIGS. 8 and 9 illustrate an outlet nozzle 300 according to one or more embodiments of the present disclosure. The outlet nozzle 300 may be removably coupled with a gas outlet port 126 of a separator 100 and configured to direct a second fluid (e.g., gas separated from liquid, sand, and debris) out of the interior chamber 122. The outlet nozzle 300 may include an outlet tubular body 302 configured to extend through the gas outlet port 126 into the interior chamber 122. In the non-limiting examples of FIGS. 8 and 9, the outlet tubular body 302 is elongated along a longitudinal axis of the outlet nozzle 300 and presents opposed first and second longitudinal sides.

[0080] The outlet nozzle 300 may include a plurality of outlet apertures 306 disposed along the outlet tubular body 302. The plurality of outlet apertures 306 is configured to permit fluid communication between the outlet tubular body 302 and the interior chamber 122. In one or more embodiments, the plurality of outlet apertures 306 may be disposed along the entire length of the outlet tubular body 302. Alternatively, the plurality of outlet apertures 306 may be disposed over only a portion of the outlet tubular body 302. For example, the plurality of outlet apertures 306 may only be disposed near a proximal portion or a distal portion of the outlet tubular body 302. In other examples, the plurality of outlet apertures 306 may only be disposed along the first longitudinal side 307 or the second longitudinal side 309 of the outlet tubular body 302. In the non-limiting example of FIG. 9, the plurality of outlet apertures 306 is disposed along the distal end of the first longitudinal side 307 of the outlet tubular body 302.

[0081] FIG. 10 depicts a section view of the outlet nozzle 300 of FIG. 9 taken along section line 10 — 10. In the non-limiting embodiment of FIG. 10, each outlet aperture 306 of a row of outlet apertures 306 is uniformly spaced apart from each other by a predetermined angle 316.

[0082] In one or more embodiments, the outlet nozzle 300 includes an outlet end plate 304 fixed to a distal end of the outlet tubular body 302. In one or more embodiments, the outlet end plate 304 is configured to seal the distal end of the outlet tubular body 302 such that no fluid is permitted to pass through the distal end of the outlet tubular body 302.

[0083] The outlet nozzle 300 may further include a first outlet flange 308 fixed to a proximal end of the outlet tubular body 302. The first outlet flange 308 is configured to be removably attached to the gas outlet port 126. In one or more embodiments, the first outlet flange 308 includes a central bore through which the outlet tubular body 302 extends. The outlet nozzle 300 may further include a second outlet flange 310 fixed to the proximal end of the outlet tubular body 302. The second outlet flange 310 is configured to be removably attached to a pipe fluidly connected with downstream components.

[0084] As seen in FIG. 8, the first outlet flange 308 includes a plurality of first outlet flange openings 312. Accordingly, mechanical fasteners (e.g., bolts) may extend through the plurality of first outlet flange openings 312 of the first outlet flange 308 to secure the outlet nozzle 300 to the gas outlet port 126. The second outlet flange 310 includes a plurality of second outlet flange openings 314, and mechanical fasteners may extend through the plurality of second outlet flange openings 314 of the second outlet flange 310 to secure the outlet nozzle 300 to a pipe that is fluidly connected with downstream components.

[0085] FIG. 11 depicts a schematic diagram of a system 1000 according to one or more embodiments of the present disclosure. The system 1000 includes a separator according to one or more embodiments of the present disclosure (e.g., a separator 100 described in relation to FIGS. 1 and 2). The system 1000 further includes an inlet nozzle (e.g., an inlet nozzle 200 described in relation to FIGS. 3-5 or an inlet nozzle 400 described in relation to FIGS. 6 and 7) and an outlet nozzle (e.g., an outlet nozzle 300 described in relation to FIGS. 8-10). In the non-limiting example of FIG. 11, the system 1000 includes an inlet nozzle 400 and an outlet nozzle 300 removably coupled with the inlet port 124 and the gas outlet port 126 of a separator 100, respectively. Components shown or described in FIGS. 1-10 have not been redescribed for purposes of readability and have the same description and purpose as outlined above.

[0086] During operation of the system 1000, fluid is delivered from a first location (e.g., a wellbore 3003) to the interior chamber 122 of the separator through the inlet port 124 by the inlet nozzle 400. One or more pipes or other forms of conduits may transport the fluid from the first location to the inlet nozzle 400. The fluid entering the separator 100 may carry with it various contaminants, including water (in both liquid and vapor form) and sand from hydraulic fracturing (i.e. , “fracking”). Additionally, the fluid may carry debris, such as fragments (e.g., plug pieces) from plugs used during a fracturing process. As such, all media, including gas, liquid, sand, and debris, delivered to the inlet nozzle 400 from the first location may flow through the inlet nozzle 400 and enter the separator 100. The flow of fluid from the first location may enter the inlet nozzle 400 in the direction of arrow A and be deflected by an inlet end plate 404 and one or more deflection plates 412 of the inlet nozzle 400 in the direction of arrow B (e.g., in a downwards direction or towards the liquid, sand, and debris outlet port 106 of the separator 100). In one or more embodiments, a portion of the fluid (e.g., vapor bubbles) transported through the inlet nozzle 400 may exit the inlet nozzle 400 through the plurality of slots 414 and the plurality of inlet apertures 424 disposed along the inlet tubular body 402. In one or more embodiments, the portion of the fluid exiting the inlet nozzle 400 through the plurality of slots 414 and the plurality of inlet apertures 424 exits the inlet nozzle 400 in the direction of arrow C (e.g., in an upwards direction or towards the gas outlet port 126 of the separator 100).

[0087] Solid contaminants, such as sand and debris, settle in the bottom of the interior chamber 122 of the separator 100. Liquid, such as water, fills the interior chamber 122 from the bottom up, establishing a liquid level. Gas, being less dense than the liquid flows toward the top of the interior chamber 122 in the direction of arrow C, rises above the liquid to fill the top of the interior chamber 122. In one or more embodiments, the separator 100 may includea diffuser within the interior chamber 122 that may assist the upward movement of gas through the interior chamber 122. Once the liquid level reaches a lowermost bridle port (e.g., lowermost bridle port 120f) of the bridle 130 of the separator 100, the gas and liquid may flow freely between the interior chamber 122 and the bridle 130 via the bridle ports (e.g., bridle ports 120a-120f). The liquid level thus equalizes between the interior chamber 122 and the bridle 130.

[0088] The separated gas flows out of the separator 100 via the outlet nozzle 300 and the gas outlet port 126 in the direction of arrow D to downstream piping in fluid communication with the outlet nozzle 300. The piping may in turn be fluidly connected to downstream components (e.g., a line heater or molecular dryer).

[0089] FIG. 12 shows a schematic diagram of a system 1100 according to one or more additional embodiments of the present disclosure. Components shown or described in FIGS. 1-11 have not been redescribed for purposes of readability and have the same description and purpose as outlined above.

[0090] In one or more embodiments, the system 1100 includes one or more baffle plates 430 extending from the inlet nozzle 400. In the non-limiting example of FIG. 12, the system 1100 includes a plurality of baffle plates 430. Here, the plurality of baffle plates 430 includes a first baffle plate 430 extending from the tubular body 402 of the inlet nozzle 400 in a first direction (e.g., a downwards direction or towards a bottom end of the main body 102 of the separator 100) and a second baffle plate 430 extending from the tubular body 402 of the inlet nozzle 400 in a second direction opposite the first direction (e.g., an upwards direction or towards an upper end of the main body 102 of the separator 100). In one or more embodiments, a plurality of baffle plates 430 may extend from the tubular body 402 in the first direction. Further, in one or more embodiments, a plurality of baffle plates 430 may extend from the tubular body 402 in the second direction.

[0091] As shown in FIG. 12, each baffle plate 430 of the plurality of baffle plates 430 may include similar dimensions. Alternatively, in one or more embodiments, one or more baffle plates 430 may include dimensions different from one or more additional baffle plates 430. For example, the plurality of baffle plates 430 may include a first baffle plate 430 having a first length and a second baffle plate 430 having a second length that is different than the first length.

[0092] FIGS. 13A-D illustrate CFD models 2000, 2100, 2200, 2300 showing vortexes 2002, 2102, 2202, 2302 formed within a separator 100 under certain flow conditions (e.g.,high fluid I low gas rate conditions). In particular, FIG. 13A depicts a vortex 2002 formed within a separator 100 employing an inlet nozzle 500. The inlet nozzle 500 of FIG. 13A includes an inlet tubular body 502 having only a single downward-facing cutout. As a result, the CFD simulation 2000 of FIG. 13A revealed that the inlet nozzle 500 only deflected incoming fluid slightly downward, causing an erosive jet to impinge on a wall of the main body 102 of the separator 100 and aggravating the entrainment of vapor bubbles into the drain of the separator 100 (e.g., the liquid, sand, and debris outlet port 106).

[0093] FIG. 13B depicts a vortex 2102 formed within a separator 100 employing the inlet nozzle 400 as described in FIGS. 6 and 7. As a result, the CFD simulation 2100 of FIG. 13B revealed that the inlet nozzle 400 was successful deflecting incoming fluid downward in a more central location of the separator 100. The CFD simulation 2100 showed fluid exiting through the upstream and downstream cutouts 410 in roughly equal portions and in the directions intended. These two streams collided below the inlet nozzle 400, dissipating some of the fluid’s kinetic energy. Further, the distal cutout 410 generated an eddy which caused a small portion of the fluid to re-enter the inlet nozzle 400 through the intermediate cutout 410. To this end, the CFD simulation 2100 demonstrated that the inlet nozzle 400 prevents erosive jets that impinge on a wall of the separator 100.

[0094] FIGS. 13C and 13D depict vortexes 2202, 2302 formed within a separator 100 employing an inlet nozzle 400 as described in FIGS. 6 and 7, further including a baffle plate 430. In the non-limiting embodiment of FIG. 13C, a baffle plate 430 is connected to the distal end of the inlet nozzle 400. In addition, the baffle plate 430 extends in a first extension direction that is axial to the extension of the tubular body 402. Further, the baffle plate 430 extends in a second extension direction that is axial to the extension of the main body 102 of the separator 100. In one or more embodiments, the baffle plate 430 may extend from the inlet nozzle 400 in a downward or an upward direction. Alternatively, in one or more embodiments, and as shown in FIG. 13C, the baffle plate 430 may extend in the second extension direction both above and below the inlet nozzle 400 within the separator 100.

[0095] In the non-limiting embodiment of FIG. 13D, a baffle plate 430 is connected to the proximal end of the inlet nozzle 400 within the main body 102 of the separator 100. Here, the baffle plate 430 extends in a first extension direction that is transverse to the extension of the tubular body 402. Further, the baffle plate 430 extends in a second extension direction that is axial to the extension of the main body 102 of the separator 100. In FIG. 13D, the baffle plate extends from the tubular body 402 of the inlet nozzle 400 to the lower end of the main body 102 of the separator 100 in the second extension direction.

[0096] The CFD simulations 2200, 2300 of FIG. 13C and 13D demonstrated further reductions in the kinetic energy of the fluid entering the separator 100. This reduction in kinetic energy of the fluid aids the gas-liquid separator process of the separator 100 and further prevents erosion within the separator 100.

[0097] FIG. 14 illustrates a gas production facility 3000 according to one or more embodiments of the present disclosure. The gas production facility 3000 includes a system according to one or more embodiments of the present disclosure (e.g., a system 1000 described in relation to FIG. 11) for performing a flowback operation for a well. The well is designated in FIG. 14 by a tree 3002, which is located at a wellhead. The tree 3002 may be a standard Christmas tree located above a well and comprising multiple valves and bores through which fluid may be directed from the well. The tree 3002 is configured to output fluid produced from a wellbore 3003. The fluid produced from the wellbore 3003 may include gas, liquid, sand, and debris.

[0098] During flowback operations, liquid, sand, and debris may make up a significant proportion of the fluid being produced from the wellbore 3003. Flowback operations may last for 5 days, 1 week, 2 weeks, or up to a month or more. Permanent production equipment that is used to process gas output from the well is not designed to handle the large amounts of liquid, sand, and debris that is removed from the well during flowback operations. The separator 100 described at length above may be used to clean the liquid, sand, and debris from the well fluid during flowback operations so that the same gas processing equipment (e.g., gas production unit 3004) may be used to process the gas during flowback operations and during the longer production phase after flowback operations. The gas production unit 3004 may include at least a choke for reducing a pressure of the gas or fluid flowing therethrough. The illustrated arrangement of the separator 100 and gas production unit 3004 used to provide flowback operations has a much smaller footprint than conventional third- party flowback spreads.

[0099] The separator 100 may be connected to the tree 3002 and gas production unit 3004 via a series of flow paths, each flow path taking the form of rigid or flexible piping. The gas production facility 3000 may include, for example, a first flow path 3006 connecting a first outlet 3008 of the tree 3002 to the inlet nozzle 400 of the system 1000. As illustrated and described in detail above, the system 1000 includes an inlet nozzle 400 and an outlet nozzle 300 removably coupled to the separator 100. The inlet nozzle 400 delivers the fluid into the separator 100 at a first pressure. The fluid may comprise liquid, gas, sand, and debris. The gas production facility 3000 may also include a second flow path 3010 connecting a second outlet 3012 of the tree 3002 to the gas production unit 3004. Fluid mayflow from the well directly to the gas production unit 3004 via the second flow path 3010 when a valve at the second outlet 3012 is open. The gas production facility 3000 may further include a third flow path 3014 connecting the outlet nozzle 300 to the gas production unit 3004 or, more particularly, to the second flow path 3010 leading to the gas production unit 3004. The outlet nozzle 300 is configured to transport gas separated from the liquid, sand, and debris out of the separator 100 at a second pressure. In one or more embodiments, the second pressure may be substantially equivalent to the first pressure. As illustrated, a valve 3016 may be disposed along the third flow path 3014 for selectively opening and closing the third flow path 3014.

[0100] As illustrated in FIG. 14, a bypass valving system (e.g., including an electronically controlled valve 3018, bypass line 3020, bypass valve 3022, and / or gas measurement device 3024) may be disposed along the third flow path 3014 in addition to the valve 3016. The bypass valving system may enable the control of gas flowing from the separator 100 throughout flowback operations (e.g., when it may be desirable to “burp” the vessel of the separator 100) and after flowback operations when a substantial flow of gas has been established. In some embodiments, the valve 3016 may not be present such that the bypass valving system provides all control of flow through the third flow path 3014.

[0101] During flowback operations, a valve at the second outlet 3012 of the tree 3002 may be closed while a valve at the first outlet 3008 of the tree 3002 may be opened. That way, fluid containing large amounts of liquid, sand, and debris is directed to the separator 100 through the first flow path 3006. The separator 100 may remove the liquid, sand, and debris through the liquid, sand, and debris outlet port 106 by controlling the valve 108 according to the embodiments described above. In one or more embodiments, the separator may include a vortex breaker at the liquid, sand, and debris outlet port 106.

[0102] The gas separated from the liquid, sand, and debris is delivered out of the separator 100 through the outlet nozzle 300 and subsequently transported through the third flow path 3014 and the second flow path 3010 to the gas production unit 3004 (e.g., following arrows E). The liquid, sand, and debris separated from the gas may pass through a junk catcher or other type of filter 128 so as not to clog the valve 108. Downstream of the valve 108, the liquid, sand, and debris may be manifolded to an outlet of the gas production unit 3004 through which liquid, sand, and / or debris may also be directed out of the gas production unit 3004.

[0103] After flowback operations are completed or once a gas volume suitable for permanent equipment is reached (e.g., once the well is producing largely gas), the valve atthe second outlet 3012 of the tree 3002 may be opened and the valve at the first outlet 3008 may be closed, thereby allowing the fluid to flow from the well directly to the gas production unit 3004 instead of the separator 100. Thus, the system 1000 may replace a conventional flowback spread for removing large amounts of liquid, sand, and debris.

[0104] While various embodiments of separators, gas processing facilities, systems, and methods were provided in the foregoing description, those skilled in the art may make modifications and alterations to these aspects without departing from the scope and spirit of the invention. For example, it is to be understood that this disclosure contemplates that, to the extent possible, one or more features of any aspect can be combined with one or more features of any other aspect. As another non-limiting specific example, because natural gas is often odorless, as those of ordinary skill in the art will appreciate it is customary to add an odorant, such as ethyl mercaptan, so that a gas leak can be detected anywhere the gas is being processed or consumed. Therefore, such an odorant can be added to any of the gas products produced in accordance with the present invention. Accordingly, the foregoing description is intended to be illustrative rather than restrictive. The invention described hereinabove is defined by the appended claims, and all changes to the invention that fall within the meaning and the range of equivalency of the claims are to be embraced within their scope.

[0105] The foregoing detailed description has set forth various forms of the systems and / or processes via the use of block diagrams, flowcharts, and / or examples. Insofar as such block diagrams, flowcharts, and / or examples contain one or more functions and / or operations, it will be understood by those within the art that each function and / or operation within such block diagrams, flowcharts, and / or examples can be implemented, individually and / or collectively, by a wide range of hardware, software, firmware, or virtually any combination thereof. Those skilled in the art will recognize that some aspects of the forms disclosed herein, in whole or in part, can be equivalently implemented in integrated circuits, as one or more computer programs running on one or more computers (e.g., as one or more programs running on one or more computer systems), as one or more programs running on one or more processors (e.g., as one or more programs running on one or more microprocessors), as firmware, or as virtually any combination thereof, and that designing the circuitry and / or writing the code for the software and or firmware would be well within the skill of one of skill in the art in light of this disclosure. In addition, those skilled in the art will appreciate that the mechanisms of the subject matter described herein are capable of being distributed as one or more program products in a variety of forms, and that an illustrativeform of the subject matter described herein applies regardless of the particular type of signal bearing medium used to actually carry out the distribution.

[0106] One or more components may be referred to herein as “configured to,” “configurable to,” “operable / operative to,” “adapted / adaptable,” “able to,” “conformable / conformed to,” etc. Those skilled in the art will recognize that “configured to” can generally encompass active-state components and / or inactive-state components and / or standby-state components, unless context requires otherwise.

[0107] Those skilled in the art will recognize that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to claims containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and / or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations.

[0108] In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would includebut not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). It will be further understood by those within the art that typically a disjunctive word and / or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms unless context dictates otherwise. For example, the phrase “A or B” will be typically understood to include the possibilities of “A” or “B” or “A and B.”

[0109] With respect to the appended claims, those skilled in the art will appreciate that recited operations therein may generally be performed in any order. Also, although various operational flow diagrams are presented in a sequence(s), it should be understood that the various operations may be performed in other orders than those which are illustrated or may be performed concurrently. Examples of such alternate orderings may include overlapping, interleaved, interrupted, reordered, incremental, preparatory, supplemental, simultaneous, reverse, or other variant orderings, unless context dictates otherwise. Furthermore, terms like “responsive to,” “related to,” or other past-tense adjectives are generally not intended to exclude such variants, unless context dictates otherwise.

[0110] It is worthy to note that any reference to “one aspect,” “an aspect,” “an exemplification,” “one exemplification,” and the like means that a particular feature, structure, or characteristic described in connection with the aspect is included in at least one aspect. Thus, appearances of the phrases “in one aspect,” “in an aspect,” “in an exemplification,” and “in one exemplification” in various places throughout the specification are not necessarily all referring to the same aspect. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner in one or more aspects.

[0111] As used herein, the singular form of “a”, “an”, and “the” include the plural references unless the context clearly dictates otherwise.

[0112] Any patent application, patent, non-patent publication, or other disclosure material referred to in this specification and / or listed in any Application Data Sheet is incorporated by reference herein, to the extent that the incorporated materials is not inconsistent herewith. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material. None is admitted being prior art.

[0113] In summary, numerous benefits have been described which result from employing the concepts described herein. The foregoing description of the one or more forms has been presented for purposes of illustration and description. It is not intended to be exhaustive or limiting to the precise form disclosed. Modifications or variations are possible in light of the above teachings. The one or more forms were chosen and described in order to illustrate principles and practical application to thereby enable one of ordinary skill in the art to utilize the various forms and with various modifications as are suited to the particular use contemplated. It is intended that the claims submitted herewith define the overall scope.

Claims

CLAIMSWhat is claimed is:

1. A system connected to a wellbore, the system comprising: a separator comprising: a main body defining an interior chamber; an inlet port; and an outlet port; an inlet nozzle removable from the inlet port and configured to direct a first fluid from the wellbore into the interior chamber, the inlet nozzle comprising: an inlet tubular body configured to extend through the inlet port into the interior chamber; a plurality of cutouts disposed along the inlet tubular body, the plurality of cutouts configured to permit fluid communication between the inlet tubular body and the interior chamber; and an inlet end plate fixed to a distal end of the inlet tubular body; and an outlet nozzle removable from the outlet port and configured to direct a second fluid out of the interior chamber, the outlet nozzle comprising: an outlet tubular body configured to extend through the outlet port into the interior chamber; a plurality of outlet apertures disposed along the outlet tubular body, the plurality of outlet apertures configured to permit fluid communication between the outlet tubular body and the interior chamber; and an outlet end plate fixed to a distal end of the outlet tubular body.

2. The system of claim 1, wherein the inlet nozzle further comprises a plurality of slots extending in an axial direction along the inlet tubular body, the plurality of slots configured to permit fluid communication between the interior chamber and the inlet tubular body.

3. The system of claim 1, wherein the inlet nozzle further comprises a plurality of inlet apertures disposed along the inlet tubular body opposite of the plurality of cutouts, the plurality of inlet apertures configured to permit fluid communication between the interior chamber and the inlet tubular body.

4. The system of claim 1, wherein the inlet nozzle further comprises a plurality of deflection plates configured to disrupt a flow of the first fluid entering the interior chamberthrough the inlet tubular body, wherein each deflection plate is fixed to a radial edge of a different cutout of the plurality of cutouts.

5. The system of claim 4, wherein a first deflection plate of the plurality of deflection plates comprises a first height and a second deflection plate of the plurality of deflection plates comprises a second, different height.

6. The system of claim 1, wherein the plurality of cutouts is disposed along a lower side of the inlet tubular body, thereby directing the first fluid to exit the inlet tubular body in a downward direction.

7. The system of claim 1 , wherein a first cutout of the plurality of cutouts comprises a first width and a second cutout of the plurality of cutouts comprises a second, different width.

8. The system of claim 1 , wherein the inlet nozzle further comprises an inlet flange fixed to a proximal end of the inlet tubular body, the inlet flange configured to be removably attached to the inlet port, and wherein the outlet nozzle further comprises an outlet flange fixed to a proximal end of the outlet tubular body, the outlet flange configured to be removably attached to the outlet port.

9. A system connected to a wellbore, the system comprising: a separator comprising: a main body defining an interior chamber; an inlet port; and an outlet port; and an inlet nozzle removable from the inlet port and configured to direct a first fluid from the wellbore into the interior chamber, the inlet nozzle comprising: an inlet tubular body configured to extend through the inlet port into the interior chamber; a plurality of cutouts disposed along the inlet tubular body, the plurality of cutouts configured to permit fluid communication between the inlet tubular body and the interior chamber; an inlet end plate fixed to a distal end of the inlet tubular body; and a plurality of deflection plates configured to disrupt a flow of the first fluid entering the interior chamber through the inlet tubular body; wherein each deflection plate is fixed to a radial edge of a different cutout of the plurality of cutouts, andwherein a first deflection plate of the plurality of deflection plates comprises a first height and a second deflection plate of the plurality of deflection plates comprises a second, different height.

10. The system of claim 9, further comprising: an outlet nozzle removable from the outlet port and configured to direct a second fluid out of the interior chamber, the outlet nozzle comprising: an outlet tubular body configured to extend through the outlet port into the interior chamber; a plurality of outlet apertures disposed along the outlet tubular body, the plurality of outlet apertures configured to permit fluid communication between the outlet tubular body and the interior chamber; and an outlet end plate fixed to a distal end of the outlet tubular body.

11. The system of claim 9, wherein the inlet nozzle further comprises a plurality of slots extending in an axial direction along the inlet tubular body, the plurality of slots configured to permit fluid communication between the interior chamber and the inlet tubular body.

12. The system of claim 9, wherein the inlet nozzle further comprises a plurality of inlet apertures disposed along the inlet tubular body opposite of the plurality of cutouts, the plurality of inlet apertures configured to permit fluid communication between the interior chamber and the inlet tubular body.

13. The system of claim 9, wherein the plurality of cutouts is disposed along a lower side of the inlet tubular body, thereby directing the first fluid to exit the inlet tubular body in a downward direction.

14. The system of claim 9, wherein a first cutout of the plurality of cutouts comprises a first width and a second cutout of the plurality of cutouts comprises a second, different width.

15. The system of claim 10, wherein the inlet nozzle further comprises an inlet flange fixed to a proximal end of the inlet tubular body, the inlet flange configured to be removably attached to the inlet port, and wherein the outlet nozzle further comprises an outlet flange fixed to a proximal end of the outlet tubular body, the outlet flange configured to be removably attached to the outlet port.

16. An inlet nozzle configured to direct a fluid from a first location to a second location, the inlet nozzle comprising: an inlet tubular body; a plurality of cutouts disposed along the inlet tubular body, the plurality of cutouts configured to permit fluid communication between the inlet tubular body and the second location; an inlet end plate fixed to a distal end of the inlet tubular body; and a plurality of deflection plates configured to disrupt a flow of the fluid entering the second location through the inlet tubular body; wherein each deflection plate is fixed to a radial edge of a different cutout of the plurality of cutouts, and wherein a first deflection plate of the plurality of deflection plates comprises a first height and a second deflection plate of the plurality of deflection plates comprises a second, different height.

17. The inlet nozzle of claim 16, further comprising a plurality of slots extending in an axial direction along the inlet tubular body, the plurality of slots configured to permit fluid communication between the second location and the inlet tubular body.

18. The inlet nozzle of claim 16, further comprising a plurality of inlet apertures disposed along the inlet tubular body opposite of the plurality of cutouts, the plurality of inlet apertures configured to permit fluid communication between the second location and the inlet tubular body.

19. The inlet nozzle of claim 16, wherein the plurality of cutouts is disposed along a lower side of the inlet tubular body, thereby directing the fluid to exit the inlet tubular body in a downward direction.

20. The inlet nozzle of claim 16, wherein a first cutout of the plurality of cutouts comprises a first width and a second cutout of the plurality of cutouts comprises a second, different width.

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