Filter Basket Debris Separation for Wet Sand Fracturing Slurry
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Solution Overview
Problem
Existing hydraulic fracturing systems face challenges in effectively removing debris such as rock, pebbles, and tree media from proppants and water due to the increased use of wet sand, which traditional processing equipment struggles to handle, potentially damaging frac pumps and wellbores.
Innovation Solution
A debris separator with a housing and filter basket is integrated into the fracking system to filter out larger solid objects from the slurry, allowing proppants to pass through while retaining debris, and can be easily replaced or cleaned to maintain continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional processing equipment is used to handle wet sand, then the equipment can process the sand, but the equipment is damaged by debris such as rock, pebbles, and tree media
Solution Approach 1:
The debris separator is positioned upstream in the slurry flow path, performing preliminary filtration of debris before the slurry reaches frac pumps and wellbores. This preliminary action prevents debris from causing downstream equipment damage while allowing the system to handle wet sand effectively.
Solution Approach 2:
The filter basket acts as an intermediary component between the wet sand source and the frac pumps. It mediates the slurry flow by selectively retaining debris while allowing proppants and water to pass through, protecting downstream equipment from damage.
2Reliability
If a filter basket is used to remove debris, then debris is retained, but the filter basket requires maintenance and replacement
Solution Approach 1:
The debris separator is designed with a removable filter basket that can be easily extracted from the housing. This segmentation allows the filter basket to be independently maintained, cleaned, or replaced without affecting the housing or other components, simplifying maintenance operations.
Solution Approach 2:
The filter basket is designed to be easily removable and replaceable by operators, enabling quick maintenance without requiring specialized tools or complex procedures. The simple cylindrical design with open ends facilitates easy access and self-service maintenance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The debris separator effectively filters out debris, protecting frac pumps and wellbores by ensuring only proppants and water reach the wellhead, thereby reducing equipment damage and maintaining operational efficiency.
Implementation Method 1
a filter basket connected to the housing at the inlet end and extending into the internal bore, thereby forming an annulus between the filter basket and the housing, the filter basket having a mesh size selected to pass a slurry of proppant therethrough and retain solid objects of a larger size than the proppant
Data Source
AI summary
A debris separator may include a housing having an inlet end, an outlet end, and an internal bore therebetween having a tapered discharge transitioning to the outlet end; and a filter basket connected to the housing at the inlet end and extending into the internal bore, thereby forming an annulus between the filter basket and the housing, the filter basket having a mesh size selected to pass a slurry of proppant therethrough and retain solid objects of a larger size than the proppant.