Fluid Testing Skid with Centrifugal Separation for Multiphase Flow
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Solution Overview
Problem
Conventional methods for separating multiphase fluids at wellheads are inefficient, leading to inaccurate measurements due to entrained gases and long retention times, requiring large equipment and high operational costs.
Innovation Solution
A method involving a testing skid with a separation component that restructures the fluid into stratified flow regimes, allowing for rapid and accurate separation of gas and liquid phases, with a liquid meter loop to determine parameters like water cut and water:oil ratio, and reinjection of gas into the liquid phase for recombination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional gravity separators are used to separate multiphase fluids, then separation of gas and liquid phases occurs, but the separation is incomplete with entrained gases and bubbles remaining, leading to inaccurate measurements
Solution Approach 1:
The patent divides the separation process into multiple stages: initial gravity separation in the separator vessel, followed by centrifugal separation in the rotating drum, and final polishing in the settling chamber. This multi-stage segmentation approach ensures complete separation by addressing different separation needs at each stage, eliminating entrained gases and bubbles that single-stage separators cannot remove.
Solution Approach 2:
The patent introduces an intermediary centrifugal separation stage between the gravity separator and the measurement devices. The rotating drum with centrifugal force acts as a mediator that aggressively removes fine bubbles and entrained gases, providing a cleanly separated fluid stream to the measurement instruments and ensuring both complete separation and accurate measurements.
2Reliability
If large gravity separators are used to achieve separation, then separation capacity increases, but equipment size and capital costs increase
Solution Approach 1:
The patent employs centrifugal hydraulic principles in the rotating drum separator, utilizing centrifugal force generated by rotation to separate phases. This dynamic hydraulic approach achieves effective separation in a compact volume, avoiding the need for large stationary gravity separators while maintaining or improving separation effectiveness.
Solution Approach 2:
The patent transitions from static gravity separation to dynamic centrifugal separation. The rotating drum creates variable centrifugal forces that enhance separation efficiency within a smaller footprint. The dynamic nature of the centrifugal field allows for more effective separation in reduced equipment volume compared to conventional static gravity separators.
3Reliability
If conventional separation methods are used, then separation occurs, but retention times are long, reducing productivity
Solution Approach 1:
The patent employs periodic centrifugal action through the rotating drum, creating repeated cycles of centrifugal separation that rapidly remove bubbles and entrained gases. This periodic centrifugal forcing accelerates the separation process compared to continuous passive gravity separation, reducing retention time while maintaining high separation quality.
Solution Approach 2:
The patent changes the separation parameter from static gravitational acceleration to dynamic centrifugal acceleration. By varying the rotational speed of the drum, the system can adjust the centrifugal force parameter to optimize separation speed and quality, achieving rapid separation with short retention times while maintaining reliable separation performance.
4Device complexity
If multiphase fluid is measured directly without complete separation, then measurement process is simplified, but measurement accuracy decreases due to entrained phases
Solution Approach 1:
The patent implements preliminary centrifugal separation before measurement, using the rotating drum to pre-treat the fluid and remove all entrained gases and bubbles. This preliminary action ensures that by the time the fluid reaches the measurement devices, it is fully separated and ready for accurate measurement, eliminating the need for complex compensation algorithms while maintaining measurement simplicity and high accuracy.
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
Achieves greater than 99% separation efficiency with minimal retention time, reducing equipment size and costs while providing accurate measurements and handling varying fluid flow rates.
Implementation Method 1
The separation component may be an external winding helically wound in a horizontal orientation... using the separation component to restructure an at least a portion of the diverted stream into stratified flow regimes comprising one or both of a gas phase and a liquid phase
Implementation Method 2
The separation component may be an external winding helically wound in a horizontal orientation... The external winding may include between 2 to 10 coil loops
Data Source
AI summary
A method for processing a fluid that includes receiving the fluid into a testing skid as an inlet flow, the fluid comprising a multi-phase fluid produced from a well. The method includes controlling the inlet flow in a manner whereby an at least a portion of the inlet flow is transferred as a diverted stream to a separation component associated with the testing skid, and using the separation component to restructure an at least a portion of the diverted stream into stratified flow regimes. The stratified flow regimes entail a gas phase and a liquid phase. The method includes using the water cut meter to determine a water:oil ratio present in the liquid phase; and discharging the liquid phase from the testing skid.