Hydrocyclone Separator Backflushing for Blockage Management

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing hydrocyclone separator systems for oil-water separation face challenges with blockage detection and cleaning, leading to reduced efficiency and reliability, requiring frequent manual intervention and resulting in logistical issues, especially in remote locations.

Innovation Solution

A fluid treatment system with a hydrocyclone separator featuring a reject chamber and backflush conduit for direct cleaning, along with pressure and flow monitoring for early blockage detection and automated intervention, and a backflush configuration that positions the backflush conduit at the bottom of the reject chamber to efficiently flush out blockages.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If narrow outlet apertures are used in hydrocyclone separators to improve size and efficiency, then separation efficiency is improved, but blockage risk increases

Engineering Contradiction:

Improveseparation efficiencyVSAvoidblockage risk

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent implements pressure differential monitoring across each hydrocyclone separator to detect blockages in real-time. When a blockage is detected in a narrow outlet aperture, the system generates an alert and can automatically initiate backflushing operations, creating a feedback loop that maintains separation efficiency while managing blockage risks proactively

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system performs preliminary backflushing operations based on predicted blockage conditions or scheduled maintenance intervals. By flushing the narrow outlet apertures before complete blockage occurs, the system prevents efficiency loss while maintaining the beneficial narrow aperture design for high separation performance

Inventive Principle:

Principle #10Preliminary action

2Reliability

If manual cleaning is performed at predetermined intervals to prevent blockages, then system reliability is maintained, but operational complexity and downtime increase

Engineering Contradiction:

Improvesystem reliabilityVSAvoidoperational complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system implements automated backflushing operations that can be triggered by pressure differential sensors detecting blockage conditions. The system self-diagnoses blockages and self-cleans the hydrocyclone separators without requiring manual intervention, reducing operational complexity while maintaining high reliability through continuous monitoring and automated response

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical cleaning operations with automated sensor-based detection and fluid-based backflushing systems. Pressure sensors and control systems substitute for manual inspection and cleaning, reducing operational complexity while improving reliability through continuous automated monitoring

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If backwashing is performed to clean blockages, then operational continuity is improved, but cleaning effectiveness decreases due to material movement without removal

Engineering Contradiction:

Improveoperational continuityVSAvoidcleaning effectiveness

Core Design Contradiction:

ProductivityVSEase of repair

Solution Approach 1:

The patent implements reverse flow backflushing through the reject chamber, injecting fluid in the opposite direction of normal flow to dislodge and remove blockages. This inverted flushing approach combines the operational continuity benefits of backwashing with improved cleaning effectiveness by actively removing rather than just moving blockage material

Inventive Principle:

Principle #13The other way round (Inversion)

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 system enables efficient and reliable separation with reduced downtime and manual intervention, allowing for automated blockage detection and effective cleaning, maintaining consistent operation and improving the overall efficiency of the separation process.

Implementation Method 1

A deoiling hydrocyclone separator operates by converting pressure energy into velocity as a fluid mixture of water and oil enters the hydrocyclone through a tangential inlet. This causes the fluid inside the hydrocyclone to spin, which creates a centrifugal force thousands of times higher than the force of gravity within the fluid.

Methodology Applied

Scientific EffectCentrifugal force: Centrifugal Force

Implementation Method 2

A deoiling hydrocyclone separator operates by converting pressure energy into velocity as a fluid mixture of water and oil enters the hydrocyclone through a tangential inlet.

Methodology Applied

Scientific EffectPressure energy conversion: Pressure Gradient

Implementation Method 3

a backflush conduit connected directly to the reject chamber for supplying fluid for cleaning the reject chamber during a backflush operation

Methodology Applied

Scientific EffectFluid flow:

Data Source

PatentEP2883586B1A fluid treatment system and a method of treating a mixture

Publication Date: 2017.02.22 NAT OILWELL VARCO LP

AI summary

A fluid treatment system, a fluid processing apparatus and a method of treating a mixture are provided in which a separator has two outlets for different components of mixed fluid.