Sand Separator with Vanes and Enclosure for Plugging Prevention
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Solution Overview
Problem
Current methods for separating sand from fluid streams in oil and gas wells, such as screens and filters, are prone to plugging and rupture, leading to erosion and plugging issues that compromise equipment safety and efficiency.
Innovation Solution
A sand separation device with a pressure vessel and internal components designed for high-pressure operation, utilizing a spiral dome and vanes to separate sand through gravity and centrifugal force, allowing gas and liquids to exit while sand collects at the bottom for removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If screens or filters are used to remove sand from the fluid stream, then particles of very small diameter are effectively removed, but the screens and filters become plugged or rupture
Solution Approach 1:
The patent extracts the harmful sand particles from the fluid stream using a centrifugal separation mechanism. The separator uses a rotating impeller to generate centrifugal force that pushes sand particles outward toward the vessel wall, allowing them to be removed at the bottom outlet while clean fluid exits through the top outlet, thus eliminating the need for filters that would become plugged
Solution Approach 2:
The patent replaces the mechanical filtration system (screens and filters) with a centrifugal separation system. Instead of using physical filters that trap particles, the invention uses rotational mechanics to generate centrifugal force, which separates sand particles from fluid based on their different responses to centrifugal acceleration, thereby avoiding filter plugging and rupture issues
2Reliability
If a large tank is used for sand separation allowing fluid to lose velocity, then gravity can pull sand to the bottom, but the device occupies excessive space and reduces flow efficiency
Solution Approach 1:
The patent uses rotational motion (centrifugal force) instead of relying solely on gravity in a large static tank. The rotating impeller creates centrifugal acceleration that forces sand particles outward toward the vessel wall, enabling effective separation in a compact configuration while maintaining high flow rates through the central outlet, thus resolving the contradiction between separation effectiveness and flow efficiency
3Reliability
If sand is allowed to drop out and collect in equipment or pipes, then separation occurs, but the sand takes up space, reduces efficiency, and can plug off flow
Solution Approach 1:
The patent segments the fluid stream into two separate outlets: a top outlet for clean fluid and a bottom outlet for sand-removed fluid. The centrifugal separation mechanism continuously divides the incoming multiphase stream, allowing sand particles to be separated and removed at the bottom while clean fluid exits at the top, preventing sand accumulation that would reduce flow efficiency or cause plugging
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 device effectively reduces downtime caused by plugging issues, efficiently separating sand from fluid streams, protecting downstream equipment from erosion and plugging, and maintaining flow efficiency.
Implementation Method 1
One or more vanes extend along at least a portion of an outer surface of the enclosure, the one or more vanes redirecting the fluid stream along curved a flow path as the fluid stream flows toward the lower edge
Implementation Method 2
The fluid is fed into the vessel, where it loses velocity, allowing gravity to pull the sand to the bottom of the vessel for extraction at a later date
Data Source
AI summary
A separator vessel has inlet, fluid outlet, and sand outlet ports. Each of the fluid and sand outlet ports are spaced below the inlet port. The separator has an enclosure between the inlet and fluid outlet ports. The enclosure redirects the fluid stream and defines an inner cavity above a lower edge of the enclosure, the lower edge defining a liquid flow area. The separator has one or more vanes extending along an outer surface of the enclosure which redirect the fluid stream along a curved flow path as the fluid stream flows toward the lower edge, and a plurality of apertures adjacent to the vanes, the apertures permitting fluid flow into the inner cavity of the enclosure. The fluid outlet port is disposed within the inner cavity above the lower edge of the enclosure and below one or more apertures.