Sand Management Vessel Switching for Pressure Equalization

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Solution Overview

Problem

The differential pressure between upstream and downstream flows in sand management systems can reach a critical threshold, causing the screen to collapse, necessitating manual vessel redirection, which is time-consuming and exposes operators to high pressure, and solids accumulation rates can be unpredictable, leading to sudden increases.

Innovation Solution

A sand management system with automatic valves that dynamically shift positions to regulate fluid flow, equalize pressure, and flush vessels, using sensors to monitor solid accumulation and adjust valve operations to prevent vessel overload and maintain system stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual redirection of flow from one vessel to another is performed before the critical threshold is reached, then screen collapse is prevented, but operator exposure to high pressure and well fluids increases and time is lost

Engineering Contradiction:

Improvescreen collapse preventionVSAvoidoperator exposure to high pressure

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The system uses automatic valves controlled by a programmable logic controller (PLC) to monitor differential pressure and autonomously redirect flow between vessels when thresholds are approached, eliminating the need for manual operator intervention and thereby removing exposure to high pressure and well fluids

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The manual mechanical operation of valve redirection is replaced with an automated control system using electrical actuators and a PLC, which monitors pressure differentials and actuates valves automatically, improving safety by removing operators from hazardous environments

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If manual redirection of flow from one vessel to another is performed, then screen collapse is prevented, but the operation time increases significantly

Engineering Contradiction:

Improvescreen collapse preventionVSAvoidvessel redirection time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The automatic control system continuously monitors differential pressure and initiates valve redirection before the critical threshold is reached, allowing for proactive management of vessel fill levels and preventing emergency situations that would require rapid manual intervention

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system autonomously manages the redirection process without requiring operator presence or decision-making, enabling continuous operation and reducing the time lost to manual intervention by automating the entire monitoring and redirection sequence

Inventive Principle:

Principle #25Self-service

3Object-affected harmful factors

If automatic valves are used to monitor and redirect flow based on differential pressure, then operator safety is improved, but device complexity increases

Engineering Contradiction:

Improveoperator exposure reductionVSAvoidautomatic valve control system

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The programmable logic controller (PLC) serves multiple functions including monitoring differential pressure, controlling valve actuation, managing the diversion sequence, and providing system diagnostics, thereby consolidating control functions into a single device and reducing overall system complexity despite the addition of automation

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The PLC acts as an intermediary between the pressure sensors and the valve actuators, processing sensor signals and controlling valve operations without requiring direct manual intervention, thus simplifying the control architecture while maintaining safety

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Automated valve control and pressure equalization prevent screen collapse, reduce operator exposure, and manage variable solid accumulation, ensuring continuous operation and safety.

Implementation Method 1

a first vessel of the two vessels include a cyclone or cyclone-shaped insert configured to initiate a cyclone effect to separate solids from fluids

Methodology Applied

Scientific EffectCyclone effect: Cyclone Separation

Implementation Method 2

a cyclone or cyclone-shaped insert configured to initiate a cyclone effect to separate solids from fluids

Methodology Applied

Scientific EffectCentrifugal force: Centrifugal Force

Implementation Method 3

a second vessel of the two vessels includes a filter element (e.g., a screen insert) configured to separate solids from fluids

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Data Source

PatentUS12534310B2Sand management systems and systems and methods to operate a sand management system

Publication Date: 2026.01.27 HALLIBURTON ENERGY SERVICES INC

AI summary

The disclosed embodiments include sand management systems and systems and methods to operate a sand management system. A sand management system includes a first vessel having a first insert and a second vessel having a second insert. The sand management system also includes a fluid flow path that fluidly connects the first vessel to the second vessel. The sand management system further includes a plurality of actuating valves each configured to dynamically shift from an open position to a closed position and from the closed position to the open position to regulate fluid flow.