Self-Cleaning Sand Screen with Rotating Spray Nozzle
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Solution Overview
Problem
Sand accumulation in sand screens used for oil and gas well fluid filtration leads to reduced effectiveness and increased maintenance costs due to plugging and pressure buildup, requiring frequent manual cleaning which is labor-intensive and hazardous.
Innovation Solution
A self-cleaning sand filtration apparatus with a pressure vessel and rotating screen, utilizing a cleaning assembly with a spray nozzle to remove obstructing sand from the screen openings, allowing for automated sand removal and reduced maintenance needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sand screen is used to remove sand from well fluid, then sand control is improved, but the screen plugging and flow restriction increase
Solution Approach 1:
The sand screen system performs self-cleaning through a combination of mechanical rotation and water spray injection. The screen rotates to prevent sand accumulation, and cleaning nozzles inject water to flush sand particles off the screen surface, allowing the system to maintain its sand control function without external intervention or flow restriction
Solution Approach 2:
The screen transitions from a static filtration structure to a dynamic rotating component. The rotation mechanism continuously moves the screen surface, preventing sand particles from settling and plugging the openings, thereby maintaining both sand control effectiveness and fluid flow rate over extended periods
2Ease of operation
If manual cleaning of sand screens is performed, then screen plugging is removed, but labor intensity and safety hazards increase
Solution Approach 1:
The system automates the cleaning process through integrated rotation mechanisms and water spray injection systems that operate autonomously within the pressure vessel. The screen rotates and self-cleans without requiring human workers to manually disassemble, remove, wash, and reassemble the screens, eliminating labor-intensive tasks and exposure to trapped sour gas hazards
Solution Approach 2:
Water serves as an intermediary cleaning agent injected through nozzles to remove sand particles from the screen surface. This intermediary substance enables automated cleaning by carrying away sand particles during the rotation process, replacing the need for manual handling and washing operations
3Quantity of substance
If sand accumulates on the screen, then sand removal effectiveness is improved, but differential pressure and production loss increase
Solution Approach 1:
The rotating screen prevents sand accumulation by continuously moving the filtration surface, ensuring that captured sand particles are periodically flushed off before they can accumulate to levels that would increase differential pressure. This dynamic approach maintains sand capture effectiveness while preventing pressure buildup
Solution Approach 2:
The system maintains continuous sand removal capability through uninterrupted rotation and periodic water spray injection. This continuous action ensures that the screen remains free of excessive sand accumulation, maintaining both sand capture effectiveness and acceptable differential pressure levels throughout operation
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 apparatus effectively maintains fluid flow and reduces maintenance costs by automatically cleaning the sand screens, preventing plugging and pressure buildup, thus enhancing the longevity and efficiency of sand filtration systems.
Implementation Method 1
a spray nozzle that is configured to spray a washing fluid radially-inward onto the outer surface of the screen
Implementation Method 2
a power device configured to rotate the screen about the central longitudinal axis
Data Source
AI summary
An apparatus for removing sand from a well fluid includes a pressure vessel having an inlet and an outlet. The well fluid flows into the pressure vessel through the inlet and flows out of the pressure vessel through the outlet. A screen is positioned at least partially within the pressure vessel and configured to remove the sand from the well fluid. At least a portion of the sand that is removed from the well fluid at least partially obstructs one or more openings in the screen. A cleaning assembly is positioned at least partially between the pressure vessel and the screen and configured to remove the sand that is obstructing the one or more openings in the screen during a screen-cleaning operation.