Skid-Mounted Wellhead Desander System for Multi-Well Sand Management
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Solution Overview
Problem
Current wellhead desanding operations face challenges with sand erosion and accumulation, leading to bottlenecks, asset degradation, and increased HSE exposure, particularly in multi-well pads, due to the inefficiencies of conventional equipment setups and the need for extensive footprints and high operational costs.
Innovation Solution
A skid-mounted system integrating multiple high-pressure desanders, automated control systems, and a valve manifold that allows for remote operation and flexible configuration to handle multiple wells, with the option for bulk and test fluid processing, enabling efficient sand management and reduced equipment footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional sand-cans or gravity-based separation devices are used, then equipment footprint is reduced, but sand removal efficiency is insufficient leading to erosion and accumulation problems
Solution Approach 1:
The patent combines multiple desanders, valve manifolds, and control systems into an integrated flowback system that processes fluids from multiple wells simultaneously. This merging of components resolves the contradiction by achieving high sand removal efficiency across multiple wells while maintaining a manageable system through integrated design.
Solution Approach 2:
The flowback system is designed with multi-functional components that can handle different well configurations and production scenarios. The valve manifold and desander array can be configured to process fluids from varying numbers of wells, providing universal applicability that maintains efficiency while adapting to different operational requirements.
2Productivity
If multiple separate desanders and equipment are provided for each well, then sand removal capacity is sufficient, but equipment footprint and operational costs increase significantly
Solution Approach 1:
The patent consolidates multiple desanders and valve manifolds into a single integrated flowback system that serves multiple wells. This merging approach maintains sufficient sand removal capacity for all wells while dramatically reducing the equipment footprint compared to providing separate equipment for each well.
Solution Approach 2:
The integrated system is designed with universal components that can process fluids from multiple wells through a single valve manifold and desander array. This multi-functionality allows the system to maintain high sand removal capacity while occupying minimal space by serving multiple wells simultaneously.
3Productivity
If manual operation and monitoring of desanders is used, then system complexity is reduced, but operational efficiency and safety are compromised due to erosion and accumulation bottlenecks
Solution Approach 1:
The patent incorporates automated control systems with sensors and monitoring that provide feedback on sand accumulation and fluid flow conditions. This feedback mechanism enables real-time adjustments to valve positions and desander operations, maintaining high operational efficiency and safety while managing the complexity through intelligent control.
Solution Approach 2:
The flowback system includes automated components that self-regulate sand removal operations based on monitored conditions. The system can automatically adjust valve manifolds and desander operations without constant manual intervention, improving operational efficiency while the automation manages the control complexity.
4Area of stationary object
If skid-mounted integrated system is implemented, then equipment footprint and mobility are improved, but installation and configuration complexity increases
Solution Approach 1:
The patent designs the flowback system as a skid-mounted modular unit with segmented components that can be manufactured separately and then assembled as an integrated system. This segmentation approach reduces the equipment footprint and improves mobility while the pre-fabricated modular design actually simplifies installation compared to custom-built systems.
Solution Approach 2:
The skid-mounted system is designed with universal interfaces and standardized configurations that can be deployed across multiple well pads. This universality reduces installation complexity by allowing repeated deployment of the same proven design rather than custom installations for each location.
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 solution provides a compact, efficient, and mobile desanding system that minimizes equipment footprint, reduces operational costs, and enhances safety by automating sand removal and fluid processing, thereby protecting downstream equipment and improving production efficiency.
Implementation Method 1
Cycloning (fluid circulation around the chamber) starts to take place in the feed chamber, and the rotation is encouraged by the injection feed speed, pressure, the angle of injection, and the internal geometry of the chamber. The cone shape causes the spinning fluids to accelerate as they travel down the cone towards the apex (same flow, but in a smaller circumference), which generates high centrifugal forces. The heavier particles are slung outwards and move to the outer walls and eventually toward the apex. The lighter particles stay near the center of the cone, to be carried away by the vortex finder.
Implementation Method 2
The cone shape causes the spinning fluids to accelerate as they travel down the cone towards the apex (same flow, but in a smaller circumference), which generates high centrifugal forces. The heavier particles are slung outwards and move to the outer walls and eventually toward the apex.
Implementation Method 3
Typically, solids are removed with equipment called sand-cans, which are often gravity-based separation devices.
Data Source
AI summary
Small footprint, portable skid mounted wellhead desander systems are disclosed. In one version, two systems are mounted on the skid, one system being a single well system for testing various properties of well fluids, and the other being a combined bulk system for desanding comingled flow from a plurality of wells. In another version, the skid mounted system has three independent desanders together with all essential equipment, including e.g., plug catcher, hydrocyclone desander, solids accumulator, choke manifold, and all necessary sensors, valving and control equipment.