Skid-Mounted Separator System for Rapid Wellsite Deployment
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Solution Overview
Problem
The current method of deploying separator vessels in oil and gas production is time-consuming, expensive, and prone to errors due to the need for manual assembly and hoisting of large, heavy equipment, which also results in higher emissions and increased labor costs.
Innovation Solution
A skid-mounted separator system that integrates one or more separators, valving systems, junk catchers, instrumentation, and other ancillary equipment, allowing for transportation and deployment on a single skid using a self-lifting trailer, which simplifies setup and teardown processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional separator vessels are trucked to wellsite and manually assembled with hammer unions, then separation function is achieved, but setup time is excessive and labor costs are high
Solution Approach 1:
The separator system is pre-assembled on a skid at the factory with all connections, valving systems, junk catchers, and instrumentation already installed and tested. This preliminary assembly eliminates the need for time-consuming on-site construction with hammer unions, allowing rapid deployment to multiple wellsites while maintaining full separation functionality.
Solution Approach 2:
The separator system is segmented into a modular skid-mounted unit that can be transported as a single integrated package. This segmentation allows the entire separator assembly to be moved efficiently between wellsites without requiring complex on-site assembly, directly reducing both setup time and labor requirements.
2Adaptability or versatility
If large heavy separator vessels require crane hoisting at each location, then separator can be transported, but transport costs and emissions increase
Solution Approach 1:
The separator is segmented into a compact skid-mounted configuration that reduces its effective transport weight and dimensions. This allows the system to be moved using lighter, lower-emission transport equipment rather than heavy cranes and large trucks, thereby reducing harmful emissions while maintaining the ability to be deployed at various wellsite locations.
Solution Approach 2:
The separator vessel, support structure, valving systems, and instrumentation are merged into a single integrated skid-mounted unit. This consolidation creates a self-contained module that can be transported as one package, eliminating the need for multiple heavy lifting operations and reducing overall transport emissions.
3Ease of manufacture
If manual assembly of production piping system is performed, then connections are made, but mistakes and safety issues arise
Solution Approach 1:
All piping connections, valving systems, and instrumentation are pre-assembled and pre-tested on the skid at the factory under controlled conditions. This preliminary action ensures high connection accuracy and eliminates the risk of mistakes that would occur during manual field assembly, while the modular design maintains ease of deployment.
4Ease of operation
If extensive production piping system with hammer unions is assembled manually, then separator is connected to wellhead, but labor costs increase
Solution Approach 1:
The complex piping system is segmented and pre-assembled on the skid as an integrated unit. This reduces the on-site deployment task to simple connection of pre-fabricated components, maintaining ease of operation while eliminating the need to manually assemble complex piping systems with multiple hammer unions.
Solution Approach 2:
The complex piping system, valving, and instrumentation are pre-assembled and configured on the skid at the factory. This preliminary action simplifies the on-site operation to merely connecting the pre-configured unit to the wellhead, thereby reducing labor costs while maintaining the complexity of the internal piping system.
Data Source
AI summary
Methods and compositions for skid-mounted separator assemblies are provided. In some embodiments, the compositions comprise at least one mobile skid, wherein the at least one mobile skid has a first frame and a second frame, and wherein the first frame is hingedly coupled to the second frame. In some embodiments, at least one separator is mounted upon the at least one mobile skid.