Sled Mounted Separator System for Low-Pressure Wells
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Solution Overview
Problem
Existing separator systems for subterranean oil and gas are costly and inefficient, particularly when wells experience reduced pressure, as they require frequent relocation and lack a compact, mobile solution that integrates the features of both horizontal and vertical separators effectively.
Innovation Solution
A compact, mobile integrated three-phase separator system that combines a horizontal separator with a vertical blowcase and vertical separator, featuring a direct fired heater and a sled-mounted design for easy transport, allowing for efficient processing and separation of oil, gas, and water by heating fluids within the horizontal separator and utilizing a mist extractor for gas and liquid separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separator systems are installed on fixed locations for oil and gas wells, then separation processing can be performed effectively, but the systems become costly to remove and install at new locations when wells are relocated or abandoned
Solution Approach 1:
The patent combines multiple separator functions (horizontal separator, vertical separator, blowcase) into a single integrated three-phase separator system that can be relocated as a complete unit. This merging of previously separate components into one relocatable system resolves the contradiction by enabling easy relocation while maintaining full separation functionality.
Solution Approach 2:
The separator system is designed with mobile characteristics, allowing it to be dynamically relocated from one well location to another. The system transitions from a fixed installation to a mobile unit that can adapt to different production locations, resolving the contradiction between effective separation processing and ease of relocation.
2Reliability
If traditional separate horizontal and vertical separator vessels are used, then each vessel can perform its specific separation function effectively, but the system requires multiple vessels increasing space requirements and relocation complexity
Solution Approach 1:
The patent integrates horizontal separator, vertical separator, and blowcase into a single three-phase separator system that maintains the separation effectiveness of each component while reducing the number of separate vessels. This merging resolves the contradiction by preserving separation reliability while improving relocation ease through consolidation into one unit.
Solution Approach 2:
The design nests the vertical separator and blowcase within or alongside the horizontal separator structure, creating a compact integrated system. This nesting arrangement maintains the functional effectiveness of each separation stage while reducing overall space requirements and simplifying relocation compared to multiple separate vessels.
3Adaptability or versatility
If wells operate at reduced pressure, then production continues from aging wells, but standard separator systems become inefficient and require frequent relocation
Solution Approach 1:
The separator system incorporates a direct-fired heater that changes the thermal parameter of the fluid stream, heating the low-pressure well fluids to improve vapor-liquid separation efficiency. This parameter change enables the system to maintain high separation productivity even when processing fluids from aging wells operating at reduced pressure.
Solution Approach 2:
The system performs preliminary heating of the fluids before they enter the separation chambers. This preliminary thermal action prepares the low-pressure fluids for effective separation by reducing fluid viscosity and improving phase separation, thereby maintaining high productivity despite operating on aging wells with reduced pressure.
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 system provides a cost-effective, efficient, and compact solution for processing fluids from low-pressure wells, enabling easy relocation and integration with wellheads and pipelines, ensuring effective separation and recycling of gases and liquids while maintaining appropriate temperatures.
Implementation Method 1
A burner assembly is provided in the three phase separator to supply heating of the fluid within the horizontal three phase separator
Implementation Method 2
the heated fluid in the horizontal separator impart heat to the fluids in the blowcase and vertical separator parts of the integrated unit
Implementation Method 3
A mist extractor at the top of the vertical vessel removes liquid from the rising gas which exits to a sales outlet
Implementation Method 4
Fluids from both the blowcase and vertical separator are transferred to the horizontal three phase separator where the fluids are separated into a gas phase, oil phase and water
Data Source
AI summary
A mobile separator system for oil and gas well production fluids consisting of a sled supporting a horizontal three phase separator vessel having an upright vessel or blowcase, with an upper section open to a lower section through a check valve, and a vertical two phase vessel mounted beside each other and seated within the horizontal vessel. A direct fired heater in the horizontal vessel provides the required heating for all three vessels. Production fluids tangentially enter the upper section of the upright vessel with gas rising and the fluid descending through a check valve to the lower section and then transferred into the horizontal vessel. The rising gas outlet is connected to the suction of a compressor and discharged under pressure to the intake of the vertical vessel. Separated gas from the horizontal vessel also is directed to the intake of the compressor. Oil and water separated in the horizontal vessel are transferred into storage or pipelines. Gas under pressure in the vertical vessel is discharged into a pipeline and tapped for operating the mobile separator system's instrumentation, controllers, valves and pressurization and also provide fuel gas for the heater.