Solids Jetting Retrofit for Separator Vessels
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Solution Overview
Problem
Gravity-based vessel separators in oil production face issues with solid particle accumulation, which disrupt fluid separation, require labor-intensive manual removal, and result in deferred production and safety risks.
Innovation Solution
A solids removal system is retrofitted into existing separators without modifying the pressure vessel, using an adjustable support structure, supply and return headers, and jetting nozzles to fluidize and remove solids while maintaining vessel pressurization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual solids removal is performed, then solids are removed from the separator, but production is deferred and labor/safety risks increase
Solution Approach 1:
The system uses the separator's own produced water as the fluidizing medium to remove solids, eliminating the need for external equipment or manual intervention. The jetting nozzles utilize the existing fluid flow to fluidize and transport solids automatically
Solution Approach 2:
Manual mechanical removal of solids is replaced by a fluidized bed system using jetting nozzles and produced water flow. The mechanical action of manual cleaning is substituted with fluid dynamics to transport solids continuously
2Ease of manufacture
If the vessel is taken offline for solids removal, then solids can be removed manually, but production time is lost
Solution Approach 1:
The solids removal system operates continuously during normal separator operation without requiring shutdown. The jetting nozzles are integrated into the existing flow path, allowing solids to be removed while the separator remains online and production continues uninterrupted
Solution Approach 2:
The system proactively fluidizes and removes solids before they accumulate to problematic levels. By continuously operating the jetting nozzles, solids are prevented from settling and accumulating, eliminating the need for periodic offline cleaning
3Extent of automation
If jetting nozzles are used to fluidize solids, then solids removal is automated, but system complexity increases
Solution Approach 1:
The jetting nozzles serve multiple functions: they fluidize solids, transport them through the return line, and utilize the existing produced water flow. The system leverages existing separator infrastructure (flow path, produced water outlet) rather than requiring completely new equipment
Solution Approach 2:
The solids removal system is nested within the existing separator structure. The jetting nozzles are positioned inside the separator vessel, utilizing the existing pressure vessel space and flow paths. The return line connects to the existing produced water outlet, integrating the new functionality into the existing design
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
Enables continuous or periodic solids removal without depressurizing the vessel, reducing labor and safety risks, and minimizing deferred production.
Implementation Method 1
introducing a jetted fluid at a high velocity into the separator pressure vessel to fluidize accumulated solids
Implementation Method 2
removing the fluidized solids with the suction header
Implementation Method 3
rely the earth's gravity to separate the different fluids based on their respective densities
Data Source
AI summary
A method of retrofitting an existing separator pressure vessel (100) with a solids removal system (118) includes installing a support structure (122) in the separator pressure vessel (100), adjusting a size of the support structure (122) within the separator pressure vessel to frictionally engage contact surfaces of the support structure with an inner surface of the separator pressure vessel or a surface of a component installed in the separator pressure vessel, installing a supply header (124) and a suction header (126) on the support structure in the separator pressure vessel, coupling a jetting nozzle (128) or a cyclonic device to the supply header, coupling the supply header to an inlet nozzle (160a) extending from an interior of the separator pressure vessel to an exterior of the separator pressure vessel; and coupling the return header to an outlet nozzle (160b) from an interior of the separator pressure vessel to an exterior of the separator pressure vessel.