Skid-Mounted Well Fluid Separation for No-Reconfiguration Operation
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Solution Overview
Problem
Existing separation systems for multiphase well fluids require labor-intensive and time-consuming reconfiguration during different phases of well operations, such as drillout, flowback, and production, to meet custody transfer conditions, and lack efficient integration of desanding and fluid separation processes.
Innovation Solution
A skid-mounted separation system comprising a desander, choke manifold, and multiphase separator, which integrates solids, gas, and liquid separation stages, allowing for efficient and automated adjustment to meet custody transfer standards without reconfiguration, and includes a system controller for managing valve positions based on real-time measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If individual desanding, separating and pressure and flow control devices are assembled into a separation system, then the system can process well fluids, but the system requires labor-intensive and time-consuming reconfiguration during different phases of well operations
Solution Approach 1:
The patent integrates multiple separation functions (desanding, gas-liquid separation, oil-water separation) into a single unified separation system that can handle different well operation phases (drillout, flowback, production) without requiring reconfiguration. The system uses a single inlet stream that is automatically separated into multiple outlet streams based on the physical properties of the fluids, providing universal applicability across different operational phases.
Solution Approach 2:
The patent combines individual separation devices (desander, gas-liquid separator, oil-water separator) into an integrated skid-mounted system where the outlet of one separator directly connects to the inlet of the next. This merging eliminates the need for disassembly and reconnection of devices during phase transitions, significantly reducing reconfiguration time while maintaining adaptability to different well operation phases.
2Manufacturing precision
If devices are specifically sized to handle different proportions of sand, water and well fluids, then the separation system can meet custody transfer conditions, but the reconfiguration process becomes labor intensive and time consuming
Solution Approach 1:
The patent incorporates dynamically adjustable components including variable speed pumps, adjustable flow control valves, and controllable mixers that can adapt to different fluid proportions and separation requirements. This dynamic capability allows the system to maintain high separation efficiency across different well operation phases without requiring physical reconfiguration of the device architecture.
Solution Approach 2:
The integrated separation system is designed with universal components that can handle varying proportions of sand, water, and well fluids through a single configuration. The system uses a standardized multi-stage separation process that automatically adapts to different input compositions, eliminating the need to swap or resize devices while maintaining separation efficiency.
3Loss of time
If the separation system integrates solids, gas, and liquid separation stages, then setup time is reduced, but the device complexity increases
Solution Approach 1:
The patent divides the separation process into distinct functional stages (solids separation, gas-liquid separation, oil-water separation) that are vertically stacked and integrated on a single skid. Each stage handles a specific separation function, and the segmented design allows for modular manufacturing and straightforward assembly, reducing setup time while managing complexity through functional decomposition.
Solution Approach 2:
The patent implements a nested arrangement where the outlet of one separation stage is directly connected to the inlet of the next stage in a vertical configuration. This nesting eliminates intermediate connections and reduces the overall footprint, allowing the integrated system to be transported as a single unit and deployed quickly without complex assembly procedures.
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 reduces setup time and operational costs by enabling direct compliance with custody transfer conditions, allowing for immediate transition from drillout to production and minimizing the need for intermediate processing, while enhancing oil recovery and producing cleaner fluids.
Implementation Method 1
a first solids separator which is mounted on the support surface and is configured to receive the multiphase well stream and separate the well stream into a first heavy fraction primarily comprising the solids fraction
Implementation Method 2
the first separator section is configured to receive the first light fraction and separate the first light fraction into a second light fraction primarily comprising the gas fraction and a second heavy fraction primarily comprising the oil and water fractions
Data Source
AI summary
The present disclosure is directed to a separation system having a first inlet line through which a multiphase fluid is directed; a first separator connected to the first inlet line, the first separator being configured to separate the fluid into a heavy fraction primarily comprising solids and a light fraction primarily comprising gas, oil and water, the first separator comprising a heavy fraction outlet for discharge of the heavy fraction and a light fraction outlet for discharge of the light fraction; a heavy fraction outlet line connected to the heavy fraction outlet; a light fraction outlet line connected to the light fraction outlet; a second inlet line connected to the light fraction outlet line; a second separator connected to the second inlet line, the second separator being configured to separate the light fraction into separate gas, oil and water fractions, and the second separator comprising a gas outlet for discharge of the gas fraction, an oil outlet for discharge of the oil fraction, and a water outlet for discharge of the water fraction; a gas line connected to the gas outlet, an oil line connected to the oil outlet and a water line connected to the water outlet; a plurality of electrically operated valves for controlling fluid flow through respective ones of said lines; a plurality of sensors for measuring respective characteristics of the fluid; and a system controller configured to operate the valves based on inputs from the sensors to thereby control fluid flow through said lines.