Wellhead Sand Separation With Dual Accumulators and TOR Transfer
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Solution Overview
Problem
Current hydraulic fracturing processes face inefficiencies in separating and managing solids, such as sand, from produced fluids, as existing separator systems struggle to effectively remove and handle these solids, leading to clogging and reduced well productivity.
Innovation Solution
A system comprising a separator, a first accumulator for solids, a second accumulator maintained at a lower pressure, and a transfer of rotation (TOR) device that utilizes high-pressure fluid to move solids from the first accumulator to the second, along with an isolation valve and a pump to facilitate the removal and disposal of solids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separator system is used to remove solids from produced fluid, then solids separation is achieved, but the separator system clogs and productivity decreases
Solution Approach 1:
The system divides the solids handling function into multiple independent accumulators (first accumulator for receiving solids from separator, second accumulator for storage) rather than using a single large separator. This segmentation allows continuous operation while one accumulator is being emptied, preventing productivity loss due to clogging or maintenance.
Solution Approach 2:
A TOR device acts as an intermediary mechanism between the two accumulators, using high-pressure fluid to transfer solids from the first accumulator to the second accumulator. This intermediary system enables automatic solids removal without requiring shutdown of the production flow, maintaining well productivity.
2Quantity of substance
If solids are accumulated in a single accumulator, then solids are collected, but the accumulator fills up and requires shutdown for emptying
Solution Approach 1:
The system uses two accumulators instead of one, allowing the first accumulator to be emptied into the second while production continues. This segmentation eliminates shutdown time for emptying, as the TOR device can transfer solids between accumulators during normal operation.
Solution Approach 2:
The dual-accumulator system with TOR device enables continuous solids removal during production. While the first accumulator is being emptied to the second, the separator continues to receive and separate solids from produced fluid, maintaining continuous useful action without interruption.
3Productivity
If high-pressure fluid is used to move solids between accumulators, then solids transfer is efficient, but system complexity increases
Solution Approach 1:
The system uses hydraulic principles through the TOR device, which utilizes high-pressure fluid to transfer solids between accumulators. This hydraulic approach provides efficient solids transfer while using readily available downhole fluid pressure, avoiding the need for complex mechanical pumping systems.
Solution Approach 2:
The system uses the existing high-pressure produced fluid from the well itself to power the solids transfer process. The TOR device is activated by the natural pressure of the produced fluid, making the system self-sufficient and eliminating the need for external power sources or complex control mechanisms.
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 efficiently separates and removes solids from the produced fluids, preventing clogging and maintaining well productivity by creating a pressure differential to move solids from the first accumulator to the second, where they can be disposed of or reused, enhancing the overall hydraulic fracturing process.
Implementation Method 1
a separator configured to receive a mixture of solids and fluid from a wellhead, a first accumulator configured to receive solids separated from the mixture by the separator
Implementation Method 2
a transfer of rotation (TOR) device configured to receive a high-pressure, relative to a pressure in the first accumulator, fluid and to remove solids from the first accumulator and deliver the solids to the second accumulator
Data Source
AI summary
A system includes a separator configured to receive a mixture of solids and fluid from a wellhead. The system also includes a first accumulator configured to receive the solids separated from the mixture by the separator. The system also includes a second accumulator configured to receive the solids from the first accumulator. The system also includes a transfer of rotation (TOR) device configured to receive a high-pressure, relative to a pressure in the first accumulator, fluid and to remove the solids from the first accumulator and deliver the solids to the second accumulator.