Patent Application
20240003238
The present disclosure relates to transportation and deployment of fluid and gas separation systems in oil and gas applications, and more particularly, to a separator system having one or more separators, valving systems, junk catchers, instrumentation, and other ancillary equipment capable of being delivered to a wellsite upon a single skid. This system can also serve as an alternative to conventional well flowback operations.
The entire disclosure of U.S. Patent Application Publication No. 2022/0154568 A1, filed Sep. 9, 2021, is incorporated by reference herein.
In the production of oil and gas, a separator vessel is needed to remove gas, aqueous liquids, and solids from any oil of interest before it is sent to be refined, and also to remove liquids and solids from any natural gas of interest before it is sold or processed. This type of separator is typically trucked to a wellsite, hoisted from its trailer, and placed on the ground, where it is then manually connected to a wellhead and to other equipment such as a valving system, a junk catcher, and/or other separators. Once the separator is no longer needed, it is disconnected from all associated equipment, hoisted back onto its trailer, and transported away from the wellsite. The hoisting of the separator vessel (which is typically very large and heavy, and thus typically requires a crane at each pickup and delivery location) and the manual assembly of a complex and extensive production piping system, often joined with hammer unions, every time the separator is deployed makes the process time-consuming, expensive, prone to mistakes, and potentially unsafe. Moreover, as production systems become instrumented and automated, setup becomes more complex and time-consuming. Therefore, a simpler, faster, and more reliable system for setting up and tearing down a production separator vessel is desired.
Embodiments of the present disclosure are generally directed to transportation and deployment of fluid and gas separation systems in oil and gas applications, and more particularly, to a separator system having one or more separators, valving systems, junk catchers, instrumentation, and other ancillary equipment capable of being delivered to a wellsite upon a single skid. The systems and methods disclosed herein may be used to transport a skid-mounted separator assembly (including one or more separators, one or more valving systems, and one or more junk catchers) to a wellsite on a single skid via a trailer, preferably a self-lifting trailer such as a silo setter. In certain embodiments, two frames may be hingedly coupled upon a skid. The two frames may collectively carry one or more separators, one or more valving systems, one or more junk catchers, and electronics. The two frames may be oriented vertically or horizontally upon a single skid during transport. The two frames may constitute the skid itself. A mobile skid is a skid that is capable of being transported via a trailer (for example, and without limitation, a truck, silo setter, or crane) without undue difficulty. One of the two frames may rest horizontally during production, while the other frame may stand vertically. When a separator assembly is ready to move from a wellsite, a mechanism may rotate one of the two frames such that the frames are parallel to one another for transport. The separator assembly's actuated valves may be electric, pneumatic, or any combination thereof. In certain embodiments, the separator assembly may include electronics to allow for one or more of pressure, temperature, liquid level, and flow rate monitoring, as well as one or more of local control, remote-control, lighting, video surveillance, backup power, and/or a human-machine interface (“HMI”). In certain embodiments, the separator may be a “super separator”; that is, it may be capable of maintaining high fluid pressure to produce one or more of compressed natural gas (“CNG”), liquified natural gas (“LNG”), electricity, hydrogen, and oxygen. The hydrogen and oxygen may be produced via electrolysis using the system's generated electricity. In certain embodiments, the electricity may be generated by sending high-pressure fluids through a turboexpander.
The present disclosure embodies several unique advantages over conventional flowback equipment. For example, certain embodiments allow for faster setup (and therefore shortened cycle times) at a wellsite. Furthermore, certain embodiments may reduce labor and transport costs by consolidating the separator(s), valving system(s), junk catcher(s), and electronics onto a single skid. Moreover, certain embodiments may achieve lower emissions than conventional methods by (1) reducing the number of trailers necessary to deliver equipment to a wellsite; and (2) producing zero-emission or near-zero-emission energy via pressurized fluids through the use of a super separator. These and other advantages of the systems and methods of the present disclosure may be used to increase the efficiency of wellsite operations. Deploying this equipment in close proximity to the wellhead and operating it in tandem with conventional production equipment offers an alternative to conventional flowback and/or well cleanup operations.
Some embodiments of the present disclosure are generally directed at a system for delivering a separator to a wellbore. In some non-limiting embodiments, the system includes at least one mobile skid. The at least one mobile skid includes a first frame and a second frame, and the first frame is hingedly coupled to the second frame. The system further includes at least one separator mounted upon the at least one mobile skid.
In some non-limiting embodiments, the at least one separator is mounted upon the first frame.
In some non-limiting embodiments, one or more of the following components are mounted to the second frame: (1) a first isolation valving system; (2) a first junk catcher; and (3) a first automated level control valve.
In some non-limiting embodiments, the system further includes a liquid level sensor mounted to the first frame.
In some non-limiting embodiments, the at least one mobile skid is removably mounted upon a trailer.
In some non-limiting embodiments, the trailer is a self-setting trailer.
In some non-limiting embodiments, the at least one separator is fluidly coupled to the wellbore, and the wellbore penetrates into a subterranean surface, the subterranean surface including a reservoir containing one or more hydrocarbons.
In some non-limiting embodiments, a fluid including one or more of gas, liquid, sand, and debris is produced from the wellbore and directed into the at least one separator.
In some non-limiting embodiments, the at least one separator includes a vessel defining an interior chamber, the vessel capable of operating at a pressure greater than the pressure of the fluid. In some non-limiting embodiments, the at least one separator further includes an inlet through which the fluid is directed into the vessel. In some non-limiting embodiments, the at least one separator further includes an outlet through which the gas is directed out of the vessel at a pressure substantially equal to the pressure of the fluid being produced from the wellbore. In some non-limiting embodiments, the at least one separator further includes at least one liquid level sensor capable of detecting a level of liquid within the interior chamber of the vessel at the pressure of the fluid being produced from the wellbore. In some non-limiting embodiments, the at least one separator further includes an electronically controlled valve in fluid communication with a lower portion of the vessel. In some non-limiting embodiments, the at least one separator further includes a controller connected to the at least one liquid level sensor and the electronically controlled valve, the controller programmed to open, close, or modulate the electronically controlled valve to regulate the combined flow of the liquid, sand and debris out of the lower portion of the vessel at least partially in response to the level of the liquid in the interior chamber of the vessel detected by the at least one liquid level sensor.
In some non-limiting embodiments, the first frame is approximately perpendicular to the surface.
In some non-limiting embodiments, the second frame is approximately parallel to the surface.
In some non-limiting embodiments, at least one outlet of the at least one separator is coupled to a GPU.
In some non-limiting embodiments, the GPU is in fluid communication with the at least one separator, and the at least one separator is coupled to an open outlet of the wellbore and a closed outlet of the wellbore.
In some non-limiting embodiments, the system further includes a choke valve in fluid communication with the at least one separator.
In some non-limiting embodiments, the first junk catcher and the choke valve are in fluid communication with the first isolation valving system.
In some non-limiting embodiments, the first isolation valving system is automated.
In some non-limiting embodiments, the system further includes one or more electronics coupled to one or more of the first frame and the second frame, the one or more electronics comprising one or more of a camera, a light source, and an HMI.
In some non-limiting embodiments, the first isolation valving system comprises one or more electric valves, one or more pneumatic valves, or any combination thereof.
In some non-limiting embodiments, the system further includes one or more choke valves, one or more switching valves, one or more purge valves, one or more manual valves, or any combination thereof.
In some non-limiting embodiments, the system further includes one or more logic controllers communicatively coupled to the first isolation valving system.
In some non-limiting embodiments, the one or more logic controllers include one or more of an FIC, an LIC, and a PIC.
In some non-limiting embodiments, the system further includes one or more sensors in electronic communication with the one or more FICs, the one or more LICs, the one or more PICs, the one or more logic controllers, and/or one or more HMIs.
In some non-limiting embodiments, one or more valves are actuated via the one or more LICs, one or more FICs, one or more PICs, one or more logic controllers, and/or one or more HMIs at least in part based on a signal from the one or more sensors.
In some non-limiting embodiments, the one or more sensors comprise one or more flow sensors, one or more liquid level sensors, and/or one or more pressure sensors.
In some non-limiting embodiments, the system further includes one or more HMIs for system monitoring and control.
In some non-limiting embodiments, at least one HMI is located remote from the mobile skid.
In some non-limiting embodiments, the at least one separator is equipped with a second isolation valving system, a second junk catcher, and a second automated level control valve arranged in parallel to the first isolation valving system, the first junk catcher, and the first automated level control valve.
Some embodiments of the present disclosure are generally directed at a method for delivering a separator to a wellbore. In some non-limiting embodiments, the method includes transporting a mobile skid to a surface near the wellbore, the mobile skid including a first frame coupled to a second frame via a hinge. In some non-limiting embodiments, the method further includes coupling at least one separator to the wellbore, wherein the at least one separator is mounted upon the mobile skid.
In some non-limiting embodiments, the method further includes mounting the mobile skid upon a trailer.
In some non-limiting embodiments, the method further includes raising or lowering one or more of the first frame and the second frame such that the second frame is disposed at an angle between 60 degrees and 120 degrees with respect to the first frame.
In some non-limiting embodiments, the method further includes lowering the mobile skid such that both the first frame and the second frame are approximately parallel to the surface and raising the first frame such that it is approximately perpendicular to the surface and such that it is disposed at an angle between 60 degrees and 120 degrees with respect to the second frame.
In some non-limiting embodiments, the mobile skid is lowered before disconnecting the mobile skid from the trailer, and the first frame is raised after disconnecting the mobile skid from the trailer.
In some non-limiting embodiments, the method further includes raising the mobile skid such that both the first frame and the second frame are approximately perpendicular to the surface and lowering the second frame such that it is approximately parallel to the surface and such that it is disposed at an angle between 60 degrees and 120 degrees with respect to the first frame.
In some non-limiting embodiments, the mobile skid is raised before disconnecting the mobile skid from the trailer, and wherein the second frame is lowered after disconnecting the mobile skid from the trailer.
In some non-limiting embodiments, the method further includes raising the second frame relative to the first frame such that the second frame is disposed at an angle within 5 degrees of parallel to the first frame and reconnecting the mobile skid to the trailer.
In some non-limiting embodiments, the method further includes lowering the first frame relative to the second frame such that the first frame is disposed at an angle within 5 degrees of parallel to the second frame and reconnecting the mobile skid to the trailer.
In some non-limiting embodiments, the at least one separator is mounted upon the first frame.
In some non-limiting embodiments, the method further includes sensing, via a liquid level sensor, a liquid level within a vessel of the at least one separator.
In some non-limiting embodiments, the method further includes actuating at least one automated level control valve based at least in part on a signal from the liquid level sensor.
In some non-limiting embodiments, at least one isolation valving system and at least one junk catcher are mounted upon the second frame.
In some non-limiting embodiments, a fluid comprising one or more of gas, liquid, sand, and debris is produced from the wellbore and directed into the at least one separator.
In some non-limiting embodiments, the at least one separator includes: (1) a vessel defining an interior chamber, the vessel capable of operating at a pressure greater than the pressure of the fluid; (2) an inlet through which the fluid is directed into the vessel; (3) an outlet through which the gas is directed out of the vessel at a pressure substantially equal to the pressure of the fluid being produced from the wellbore; (4) at least one liquid level sensor capable of detecting a level of liquid within the interior chamber of the vessel at the pressure of the fluid being produced from the wellbore; (5) an electronically controlled valve in fluid communication with a lower portion of the vessel; and (6) a controller connected to the at least one liquid level sensor and the electronically controlled valve, the controller programmed to open, close, or modulate the electronically controlled valve to regulate the combined flow of the liquid, sand and debris out of the lower portion of the vessel at least partially in response to the level of the liquid in the interior chamber of the vessel detected by the at least one liquid level sensor.
In some non-limiting embodiments, at least one outlet of the at least one separator is coupled to a GPU.
In some non-limiting embodiments, the method further includes coupling the at least one separator to an open outlet of the wellbore and a closed outlet of the wellbore and allowing a portion of the fluid to flow from the at least one separator to a GPU.
Some embodiments of the present disclosure are generally directed at a system for delivering a separator to a wellbore. In some non-limiting embodiments, the system includes at least one mobile skid, wherein the at least one mobile skid includes a first frame and a second frame, and wherein the first frame is hingedly coupled to the second frame. In some non-limiting embodiments, the system further includes at least one wellbore penetrating a subterranean surface including a reservoir containing one or more hydrocarbons, wherein a fluid including one or more of gas, liquid, sand, and debris is produced from the wellbore. In some non-limiting embodiments, the system further includes at least one separator mounted upon the at least one mobile skid and in fluid communication with the reservoir via the at least one wellbore. In some non-limiting embodiments, the at least one separator includes a vessel defining an interior chamber, the vessel capable of operating at a pressure greater than the pressure of the fluid. In some non-limiting embodiments, the at least one separator further includes an inlet through which the fluid is directed from the at least one wellbore into the vessel. In some non-limiting embodiments, the at least one separator further includes an outlet through which the gas is directed out of the vessel at a pressure substantially equal to the pressure of the fluid being produced from the at least one wellbore. In some non-limiting embodiments, the at least one separator further includes at least one liquid level sensor capable of detecting a level of liquid within the interior chamber of the vessel at the pressure of the fluid being produced from the at least one wellbore. In some non-limiting embodiments, the at least one separator further includes an electronically controlled valve in fluid communication with a lower portion of the vessel. In some non-limiting embodiments, the at least one separator further includes a controller connected to the at least one liquid level sensor and the electronically controlled valve, the controller programmed to open, close, or modulate the electronically controlled valve to regulate the combined flow of the liquid, sand and debris out of the lower portion of the vessel at least partially in response to the level of the liquid in the interior chamber of the vessel detected by the at least one liquid level sensor.
In some non-limiting embodiments, the at least one separator is mounted upon the first frame.
In some non-limiting embodiments, the system further includes one or more of the following components mounted to the second frame: (1) a first isolation valving system; (2) a first junk catcher; and (3) a first automated level control valve.
In some non-limiting embodiments, the at least one mobile skid is removably mounted upon a trailer.
In some non-limiting embodiments, the trailer is a self-setting trailer.
In some non-limiting embodiments, the first frame is approximately perpendicular to the subterranean surface.
In some non-limiting embodiments, the second frame is approximately parallel to the subterranean surface.
In some non-limiting embodiments, at least one outlet of the at least one separator is coupled to a GPU.
In some non-limiting embodiments, the GPU is in fluid communication with the at least one separator, and the at least one separator is coupled to an open outlet of the wellbore and a closed outlet of the wellbore.
In some non-limiting embodiments, the system further includes a choke valve in fluid communication with the at least one separator.
In some non-limiting embodiments, the first junk catcher and the choke valve are in fluid communication with the first isolation valving system.
In some non-limiting embodiments, the first isolation valving system is automated.
In some non-limiting embodiments, the system further includes one or more electronics coupled to one or more of the first frame and the second frame, the one or more electronics including one or more of a camera, a light source, and an HMI.
In some non-limiting embodiments, the first isolation valving system includes one or more electric valves, one or more pneumatic valves, or any combination thereof.
In some non-limiting embodiments, the system further includes one or more choke valves, one or more switching valves, one or more purge valves, one or more manual valves, or any combination thereof.
In some non-limiting embodiments, the system further includes one or more logic controllers communicatively coupled to the first isolation valving system.
In some non-limiting embodiments, the one or more logic controllers include one or more of an FIC, an LIC, and a PIC.
In some non-limiting embodiments, the system further includes one or more sensors in electronic communication with the one or more FICs, the one or more LICs, the one or more PICs, the one or more logic controllers, and/or one or more HMIs.
In some non-limiting embodiments, one or more valves are actuated via the one or more LICs, one or more FICs, one or more PICs, one or more logic controllers, and/or one or more HMIs at least in part based on a signal from the one or more sensors.
In some non-limiting embodiments, the one or more sensors include one or more flow sensors, one or more liquid level sensors, and/or one or more pressure sensors.
In some non-limiting embodiments, the system further includes one or more HMIs for system monitoring and control.
In some non-limiting embodiments, at least one HMI is located remote from the mobile skid.
In some non-limiting embodiments, the at least one separator is equipped with a second isolation valving system, a second junk catcher, and a second automated level control valve arranged in parallel to the first isolation valving system, the first junk catcher, and the first automated level control valve.
These and other features and characteristics of the disclosed systems and methods for transporting fluid separators will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the disclosure. As used in the specification and the claims, the singular forms of “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise.
For a more complete understanding of the present disclosure and its features and advantages, reference is now made to the following description, taken in conjunction with the accompanying drawings, in which:
For purposes of the description hereinafter, it is to be understood that the disclosure may assume alternative variations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings and described in the following specification are simply exemplary aspects of the disclosure. Hence, specific dimensions and other physical characteristics related to the aspects disclosed herein are not to be considered as limiting.
As used herein, the term “coupled” should be understood to include any direct or indirect connection between two things, including, and without limitation, a physical connection (including, and without limitation, a wired or mechanical connection), a non-physical connection (including, and without limitation, a wireless connection), a fluid connection (including, and without limitation, a connection allowing for fluid communication), or any combination thereof. Furthermore, the words “comprising” (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “has” and “have”), “including” (and any form of including, such as “includes” and “include”) or “containing” (and any form of containing, such as “contains” and “contain”) are to be understood as inclusive and open-ended and do not exclude additional, unrecited elements or method steps. Additionally, the terms “fluid” and “fluids” are to be understood as comprising one or more gases, one or more liquids, one or more solids carried by the flow of one or more gases and/or one or more liquids, and any combination thereof. As used herein, the words “trailer” or “trailers” are to be understood to include any method of ground-based transportation for oilwell equipment known in the art, including, and without limitation, trucks, cranes, and their singular equivalents.
As used herein, the term “at least one of” is synonymous with “one or more of” For example, the phrase “at least one of A, B, and C” means any one of A, B, and C, or any combination of any two or more of A, B, and C. For example, “at least one of A, B, and C” includes one or more of A alone; or one or more of B alone; or one or more of C alone; or one or more of A and one or more of B; or one or more of A and one or more of C; or one or more of B and one or more of C; or one or more of all of A, B, and C. Similarly, as used herein, the term “at least two of” is synonymous with “two or more of” For example, the phrase “at least two of D, E, and F” means any combination of any two or more of D, E, and F. For example, “at least two of D, E, and F” includes one or more of D and one or more of E; or one or more of D and one or more of F; or one or more of E and one or more of F; or one or more of all of D, E, and F.
In certain embodiments, the interior chamber of the separator 110 may comprise a vessel, wherein the vessel is capable of operating at a pressure greater than that of fluid produced from the wellbore. An electronically controlled valve may be in fluid communication with a lower portion of the vessel, and a controller may be connected to the electronically controlled valve and one or more sensors. The one or more sensors may comprise one or more of liquid level sensor(s), pressure sensor(s), and flow sensor(s). The controller may be programmed to open, close, or modulate the electronically controlled valve to regulate the combined flow of the liquid, sand and debris out of the lower portion of the vessel. In certain embodiments, the controller may direct the electronically controlled valve in response to a level of liquid, a pressure, and/or a liquid flow detected by the one or more sensors.
In certain embodiments, a separator assembly may be equipped with one or more equalization ports. In certain embodiments, one or more separators may be equipped with one or more choke valves, switching valves, and/or isolation valves. In certain embodiments, one or more valves may be automated, such that the one or more valves actuate based at least in part on one or more inputs from one or more sensors (for example, and without limitation, fluid level sensors) within the system. In certain embodiments, the separator assembly may be outfitted such that one or more valves may be actuated via a human-machine interface. The separator assembly may be operated remotely, locally, or any combination thereof.
In some non-limiting embodiments, one or more junk catchers or strainers may be transported with a separator 110. In some non-limiting embodiments, one or more valving systems may be transported with a separator 110. A valving system may incorporate one or more control valves, isolation valves, automated valves, manual valves, and any combination thereof. During production, the one or more junk catchers or strainers may be coupled to the one or more valving systems, and the one or more valving systems may be coupled to one or more separators 110. The one or more junk catchers or strainers may be located downstream from the one or more separators and may capture debris. Liquid, sand, and debris separated from the gas may pass through the one or more junk catchers or strainers so as to not clog the downstream choke valve or any other component of the system. Downstream of separator 110, gas and any liquid allowed to carry out of the separator may be connected to the inlet of a conventional gas production unit (“GPU”) through which further liquid and gas separation may occur. In certain embodiments, a GPU may modulate pressure and/or introduce heat to safeguard against the freezing effects of the pressure reduction. In certain embodiments, a GPU may be omitted from the system entirely.
Several orientations and transportation steps may be performed with respect to the skid-mounted system. In one illustrative embodiment, the two frames may be transported upon a single skid on a trailer in a horizontal orientation. In certain embodiments, the trailer may be a silo setter as depicted in
In certain embodiments, one or more separators 300 may be provided upon the first frame 308. In certain embodiments, one or more junk catchers/strainers and one or more valving systems may be provided upon the second frame 310. The entire separator assembly may be mounted upon a single skid, which may be transported upon a trailer (for example, and without limitation, a silo setter). In certain embodiments, the trailer may place the entire separator assembly on the ground near a wellhead in a horizontal position; following this, the first frame 308 may be lifted approximately ninety degrees to a vertical position. In other embodiments, the trailer may place the entire separator assembly on the ground near a wellhead in a vertical position; following this, the second frame 310 may be lowered approximately ninety degrees to a horizontal position. In certain embodiments, a single trailer may serve to pick up and put down several separator assemblies in succession; it is not necessary to procure a separate trailer for each separator assembly.
In certain embodiments, two separators 300 may be provided upon a single skid. In certain embodiments, the skid may be positioned between two wellheads such that each separator may be coupled to one wellhead. In certain embodiments, the one or more separators may perform the function of a GPU, separating gases, liquids, and/or solids from one or more produced liquids and/or natural gases. In certain embodiments, the separator assembly may fully remove the need for a GPU at the wellsite. In other embodiments, the one or more separators may allow temporary flowback while the GPU is being set up at the wellsite. In certain embodiments, each separator assembly may have a junk catcher, valving system, and isolation equipment 302; a choke valve may have independent isolation equipment. In other embodiments, a separator assembly and choke valve may share isolation equipment. Separate isolation equipment 302 allows for increased operational flexibility; conversely, shared isolation equipment cuts down on capital expense, size, and weight. It is within the ability of those skilled in the art with the benefit of the present disclosure to determine the degree to which isolation equipment should be shared between elements of the present disclosure. In certain embodiments, some or all of the equipment of the separator assembly may be pre-wired and pre-connected pneumatically, such that once the skid is delivered to the wellsite, minimal setup is required.
The embodiments depicted in
In certain embodiments, one or more junk catchers 404 may share isolation equipment with one or more choke valves 406; this is depicted in
The systems and methods disclosed herein may separate all or a fraction of the fluid from a wellbore. In certain embodiments wherein a separator is connected to a well producing gas, oil and water, the bulk of the water may be separated while letting the gas, oil, and a portion of the water carry over to be separated by conventional production equipment.
In certain embodiments, the one or more purge-actuating LICs 514 may actuate one or more purge valves to maintain a certain liquid level in the one or more separator vessels 500. In certain embodiments, the purge-actuating LICs 514 may be used in early flowback, when a substantial portion of the produced fluids comprises water and/or solids. In certain embodiments, one or more purge valves 512 may be bypassed after a gas flow rate becomes significant. It is within the ability of one of ordinary skill in the art with the benefit of this disclosure to determine when to bypass the purge valves 512.
In certain embodiments, the one or more choke-actuating LICs 516 and/or one or more flow indicator controllers (“FIC” or “FICs”) 517 may actuate whichever choke valve is currently in use. In certain embodiments, the one or more FICs 517 may be set up such that they target a fixed flow rate. In certain embodiments, the one or more choke-actuating LICs 516 may be set up such that they target a fixed liquid level in the separator vessel 500. One or more level switches may select which controller controls the choke valve based on which one would place the greatest limit on flow rate. In certain embodiments, the one or more FICs 517 may control flow rate initially, but the one or more choke-actuating LICs 516 may subsequently take precedence to ensure that a liquid level is maintained in the one or more separator vessels 500 and to ensure that no vapor blowby occurs. One or more pressure indicating transmitters 515 may be employed as an additional precaution to prevent blowby or gas loss to tanks. In certain embodiments, the vessel 500 may operate at much higher pressures than the pressure downstream of the dump/choke valve. In certain embodiments, if a pressure is sensed that is greater than the expected dump pressure, the system may be programmed to shut in.
Any of the valving systems of the present disclosure may be electric, pneumatic, or any combination thereof. The separator assembly may include one or more of isolation valves, shutdown valves, pneumatic valves, chock valves, other suitable valves known within the art, or any combination thereof. In certain embodiments, each separator vessel may be equipped with redundant isolation valving, junk catching, and/or automated level control valves. Such redundancy may be used in order to facilitate uninterrupted production during maintenance.
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In certain embodiments, one or more logic controllers may be used to control one or more elements of the separator. The one or more logic controllers may include one or more FICs 517, one or more LICs 516, one or more pressure indicating controllers (“PIC” or “PICs”) (not shown), one or more other logic controllers known in the art, or any combination thereof.
One or more purge valves 512 may be included in the valving system in some embodiments. During production, a pocket of natural gas may build up in the top of vessel 500 as the flow rate of the hydrocarbon fluid increases. In some embodiments, the flow rate of natural gas during this time may be too low for the hydrocarbon fluid to exit the vessel 500 at a steady rate. In some embodiments, the one or more purge valves 512 may open when the fluid level at the bottom of the hydrocarbon pocket reaches a first (lower) preset level. In certain embodiments, the one or more purge valves 512 may close when the fluid level reaches a second (higher) preset level. Thus, the one or more purge valves 512 may actuate intermittently in order to keep the fluid level in vessel 500 within a certain range. In some embodiments, the one or more purge valves may target a selected purge rate, which is the rate of flow through the one or more purge valves when open. Higher purge rates may more reliably mitigate buildup of the hydrocarbon pocket, while lower purge rates may more reliably avoid excessively frequent purge valve actuation. It is within the ability of one of ordinary skill in the art with the benefit of this disclosure to determine an appropriate purge rate and appropriate preset levels for the purge valves 512.
In certain embodiments, the separator assembly of the present disclosure may be fitted with or in electronic communication with one or more electronic instruments. For example, and without limitation, the separator assembly may be in electronic communication with a lighting system. The lighting system may be deliverable on the skid or may be communicatively coupled to the skid. The lighting system may be engaged via a remote interface, an interface located on-site, or an automatic system. In certain embodiments, the separator assembly may be in electronic communication with one or more surveillance cameras. Furthermore, in certain embodiments, the one or more surveillance cameras may be communicatively coupled to the lighting system. The one or more surveillance cameras may be deliverable on the skid or may be communicatively coupled to the skid. The one or more surveillance cameras may be engaged via a remote interface, an interface located on-site, or an automatic system. In certain embodiments, the separator assembly may be in electronic communication with one or more human-machine interfaces (“HMI” or “HMIs”). Furthermore, in certain embodiments, the one or more HMIs may be communicatively coupled to one or more of the lighting system or the one or more surveillance cameras. The one or more HMIs may be deliverable on the skid or may be communicatively coupled to the skid. In certain embodiments, one or more HMIs may be used to control one or more valves on the separator assembly. In certain embodiments, an HMI may act as one or more of a controller and an interface. The separator assembly may be operated remotely, locally, or any combination thereof.
In certain embodiments, one or more elements on the separator assembly (for example and without limitation, a lighting system) may require electrical power. In certain embodiments, electrical power may be provided from an electrical grid, an on-site generator, a solar panel, an on-skid generator (for example, and without limitation, a turboexpander), a backup power source (for example, and without limitation, one or more batteries), multiple variants of any of the preceding elements, or any combination thereof. The separator assembly may be electrically coupled to one or more of a gasoline generator, diesel generator, biodiesel generator, emulsified diesel generator, propane gas generator, natural gas generator, solar generator, hydrogen generator, turboexpander, or other generator known in the art. In certain embodiments, the separator assembly may pass high-pressure gas from a wellhead through a turboexpander to generate electricity. In certain embodiments, the generated electricity may be used to power one or more electronic elements on or in electronic communication with the separator assembly.
Early production fluids from wellheads tend to carry a higher volume of dust and debris than later production fluids. This dust and debris can cause damaging erosion. In certain embodiments, a separator assembly may be used to separate early production fluids in order to protect expensive, fixed equipment such as a GPU. In certain embodiments, the separator 602 may be connected to both sides of the wellhead 600. During early production, a first outlet of the wellhead 600 may be open and a second outlet of the wellhead 600 may be closed. Fluid may pass from the first outlet of the wellhead 600 into the separator 602. Once separated, hydrocarbon gas and/or a minority of the fluid may pass from the first outlet of the separator 602 to the GPU (not shown). Byproducts may pass from the second outlet of the separator 602 to the junk catcher 604. After a first period of production, the first outlet of the wellhead 600 may be closed and the second outlet of the wellhead 600 may be opened, such that fluid may pass directly to the GPU without passing through the separator 602. The separator 602 may be disconnected or left attached to the wellhead 600 as needed. Accordingly, the separator 602 may process the most erosive portion of the production fluids, thereby protecting the GPU. The embodiments listed in this paragraph are purely exemplary and non-limiting. Other wellhead configurations and production schedules may be used without departing from the scope of the present disclosure, and it is within the ability of one skilled in the art having the benefit of the present disclosure to select appropriate wellhead configurations and production schedules.
While various embodiments of a separator assembly were provided in the foregoing description, those skilled in the art may make modifications and alterations to these aspects without departing from the scope and spirit of the invention. For example, it is to be understood that this disclosure contemplates that, to the extent possible, one or more features of any aspect can be combined with one or more features of any other aspect. Accordingly, the foregoing description is intended to be illustrative rather than restrictive. The invention described hereinabove is defined by the appended claims, and all changes to the invention that fall within the meaning and the range of equivalency of the claims are to be embraced within their scope.
