Oil and Gas Well Primary Separation Device

Abstract

A primary separation apparatus for separating natural gas from high pressure, high velocity production streams comprising a liquid dispersion of water, sand, natural gas, and isolation plug cuttings.

What is claimed is: 
     
         1 . An apparatus ( 100 ) for separating natural gas from high pressure, high velocity production streams comprising a liquid dispersion of water, sand, natural gas, and isolation plug cuttings, said apparatus comprising:
 a housing ( 102 ) having a first end and a second end, and an interior cavity ( 108 ) extending therebetween;   an inlet port ( 110 ) disposed at said first end of said housing;   a flow sleeve ( 142 ) disposed within said interior cavity of said housing and extending from said first end to said second end of said housing;   a first screen ( 144 ) disposed within said flow sleeve and in fluid communication with said inlet port, wherein an annulus ( 143 ) is formed between an outer diameter of said first screen and an inner diameter of said flow sleeve;   a baffle ( 150 ) within said interior cavity at said second end of said housing, wherein said baffle is arranged and designed to enhance separation of said production stream into its constituents;   a liquid drain ( 138 ) in a lower portion of said housing;   a second screen ( 178 ) coupled to an upper portion of said housing; and   a gas outlet ( 168 ).   
     
     
         2 . The apparatus of  claim 1 , further comprising a plurality of perforations in said first screen ( 144 ) having a diameter of at least about ⅛ inch up to about 3 inches. 
     
     
         3 . The apparatus of  claim 1 , said flow sleeve further comprising one or more ports ( 145   a ,  145   b ) located proximate a second end of said flow sleeve. 
     
     
         4 . The apparatus of  claim 1 , further comprising a plurality of perforations in said second screen ( 178 ) having a diameter of at least about 20 microns up to about 1 inch. 
     
     
         5 . The apparatus of  claim 1 , wherein said baffle ( 150 ) is sized to have an outer diameter that is less than an inner diameter of said housing ( 102 ) thereby forming an upper passageway ( 152 ) and a lower passageway ( 154 ) there between. 
     
     
         6 . The apparatus of  claim 1 , further comprising a pressure gauge ( 137 ) coupled to said inlet port ( 110 ) and arranged and designed to monitor pressure entering said inlet port. 
     
     
         7 . The apparatus of  claim 1 , further comprising a pressure gauge ( 139 ) coupled to said main housing ( 102 ) and arranged and designed to monitor pressure within said interior cavity ( 108 ) of said main housing. 
     
     
         8 . The apparatus of  claim 1 , wherein said first and second screens are removable from said housing for replacement or cleaning. 
     
     
         9 . A flowback system comprising:
 a fracturing tree ( 10 ) disposed on a producing well from which a high pressure, high velocity production stream comprising a liquid dispersion of water, sand, natural gas, and drilled plug cuttings flows;   a primary separator ( 100 ) configured for receiving said production stream through a fluid line ( 12 ) from said fracturing tree, the primary separator comprising:
 an isolation plug cutting separator comprising a first screen ( 144 ) having a plurality of perforations and extending axially within a flow sleeve ( 142 ), wherein said perforations are configured having a diameter such that drilled plug cuttings remain within said first screen; 
 a gas separator comprising a second screen ( 178 ) having a plurality of perforations configured having a diameter such that gas particles flow outwardly through the perforations and sand and other small sediment remains within said second screen; 
   a three-phase separator ( 16 ) configured for receiving gas particles separated in said gas separator and exiting said primary separator through a gas line ( 14 ); and   a fluid-sand clean-up line ( 18 ) configured for removing separated liquid and solid matter exiting said primary separator.   
     
     
         10 . The flowback system of  claim 9 , wherein said plurality of perforations in said first screen ( 144 ) are configured having a diameter of at least about ⅛ inch up to about 3 inches. 
     
     
         11 . The flowback system of  claim 9 , wherein said plurality of perforations in said second screen ( 178 ) are configured having a diameter of at least about 20 microns up to about 1 inch. 
     
     
         12 . The flowback system of  claim 9 , the primary separator further comprising a liquid drain ( 138 ) through which liquid and solid matter may flow out of said primary separator into said fluid-sand clean-up line ( 18 ). 
     
     
         13 . The flowback system of  claim 9 , the primary separator further comprising a gas outlet ( 168 ) through which gas particles may flow out of said primary separator into said gas line ( 14 ). 
     
     
         14 . A method of processing a production fluid containing a mixture of fracking fluids, drilled isolation plug cuttings, oil and natural gas, water, and sand or other sediment and small solid matter using a single separation device, the method comprising:
 flowing said production fluid into said separation device ( 100 ) through an inlet port ( 110 ) and through a first screen ( 144 ), thereby trapping drilled isolation plug cuttings within said first screen and filtering fluids and smaller solid matter radially outward through perforations of said first screen;   impinging filtered fluids and smaller solid matter on a flow baffle ( 150 ), thereby further separating gas particles from said filtered fluids;   flowing separated gas particles through a second screen ( 178 ), thereby trapping remaining sand and other small sediment within said second screen, wherein said separated gas particles then exit said separation device; and   evacuating remaining separated fluids and solid matter through a liquid drain ( 138 ) at a bottom portion of said separation device.   
     
     
         15 . The method of  claim 14 , further comprising flowing said production fluid through said separation device at a rate of between about two and twenty barrels per minute, thereby optimizing separation mechanisms dependent on gravity and retention time. 
     
     
         16 . The method of  claim 14 , further comprising processing said separated gas particles, after exiting said separation device, in a three-phase separator ( 16 ). 
     
     
         17 . The method of  claim 14 , further comprising transferring said separated fluids and solid matter, after exiting said separation device, through a fluid-sand clean-up line ( 18 ).