Patent Publication Number: US-2021178405-A1

Title: Modular cyclone

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application having Ser. No. 16/446,165, which was filed on Jun. 19, 2019, and which claims priority to U.S. Provisional Patent Application Ser. No. 62/690,061, which was filed on Jun. 26, 2018. Each of these priority applications is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND 
     A cyclone is a device that is used to separate and remove particles from a fluid. In one example, the fluid may be from a well and have sand particles dispersed therein. The particles may be removed based on a ratio of their centripetal force to fluid resistance. The ratio may be high for dense and/or coarse particles, and low for light and/or fine particles. 
     The cyclone may need to be replaced with a different cyclone in response to one or more properties of the fluid changing. The properties may be, for example, flow rate, viscosity, particle size, particle concentration, and the like. However, replacing the cyclone every time the properties change may be time-consuming and expensive. Therefore, what is needed is an improved cyclone that may be modified, rather than replaced, when the properties of the fluid change. 
     SUMMARY 
     Embodiments of the disclosure may provide a cyclone sand separator kit that includes a cyclone body having an inlet, a fluid outlet, and a solids outlet, the inlet being configured to receive a mixed fluid including a solid portion and a fluidic portion, the solids outlet being configured to receive the solid portion separated from the fluidic portion, and the fluid outlet being configured to receive the fluidic portion separated from the solids portion. The kit also includes a plurality of cyclone inserts configured to be positioned in the cyclone body, at least partially between the inlet and the solids outlet and at least partially between the fluids outlet and the solids outlet. The cyclone inserts each define a vortical section configured to induce inertial separation of the mixed fluid, and include different geometries including different inner diameters, different lengths for respective cylindrical sections thereof, different angles for respective conical sections thereof, different underflow outlet sizes, different vortex finder placements, or a combination thereof. 
     Embodiments of the disclosure may also provide a method for assembling a cyclone separator. The method includes determining a volumetric flow rate of fluid flowing out of a well, determining a target velocity of the fluid flowing through an inlet insert after the fluid flows out of the well, selecting the inlet insert from a plurality of inserts based at least partially upon the volumetric flow rate of the fluid and the target velocity of the fluid, selecting a cyclone starter insert from a plurality of cyclone starter inserts based at least partially upon a diameter of the cyclone starter insert and a first well flow condition, selecting a cyclone insert based at least partially upon a height of the cyclone insert and a second well flow condition, and inserting the inlet insert, the cyclone starter insert, and the cyclone insert into a cyclone body. 
     Embodiments of the disclosure may further provide a modular cyclone separator including a cyclone body having an inlet and an underflow outlet. The inlet is configured to receive a mixed fluid therethrough and into the cyclone body, and an underflow is separated from the mixed fluid and directed to the underflow outlet. The separator also includes an inlet insert removably positioned in inlet and coupled to an outside of the cyclone body, the inlet insert having a bore and a nozzle configured to direct the mixed fluid generally tangent to an interior surface of the cyclone body, at least a portion of the bore decreasing in diameter as proceeding to a tip of the nozzle. The separator further includes a cyclone insert removably positioned at least partially within the cyclone body, the cyclone insert having a conical cyclone and a height configured to produce a predetermined dwell time for fluid in the conical cyclone. The separator additionally includes a cyclone starter insert removably coupled to the cyclone insert and positioned in the cyclone body, the cyclone starter insert being received at least partially in the cyclone insert, and the cyclone starter insert being configured to induce a vortical flow in the mixed fluid received through the inlet insert. The separator also includes a sand collection vessel removably coupled to the cyclone body and in communication with the underflow outlet. The underflow is directed to within the sand collection vessel when separated from the mixed fluid in the cyclone body, and the cyclone insert and the cyclone starter insert are removable from within the cyclone body by disconnecting the cyclone body and the sand collection vessel. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present disclosure may best be understood by referring to the following description and accompanying drawings that are used to illustrate embodiments of the invention. In the drawings: 
         FIG. 1  illustrates a side view of a cyclone, according to an embodiment. 
         FIG. 2  illustrates a cross-sectional side view of the cyclone taken through line  2 - 2  in  FIG. 1 , according to an embodiment. 
         FIG. 3  illustrates an exploded cross-sectional side view of the cyclone shown in  FIG. 2 , according to an embodiment. 
         FIG. 4  illustrates an enlarged cross-sectional view of a portion of the cyclone shown in  FIG. 3 , according to an embodiment. 
         FIG. 5  illustrates an enlarged cross-sectional view of another portion of the cyclone shown in  FIG. 3 , according to an embodiment. 
         FIG. 6  illustrates an enlarged cross-sectional view of the portion of the cyclone shown in  FIG. 5  after the cyclone has been rotated 90° back into the position shown in  FIG. 1 , according to an embodiment. 
         FIG. 7  illustrates a cross-sectional side view of the cyclone with an alternative hopper blow-down nozzle, according to an embodiment. 
         FIG. 8  illustrates a flowchart of a method for assembling (e.g., sizing) a cyclone, according to an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     The following disclosure describes several embodiments for implementing different features, structures, or functions of the invention. Embodiments of components, arrangements, and configurations are described below to simplify the present disclosure; however, these embodiments are provided merely as examples and are not intended to limit the scope of the invention. Additionally, the present disclosure may repeat reference characters (e.g., numerals) and/or letters in the various embodiments and across the Figures provided herein. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed in the Figures. Moreover, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact. Finally, the embodiments presented below may be combined in any combination of ways, e.g., any element from one exemplary embodiment may be used in any other exemplary embodiment, without departing from the scope of the disclosure. 
     Additionally, certain terms are used throughout the following description and claims to refer to particular components. As one skilled in the art will appreciate, various entities may refer to the same component by different names, and as such, the naming convention for the elements described herein is not intended to limit the scope of the invention, unless otherwise specifically defined herein. Further, the naming convention used herein is not intended to distinguish between components that differ in name but not function. Additionally, in the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to.” All numerical values in this disclosure may be exact or approximate values unless otherwise specifically stated. Accordingly, various embodiments of the disclosure may deviate from the numbers, values, and ranges disclosed herein without departing from the intended scope. In addition, unless otherwise provided herein, “or” statements are intended to be non-exclusive; for example, the statement “A or B” should be considered to mean “A, B, or both A and B.” 
       FIG. 1  illustrates a side view of a cyclone separator  100 , according to an embodiment. The cyclone  100  may include an inlet  102  configured to receive a mixed fluid (e.g., a fluid containing two or more liquids or gases of different density, fluid containing liquids and solid particles, or some combination of the two). The cyclone  100  may also include a cyclone body (or “vessel”)  104  that may define an internal volume (e.g., a hollow interior). As described in greater detail below, the mixed fluid may flow through the inlet  102  and into the cyclone body  104 , and at least a portion of the particles may be separated/removed from the fluid in the cyclone body  104 . 
     The cyclone  100  may also include an overflow or “fluid” outlet  106  through which the fluid may flow after at least a portion of the particles have been removed therefrom. If two gasses or fluids of different densities are being separated, the relatively lower density fluid may proceed through the overflow outlet  106 . 
     The cyclone  100  may also include a sand collection vessel  108 , which may be coupled with the cyclone body  104 . After being separated from the mixed fluid, the underflow (e.g., separated solids or relatively denser fluids) may be received into the sand collection vessel  108 , e.g., for storage therein, as will be described in greater detail below. The cyclone  100  may also include a blow-down nozzle  110 , which may be connected to the sand collection vessel  108  proximal to a bottom thereof and may be used to evacuate or clean out the sand collected in the sand collection vessel  108 . 
       FIG. 2  illustrates a cross-sectional side view of the cyclone  100  taken through line  2 - 2  in  FIG. 1 , according to an embodiment. As shown, the cyclone body  104  may include an underflow or “solids” outlet  111  through which the underflow that is separated from the mixed fluid may proceed. Further, a cyclone starter insert  112  may be positioned at least partially within the cyclone body  104  and proximate to and/or axially-aligned with the inlet  102 . The cyclone starter insert  112  may have an aerodynamic surface that directs the mixed fluid stream to begin its helical flow path in the cyclone  100  and avoid or mitigate turbulent flow. In at least one embodiment, the cyclone starter insert  112  may be or include spiral surface. 
     A cyclone insert  114  may also be positioned at least partially within the cyclone body  104 . The cyclone insert  114  may be positioned between the inlet  102  and the sand collection vessel  108 , and may communicate therewith via the underflow outlet  111 . The cyclone insert  114  may define the shape of various internal characteristics of the cyclone body  104  (e.g., the inner diameter, the length of the cylindrical section, the angle of the conical section or filtering section, the size of the underflow outlet  111 , the placement of the vortex finder, etc.). 
     A sand hopper  116  may be positioned at least partially within the sand collection vessel  108 . For example, the sand hopper  116  may be suspended in the sand collection vessel  108 , and may not rest on the bottom of the sand collection vessel  108 . In an embodiment, the sand hopper  116  may be suspended from a flange  140  positioned at the inlet of the sand collection vessel  108 . The sand hopper  116  may be configured to receive the solids (or higher density fluids) that drop out of the underflow outlet  111 . Suspending the sand hopper  116  may allow for a more direct measurement of the weight of the sand hopper  116 , which may provide a more accurate measurement of the amount of sand (and/or fluid and/or other solids) that are contained in the sand hopper  116 . 
       FIG. 3  illustrates an exploded cross-sectional side view of the cyclone  100  shown in  FIG. 2 , according to an embodiment. An inlet insert  120  may be configured to be inserted at least partially into the inlet  102 . As described in greater detail below, the inlet insert  120  may have a tubular body with a bore formed at least partially axially therethrough. The inlet insert  120  may receive the fluid flow at the incoming large pipe diameter and converge the flowpath down to a predetermined inlet nozzle diameter, which may be eccentric to the pipe axis so as to align with the tangent of cyclone body  104 . The inlet insert  120  may have a flange (e.g., a sandwich flange)  122  coupled to or integral with a distal end thereof to limit axial movement of the inlet insert  120  within the inlet  102 . In at least one embodiment, the inserts (i.e., the cyclone starter insert  112 , the cyclone insert  114 , and/or the inlet insert  120 ) may be rigid and fixed in place, so that they do not move with respect to the remainder of the cyclone  100  (or any component thereof) during operation of the cyclone  100 . The inlet insert  120  may be selected from a plurality of inserts having different sizes (e.g., diameter, axial length, etc.), depending on operating (e.g., well) conditions. Similarly, the cyclone starter insert  112  and/or the cyclone insert  114  may be changed/replaced (e.g., selected from a plurality of different inserts of the respective type) allows for modifications to the design if the well flow conditions change. 
     A cyclone overflow tube  124  may be positioned at least partially within the cyclone body  104 . The cyclone overflow tube  124  may be in fluid communication with the overflow outlet  106 . The cyclone overflow tube  124  may allow the cleaned fluid to exit the cyclone  100  via the overflow outlet  106 . 
     As shown, the cyclone insert  114  may be configured to be inserted at least partially into the cyclone body  104 . The cyclone starter insert  112  may be positioned at least partially within the cyclone body  104  and/or the cyclone insert  114 . The cyclone body  104  may include a flange (e.g., a nozzle flange; RTJ style)  126  that may be configured to couple with a flange (e.g., a sandwich flange)  128  of the cyclone insert  114 . The sand collection vessel  108  may include or be coupled to the flange  140 , mentioned above. Thus, the flange  128  of the cyclone insert  114  may be sandwiched between two high pressure flanges  126 ,  140 . As a result, the orientation and the features and datums of the cyclone starter insert  112  and/or cyclone insert  114  may be based off of the flange  128  itself, e.g., the flange  128  may be configured to guide the angular positioning of the cyclone insert  114 . Thus, there may be no need for internal features on the cyclone body  104  to properly align or seal the cyclone insert  114 . Alignment marks may be indicated on the cyclone body  104  and/or the flanges  126 ,  128 ,  140  to enable a user to visually confirm alignment. 
     A cyclone cone  130  may be positioned at least partially within and/or form a part of the cyclone insert  114 . The cyclone cone  130  may take the primary vortex flow, which is large in diameter and travels in a downward direction, and reduce its diameter and send it upwards, making a secondary vortex spinning in the same direction and, e.g., concentric to the primary vortex flow, but traveling upward not downward. A diameter of the cyclone cone  130  may decrease proceeding downward. An underflow tube  132  may also be positioned at least partially within the cyclone insert  114 , and may form part of the underflow outlet  111  (see  FIG. 2 ). More particularly, the underflow tube  132  may be coupled to and/or in communication with a lower end of the cyclone cone  130 . 
     The sand hopper  116  may be positioned at least partially within the sand collection vessel  108 . For example, the sand hopper  116  may be suspended inside the sand collection vessel  108  and not otherwise provided with weight-bearing attachment to the sand collection vessel  108 . In other words, the sand hopper  116  may be positioned within but not coupled directly to the sand collection vessel  108  in a structural manner. The sand hopper  116  may be hung from above, e.g., from the flange  140  via a line or another suspension assembly. As such, the weight of the sand hopper  116  may be measured, without consideration to the weight of the cyclone body  104  or components/contents thereof, and/or of the sand collection vessel  108 . 
     For example, a first (e.g., male) hopper hanger clevis  136  may be positioned at least partially within the sand collection vessel  108  and/or the sand hopper  116 . The first hopper hanger clevis  136  may be used to hang the sand hopper  116  from a second (e.g., female) load hanger clevis  146  (discussed below) using a load sensing pin. The clevises  136 ,  146  may also be referred to as couplings. 
     In at least one embodiment, a diameter of a lower portion of the sand hopper  116  may decrease proceeding downward. A lowermost end of the sand hopper  116  may in communication with the blow-down nozzle  110 . 
       FIG. 4  illustrates an enlarged cross-sectional view of a portion of the cyclone  100 , specifically the inlet insert  120 , shown in  FIG. 3 , according to an embodiment. The inlet insert  120  may have a tubular body  402  having a bore  404  formed at least partially axially therethrough. In at least one embodiment, a diameter  406  of the bore  404  may remain substantially constant along a first axial portion  410  that is proximate to an inner end  408  of the inlet insert  120 . The diameter of the bore  404  may then vary in a second axial portion  412  that is proximate to the flange  122 . More particularly, the diameter of the bore  404  may increase in the second axial portion  412  proceeding toward the flange  122 . In addition, the inner end  408  may not be perpendicular to a longitudinal centerline  414  through the body  402 . Rather, a distance between the inner end  408  and the flange  122  may vary proceeding around a circumference of the inner end  408 . 
       FIGS. 5 and 6  illustrate enlarged cross-sectional views of another portion of the cyclone  100  shown in  FIG. 3 , according to an embodiment. In this embodiment,  FIGS. 5 and 6  are 90° offset from one another, with  FIG. 5  being at the same angle as  FIG. 3 , and  FIG. 6  being at the same angle as  FIG. 1 . The upper end of the sand collection vessel  108  may include or be coupled to the flange  140  that is configured to couple with the flange  128  of the cyclone insert  114 . The flange  140  may be coupled to another flange  142 , which may be a nozzle or RTJ style flange. 
     The first hopper hanger clevis  136  may extend at least partially through the flanges  140 ,  142 . For example, the first hopper hanger clevis  136  may be connected to one of the flanges  140 ,  142 . The first hopper hanger clevis  136  may also extend at least partially through a load pin (an example of a load cell)  118  and/or the second load hanger clevis  146 . The hanging of the sand hopper  116  via the first and second hopper hanger clevises  136 ,  146  (as compared to setting it on feet) may allow for loads on the sand hopper  116  to be applied to the load pin  118 . The load pin  118  being located in-line with a nozzle  500  extending through the sand collection vessel  108  (as shown), the cyclone body  104 , or both. Further, the load pin  118  may extend through the underflow path between the cyclone body  104  to the sand hopper  116 , and may allow a piece of tubing to align with the load pin  118  and allows for assembly of a weight mechanism. A blank flange  502  on an end of the nozzle  500  may be used to allow an atmospheric pressure conduit to a sensor of the load pin  118 . The load pin  118  may engage the clevis  136  and determine a tension therein, as generated by the weight of the sand hopper  116 . 
     The sandwich flanges  122 ,  128 , and/or  140  may be used for bleed rings and small instruments. The sandwich flanges  122 ,  128 , and/or  140  may also be used to mount internal structures, such as the inlet insert  120 , the cyclone insert  114 , and the second load hanger clevis  146 . Often the bleed rings and the like do not have a full flange with the holes, as they do not orientate any component to another component, but are pinched-in via the RTJ fitting. 
     Any type of load cell/load pin  118  may be used, e.g., to measure tension in the suspension assembly (in this case, the clevis  136 ) from which the sand hopper  116  is suspended. For example, the load pin  118  may have a high differential pressure cavity. A high-pressure tubing  148  may extend at least partially through the nozzle  500  and be coupled to and/or in communication with the load pin  118 . The tubing  148  may be in communication with the atmosphere on one side (e.g., outside the cyclone  100 ) and to the high-differential pressure cavity on the other side. 
       FIG. 7  illustrates a cross-sectional side view of the cyclone  100  with an alternative hopper blow-down nozzle  150 , according to an embodiment. In this embodiment, the sand hopper  116  may not have an open drain at the bottom. Instead, it may have a tube  152  that reaches down to the bottom of the sand hopper  116  and sucks/vacuums out the particles (e.g., sand) in the bottom of the sand hopper  116 . The blow-down nozzle  110  may remain present to clean out the sand collection vessel  108  (e.g., in the event that sand escapes the sand hopper  116 . In this embodiment, a seal may be omitted. 
       FIG. 8  illustrates a flowchart of a method  800  for assembling (e.g., sizing) a cyclone  100 , according to an embodiment. The method  800  may include determining (e.g., measuring) a volumetric flow rate of fluid flowing out of a well, as at  802 . The method  800  may also or instead include determining (e.g., measuring) an operating pressure of the fluid in the well, as at  804 . The method  800  may also or instead include determining (e.g., measuring) a (gas:liquid) ratio of the fluid flowing out of the well, as at  806 . For example, the ratio may be 200,000 cubic feet per day (scfd) of gas and 5,000 barrels per day (bbpd) of oil that is API grade  50 . The method  800  may also or instead include determining (e.g., measuring) a sand content and/or separation expectation (e.g.,  100  microns) of the fluid flowing out of the well, as at  808 . 
     Once one or more of the foregoing parameters are determined, the method  800  may include determining a size (e.g., exit diameter) of the inlet insert  120  based at least partially on one or more of the parameters (e.g., the volumetric flow rate) and a target velocity of the fluid flowing through the inlet insert  120 , as at  810 . For example, the user may select a target velocity of 65 ft/sec, and the size of the inlet insert  120  may be determined/selected such that it would cause the inlet velocity through the inlet insert  120  to be within a predetermined range (e.g., +/−5 ft/sec) of the target velocity (e.g., based at least partially upon the volumetric rate of the fluid flowing out of the well). As will be appreciated, 200,000 cfpd is much more voluminous at lower pressures, while the volume of the liquid generally does not vary with pressure. 
     A range of inlet inserts  120  may correspond to a cyclone body  104  with a particular size (e.g., diameter). For example, inlet inserts  120  from about 0.5 inches to about 1.5 inches may fit in a cyclone body  104  with an 8 inch diameter (e.g., because the cyclone body  104  has a 1.75 inch inlet  102 ). Thus, a 1.75 inch inlet insert  120  may be used in a larger cyclone body  104  having, for example, a 3 inch inlet  102 . There may also be more than one height available for any given cyclone body diameter. In other words, each cyclone body  104  may have a short version and a tall version, which may accommodate cyclone inserts  114  of different sizes/lengths. Longer cyclone inserts  114  may have a longer dwell time that helps to separate sand depending on well conditions. A tall cyclone body  104  may be selected, not because there is more flow, but because the flow includes a higher liquid content or because the user wants to separate to a higher efficiency or lower particle size. 
     The method  800  may also include selecting a cyclone starter insert  112  based at least partially upon the size of the inlet insert  120 , the location of the inlet insert hole, and the initial flowpath whether spiraling inwards or downwards primarily as a start, as at  812 . The cyclone starter insert  112  may be inserted/assembled on top of the cyclone insert  114 , and it may be secured before the cyclone insert  114  is inserted/assembled into the cyclone body  104 . This may be used to determine whether the cyclone starter insert  112  works well for all sizes of inlet insert  120 . If it does not, the cyclone starter insert  112  may be removed and replaced corresponding to even small changes in the size of the inlet  102 . 
     The method  800  may also include selecting a cyclone insert  114  based at least partially upon the gas/oil/water volumetric percentages, the viscosity of the oil, and/or the size of the particle of sand targeted, as at  814 . The cyclone insert  114  may have different lengths, cone dimensions, and/or angles to allow for longer or shorter dwell times (e.g., depending on the amount of fluid and its viscosity). For example, greater amounts of fluid and/or greater viscosity may require longer for the particles (e.g., sand) to separate therefrom. The inner diameter and cone dimensions may be changed to adapt to different well conditions and/or to improve cyclonic action. 
     The method  800  may also include inserting the cyclone starter insert  112 , the cyclone insert  114 , and the inlet insert  120  into the cyclone body  104 , as at  816 . The method  800  may also include placing the cyclone body  104  onto the sand collection vessel  108 , as at  818 . In at least one embodiment, a plurality of cyclone bodies  104  may be mounted/coupled to the top of a common sand collection vessel  108  (e.g., if a single cyclone body  104  cannot accommodate the entire flow). In another embodiment, several small cyclone bodies  104  may be selected, even if a single, larger cyclone body  104  can take the flow, but the smaller cyclone bodies  104  may offer higher efficiency or be able to remove smaller particles. 
     As used herein, the terms “inner” and “outer”; “up” and “down”; “upper” and “lower”; “upward” and “downward”; “above” and “below”; “inward” and “outward”; “uphole” and “downhole”; and other like terms as used herein refer to relative positions to one another and are not intended to denote a particular direction or spatial orientation. The terms “couple,” “coupled,” “connect,” “connection,” “connected,” “in connection with,” and “connecting” refer to “in direct connection with” or “in connection with via one or more intermediate elements or members.” 
     The foregoing has outlined features of several embodiments so that those skilled in the art may better understand the present disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure.