Abstract:
A method for removing particlesParticles are removed from a high pressure flow stream entailsby flowing the high pressure flow stream into an inlet of a high pressure trap and flowing the flow stream from the inlet  into a tube in the high pressure trap. The tube is adapted to accelerate the flow stream. The flow stream leaves the tube and de-accelerates as the stream flows into a chamber. The method continues by contacting theThe flow stream withcontacts a plate wound helically around an outside surface of the tube. The plate creates a cyclonic effect within the flow stream to remove particles from the flow stream. The particles are collected in a reservoir. The remainingRemaining particles are removed by flowing the flow stream towards a side outlet over the plate. The methods end by collecting theThe remaining particles are collected in athe reservoir forming collected particles and dumping the. The collected particles are periodically dumped from the reservoir.

Description:
The present application is a continuation of U.S. patent application No. Ser. 10/345,520, filed on Jan. 16, 2003, now U.S. Pat. No. 6,893,558, which claims priority to U.S. Provisional patent application Ser. No. 60/352,450, filed on Jan. 28, 2002. 
    
    
     FIELD OF THE INVENTION 
     The present embodiments relate to methods for the removal of sand, or rock or other particulate matter from a flow stream at high pressure, before the flow stream reaches manifolds or other production or drilling equipment with moving parts, which is typically called a sand knock out system. 
     The present embodiments relate  further relate to methods of use to  of equipment associated with a fluid producing well. In particular, the present embodiments relate to methods of use of an apparatus for separating sand from the fluids extracted  produced from a well. The description, which follows, discloses the present embodiments in use with an oil well or a natural gas well, but the present embodiments are not limited to such use. 
     BACKGROUND OF THE INVENTION 
     A need exists for a device for well completions,  which is inexpensive and can maintain  sustain the high pressure of a  the well, typically in the range of 15,000 psi, while removing particles  particulate matter such as sand from the flow stream. 
     In flowing fluids from a well, such as an oil well,  or natural gas well, certain difficulties may arise depending upon the  a nature of the fluids being extracted. Frequently, sand is encountered as fluid is taken from the well. Sand, rock, and plug material must  needs to be separated from the liquid or natural gas flow to keep the completions  well completion running. If equipment is employed to remove the fluids, it is desirable that the rock and sand be removed from the other  fluids or gasses before the liquid and/or natural  fluid or gas enters the equipment, or the equipment may stop working as effectively. 
     Particulate matter, especially sand, tends to abrade the moving surfaces into which the sand-bearing liquids, dry gas, wet gas and similar flow streams come into contact. For example, production equipment has a significantly shortened working lifetime when the liquids carry sand or other abrasive particulate matter. 
     Sand strainers are commercially available for insertion into a well casing to separate sand or other particulate matter from a flow stream. A need exists for a sand or rock remover, which performs at high pressures, such as between 8,000, and 20,000 psi. 
     While drilling or during operations, material coming  flowing from the well can include a combination of oil, natural gas and sand and possibly rock in the flow stream. The rock and sand impede the flow of the oil or natural gas or desired material coming  flowing from the well. A need has existed to reduce the amount of sand in the flowing  oil or natural gas flowing from a well. The invention provides a method to reduce sand in the oil or natural gas flow from a well. 
     For purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe it. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Alterations and modifications of the illustrated device are contemplated, as are such further applications of the principles of the invention as would normally occur to one skilled in the art to which the invention pertains. 
     SUMMARY OF THE INVENTION 
     
       The invention provides a method of removing particulate matter from a flow stream produced by a well, comprising: connecting the flow stream to an inlet at a top of a particle trap so that the flow stream enters a top of a tube connected to the top of the particle trap and flows downwardly through the tube; providing a chamber at a bottom of the tube where the flow stream decelerates and a portion of the particulate matter falls out of the flow stream and collects at a bottom of the chamber as the flow steam is redirected upwardly around an outside of the tube; providing a plate wound helically around an outside surface of the tube to create a cyclonic effect in the flow stream as the flow stream flows upwardly around the tube so that more of the particles drop to the bottom of the chamber; providing a side outlet for the flow stream near a top of the chamber above a top end of the plate; and providing a dump outlet at a bottom of the chamber to permit the particulate matter to be removed from the bottom of the chamber.  
     
     
       The invention further provides a method of removing particulate matter from a high pressure flow stream produced by a well, comprising: connecting the high pressure flow stream to an inlet at a top of a high pressure particle trap so that the high pressure flow stream enters a top end of a tube connected to the top of the high pressure particle trap and flows downwardly through the tube; providing a chamber below a bottom of the tube where the high pressure flow stream decelerates and a portion of the particulate matter falls out of the high pressure flow stream and collects at a bottom of the chamber as the high pressure flow stream is redirected upwardly around an outside of the tube; providing a plate helical plate around an outside surface of the tube that creates a cyclonic effect in the high pressure flow stream as the high pressure flow stream flows upwardly around the tube and the plate so that more of the particulate matter is removed from flow stream and drops to the bottom of the chamber; providing a side outlet for the high pressure flow stream near a top end of the high pressure particle trap; and providing a dump outlet at a bottom of the chamber to permit accumulated particulate matter to be removed from the bottom of the chamber.  
     
     
       The invention yet further provides a method of removing particulate matter from a high pressure flow stream produced by a hydrocarbon well, comprising: connecting the high pressure flow stream to an inlet at a top of a high pressure particle trap so that the high pressure flow stream enters a top of a tube connected to the inlet and flows downwardly through the tube and is dispersed by a deflector plate suspended from a bottom of the tube; providing a particle trap chamber below the bottom of the tube where the high pressure flow stream decelerates and a portion of the particulate matter falls out of the high pressure flow stream and collects at a bottom of the particle trap chamber as the high pressure flow steam is redirected upwardly around an outside of the tube; providing a helical plate connected to an outside surface of the tube to create a cyclonic effect in the high pressure flow stream as the high pressure flow stream flows upwardly around the tube following the helical plate, so that more of the particulate matter drops out of the high pressure flow stream and falls to the bottom of the particle trap chamber; providing a side outlet for the high pressure flow stream near a top of the high pressure particle trap; and providing a dump outlet at a bottom of the chamber with a dump outlet controller to permit accumulated particulate matter to be removed from the chamber. 
     
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present embodiments will be explained in greater detail with reference to the appended Figures, in which: 
         FIG. 1  is a schematicflow diagram of an embodiment of a method for removing particlesparticulate matter from a high pressure flow stream; and  
         FIG. 2  depicts an embodiment of a high pressure device or trap for removing particlesparticulate matter from a flow stream from a high pressure well through a Christmas tree . 
     
    
    
     The present embodiments are detailed  described below with reference to the listed Figures  drawings. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Before explaining the present embodiments in detail, it is to be understood that the embodiments are not limited to the particular embodiments herein and it can be practiced or carried out in various ways. 
     The present embodiments are for methods of use of a sand trap or device for collecting rock, sand, or other particulate matter from a high pressure well. The methods provide a simple particulate removal device, particularly adapted for removing sand from flow streams as they come from the well. The methods further remove water-borne sand, or oil-borne sand, or both from a flow stream. 
     The present embodiments contemplate using a high pressure device to remove particles such as sand from a flow stream of a high pressure well while the device maintains  sustains the full pressure of the well. 
     The high pressure  methods for removing particles from the flow stream of a high pressure well entail flowing the high pressure flow stream into an inlet; flowing the flow stream into a tube; and ejecting  flowing the flow stream from the tube into a chamber thereby changing the velocity of the flow stream. A plate is wound helically around the outside surface of the tube to contact the flow stream creating a cyclonic effect that removes particles from the flow stream. Some of the particles removed from the flow stream are collected into  in a reservoir, thereby forming a cleaner flow stream. The remaining particles  Particles are removed from the cleaner flow stream are removed while  by flowing the cleaner flow stream toward a side outlet over the plate. The remaining  Those particles are also collected in the bottom reservoir. The methods end by dumping the  The collected particles are dumped from the bottom reservoir using a dump outlet controller. 
     Preferably, the device comprises an inlet port connected to a Christmas tree; a flange connected to the inlet port, a chamber connected to a top flange, a bottom flange connected to the chamber, a bottom reservoir formed in the chamber, a side wall connecting the top flange and the bottom flange, and wherein the side wall comprises a side outlet in fluid communication with a choke manifold; a dump outlet in communication with the bottom reservoir and connected to the bottom flange; and a dump outlet controller for opening and closing the dump outlet. In addition, a tube is connected to the top flange and the tube has a plate, which winds around the outside of the tube in a helical fashion creating a cyclonic effect with the flow stream. 
     In an alternative embodiment, the device includes a sand separator for use in separating sand and other particulates from a flow stream. The sand separator includes a deflector used at the end of the  a tube to deflect fluids from the tube and into the  a chamber. The plates  Plates are oriented on the outside of the tube such that the plates cause a cyclonic effect within the chamber as the flow stream moves from the tube orifice to the  an outlet of the chamber. The high velocity orifice of the  tube through which liquids are expelled into the sand trapping  chamber expels sand and particulate matter carried by the flow stream and accelerates the flow stream through the high velocity orifice . The flow stream is decelerated as the stream enters the sand trapping  chamber because the sand trapping  chamber has a greater flow section area than the inlet  tube. This change in flow section area changes the velocity of the flow stream causing a portion of the sand and particulate matter carried by the flow stream to fall to a bottom reservoir. As the flow stream passes up the  an outside of the tubing along the plates on the outside surface; the remaining  sand and particulate matter drop toward the bottom of the sand trapping  chamber and are collected in the bottom reservoir. Sand and particulate matter additionally  collected on the plates fall to the bottom reservoir. The bottom reservoir is opened to allow egress of the sand and particulate matter from the sand trapping  chamber. 
     With reference to the figures,  FIG. 1  is a schematic of an embodiment of a method for removing particles from a high pressure flow stream. The method begins by flowing the high pressure flow stream into an inlet of a high pressure trap (Step  100 ) and flowing the flow stream from the inlet into a tube in the high pressure trap, wherein the tube is adapted to accelerate the flow stream (Step  110 ). The methods can include the step of flowing the stream over a deflector, which is preferably, a “c” shaped deflector. 
     The flow stream travels from the tube into a chamber in the high pressure trap (Step  120 ). The chamber is adapted to de-accelerate the flow stream (Step  120 ). The flow stream contacts the plate wound helically around an outside surface of the tube (Step  130 ). The plate creates a cyclonic effect with the flow stream, thereby forcing particles to fall from the flow stream. The particles from the flow stream are collected in a reservoir located in the chamber (Step  140 ). 
     The remaining particles are removed from the cleaner flow stream by flowing the cleaner flow stream toward a side outlet over the plate (Step  150 ). The remaining particles are collected in the reservoir and the collected particles are dumped from the reservoir (Step  160 ). 
       FIG. 2  depicts an embodiment of a high pressure device or trap  10  for removing particles from a flow stream  8 that flows from a high pressure well through a Christmas tree  14 , such as an oil well or natural gas well, wherein the trap maintainssustains the full pressure (psi) of the well. 
     In the most preferred embodiment, the trap  10  has an inlet port  12  connected to the Christmas tree  14 . A typical inlet port size has a 3- 1/16″ ID with a 15,000 psi working pressure. A top flange  18  connects to the inlet port  12 . The flange  18  engages a chamber  16  and bottom flange  20 . A typical chamber has a 13 ⅝″ ID with a typical length of 7 feet. A side wall  17  connects between top flange  18  and bottom flange  20 . Bottom flange  20  connects to a bottom reservoir  22 . A side outlet  23  is disposed in the side wall  17  is in fluid communication with a choke manifold  21 . The side outlet typically has 3- 1/16″ ID with a 15,000 psi working pressure. A dump outlet  24  is connected to the bottom flange  20  and is in communication with the bottom reservoir  22 . The dump outlet typically has a 2- 1/16″ ID with a 15,000 psi working pressure. 
     A dump outlet controller  26  can be connected to the dump outlet  24  and used for opening and closing the dump outlet  24 . The dump outlet controller  26  can be a manual valve or manual controller, or alternatively, a hydraulic valve or hydraulic controller. The most preferred dump controller  26  is a combination of a hydraulic gate valve and a hydraulic choke. Either a hydraulic gate valve or a manual device can be used. An example of a usable hydraulic gate valve is a Cooper Cameron type FC 2- 1/16″ ID with a 15,000 psi working pressure. A typical manual dump controller can be a plug valve with 15,000 psi working pressure. 
     Continuing with  FIG. 2 , a tube  28  is secured to the top flange  18 . The tube  28  has a first end  50  connected to the top flange  18 , and a second end  30  opening into the chamber  16 . The tube  28  has an inside surface (not shown) and an outside surface  34 . A tube  28  is typically 5 feet long with an inner diameter of 3″. A plate  38  is disposed on the outside surface  34  of the tube  28  and is oriented in a helical arrangement around the outside surface  34 . The tube  28  is mounted within the chamber  16  to the top flange  18  such that the tube  28  does not contact the side wall  17  of the chamber  16 . The tube  28  is disposed between the bottom reservoir  22  and the side outlet  23 . 
     The top flange  18  and the bottom flange  20  can each be one flange, two flanges bolted together, or a flange and a plate bolted together. Bolts are the preferred attaching means of the tubing, flanges, inlets and outlets to facilitate repair of the flange and the trap. Preferably, the top flange  18  is about 8- 1/16″ thick with a 34-⅞″ OD and a 3- 1/16″ID. The top flange  18  can be bolted to the chamber with about 20 bolts, each bolt being about 21″ in length with a 2¼″ diameter. The bottom flange  20  can be identical to the top flange  18  in the most preferred embodiment, although the flanges can be different in size and still be workable in the invention. 
     In a preferred embodiment, a deflector  40  is mounted on the second end  30  of the tube  28  to increase the dispersion of the flow stream as the stream exits the second end  30  of the tube  28 . The deflector  40  is typically  3″ across  wide  and  6″ wide  long . The deflector  40  can have a rounded downward shape similar to a downwardly facing “c” shape. The tube  28  is connected near the center of the “c” to facilitate the dispersion of the flow stream into the chamber. Other deflectors could be used which are conical, plates or box shaped. 
     The sand trap can sustain pressures between 8,000 psi and 20,000 psi, most preferably between 10,000 psi and 15,000 psi, and specifically, the pressure of the well. The flow rate through the trap can be between 1 million cubic feet per day and 400 million cubic feet per day for natural gas and between 200 barrels per day and 5000 barrels per day for oil. 
     The apparatus used in the methods is designed such that the helically wound plate creates a cyclonic effect in the chamber and producing interference with the flow of the particles from the second end of the tube  28  to the side outlet  23 . This plate can be formed from one plate cut from metal or can be made from metal segments, such as segmented plates welded together. 
     The helical plates  38  attached to the outside surface of the tube most preferably have a dimension of a 13½″ OD welded to the 4½″ OD of the tube  28 . Typically, about 40 to 50 plates, preferably 45 plates, are welded together to form the helical plates. 
     In an alternative embodiment, the wall of the chamber can be coated with a ceramic material, a graphic  graphite composite material or combinations of these to improve  reduce wear on the chamber. Similarly, the inside surface of the tube  28  can be coated with the same material or combination to improve  reduce wear. Additionally, the high pressure trap can be made from a low  an alloy steel. 
     The trap and methods can be used collect particles, such as rocks, sand, cement, and drillable plug particles. Other particulate material can be trapped as well. 
     The methods can utilize a sand separator to separate sand and other particulates from a flow being extracted  stream from a well. The sand separator includes an inlet for receiving the fluids; a sand trapping chamber coupled to the inlet; and a tube, with plates on the outside surface, for accelerating the flow being extracted  stream from the well. A deflector is located on one end of the tube for deflecting the fluids from the tube into the chamber. The tube has a high velocity orifice through which liquids are expelled into the sand-trapping chamber.  The velocity of the flow rate  stream is decreased as the flow stream enters the chamber. The liquids  fluids and any sand and particulate matter carried by the liquids  fluids are accelerated through the high velocity orifice  propelled against the deflector. A portion of the sand falls to a bottom reservoir. The fluid flow passes up the outside of the tube along the plates on the outside surface. The fluid flow changes using  creating a cyclonic effect to a laminar flow  as it pass  passes over the plates. Sand and particulate matter falls to the bottom of the sand-trapping chamber and is collected in the bottom reservoir. Sand and particulate matter collected on the plates also falls to the bottom reservoir. The bottom reservoir is opened to allow egress of the sand and particulate matter from the chamber. The sand separator can be used to extract small particulate matter from both gaseous and liquid components. 
     The devices and methods described above can be used with various types of production, completion and drilling equipment, including standard tubing completions, concentric completions, casing tubing, dual completions, and other multiple zone completions. All of these are compatible with no modification or special treatment necessary to the sand trap unless the sand trap needs to be installed subsea. For subsea applications, the devices and methods can be used on diver less  diver- less, diver assist  diver - assist , spool trees, platform tieback, side valve trees, vertical production tress  trees, multi-well trees and several  or any combination of the above. The devices and methods can be used with all choke manifolds that , which serve the purpose which is  of controlling flow and reducing pressure. The choke manifold can be a drilling, production, well testing or more sophisticated  subsea manifold. 
     While these embodiments have been described with emphasis on the preferred embodiments, it should be understood that within the scope of the appended claims the embodiments might be practiced other than as specifically described herein.