Oil and gas well primary separation device

1. A flowback system comprising:

a fracturing tree ( 10 ) disposed on a producing well from which a production stream comprising a liquid dispersion of water, sand, natural gas, and drilled plug cuttings flows;

a primary separator ( 100 ) configured for receiving the production stream through a fluid line ( 12 ) from the fracturing tree, the primary separator comprising:

a plug cutting separator comprising:

a housing ( 102 ) having a first end and a second end, and an interior cavity ( 108 ) extending there between;

an inlet port ( 110 ) disposed at the first end of the housing in fluid communication with the fluid line;

a first screen ( 144 ) having a plurality of perforations and extending axially within a flow sleeve ( 142 ), wherein the first screen perforations are configured having a diameter such that drilled plug cuttings remain within the first screen;

the flow sleeve disposed within the interior cavity of the housing and extending from the first end to the second end of the housing; and

the first screen disposed within the flow sleeve and in fluid communication with the inlet port, wherein an annulus ( 143 ) is formed between an outer diameter of the first screen and an inner diameter of the flow sleeve; and

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 second screen perforations and sand and other small sediment remains within the second screen;

a three-phase separator ( 16 ) configured for receiving gas particles separated in the gas separator and exiting the primary separator through a gas line ( 14 ); and

a fluid-sand clean-up line ( 18 ) configured for removing separated liquid and solid matter exiting the primary separator.

2. The flowback system of claim 1 , wherein the plurality of perforations in the first screen ( 144 ) are configured having a diameter of at least about ⅛ inch up to about 3 inches.

3. The flowback system of claim 1 , wherein the plurality of perforations in the second screen ( 178 ) are configured having a diameter of at least about 20 microns up to about 1 inch.

4. The flowback system of claim 1 , wherein the primary separator further comprises a liquid drain ( 138 ) through which liquid and solid matter flow out of the primary separator into the fluid-sand clean-up line ( 18 ).

5. The flowback system of claim 1 , wherein the primary separator further comprises a gas outlet ( 168 ) through which gas particles flow out of the primary separator into the gas line ( 14 ).

6. The flowback system of claim 1 , wherein the primary separator further comprises a baffle ( 150 ) within the interior cavity at the second end of the housing, wherein the baffle is arranged and designed to enhance separation of the production stream into its constituents.

7. The flowback system of claim 6 , wherein the baffle ( 150 ) is sized to have an outer diameter that is less than an inner diameter of the housing ( 102 ) thereby forming an upper passageway ( 152 ) and a lower passageway ( 154 ) therebetween.

8. The flowback system of claim 6 , wherein the flow sleeve ( 142 ) further comprises one or more ports ( 145 a , 145 b ) located proximate a second end of the flow sleeve.

9. The flowback system of claim 1 , further comprising a pressure gauge ( 137 ) coupled to the inlet port ( 110 ) and arranged and designed to monitor pressure entering the inlet port.

10. The flowback system of claim 1 , further comprising a pressure gauge ( 139 ) coupled to the housing ( 102 ) and arranged and designed to monitor pressure within the interior cavity ( 108 ) of the housing.

11. The flowback system of claim 10 , further comprising a pressure gauge ( 137 ) coupled to the inlet port ( 110 ) and arranged and designed to monitor pressure entering the inlet port.

12. The flowback system of claim 1 , wherein the first and second screens are removable from the primary separator for replacement or cleaning.

13. A flowback system comprising:

a fracturing tree disposed on a producing well from which a production stream comprising a liquid dispersion of water, sand, natural gas, and drilled plug cuttings flows;

a primary separation assembly configured for receiving the production stream through a fluid line from the fracturing tree, the primary separation assembly comprising:

a plug cutting separator comprising a tubular first screen having a plurality of perforations and extending axially within a tubular flow sleeve, an annulus being formed between an outer diameter of the tubular first screen and an inner diameter of the tubular flow sleeve, the first screen arranged and designed to receive the production stream flowing from the fluid line,

wherein the first screen perforations are configured having a diameter such that drilled plug cuttings remain within the first screen while the water, gas and sand exit the first screen through the first screen perforations into the annulus;

a housing having first and second ends and an interior cavity, wherein the flow sleeve is disposed within the interior of the cavity between the first and second ends of the housing;

a gas separator comprising a second screen having a plurality of perforations configured having a diameter such that gas particles flow outwardly through the second screen perforations and sand and other small sediment remains within the second screen;

a three-phase separator configured for receiving the gas particles separated in the gas separator and exiting the primary separator through a gas line; and

a fluid-sand clean-up line configured for removing separated liquid and solid matter exiting the primary separator.

14. A flowback system comprising:

a tree disposed on a well from which a production stream comprising a liquid dispersion of water, sand, gas, and drilled plug cuttings flows;

a primary separation assembly configured for receiving the production stream from the tree through a fluid line, the primary separation assembly comprising:

a main housing having an inlet, first and second ends, a bottom portion, a top portion and an interior cavity;

a tubular flow sleeve extending axially between the first and second ends of the main housing, the flow sleeve having at least one radial port located proximate the second end of the main housing;

a tubular first screen extending axially within the flow sleeve, the first screen having a plurality of perforations and a first end coupled to the main housing inlet such that the production stream flows from the fluid line into the tubular first screen;

an annulus formed between an outer diameter of the tubular first screen and an inner diameter of the tubular flow sleeve,

wherein the first screen perforations have a diameter such that the drilled plug cuttings remain within the tubular first screen while the water, gas and sand exit the first screen through the first screen perforations into the annulus, and

wherein the at least one radial port allows the water, gas and sand to exit the flow sleeve and enter the interior cavity of the main housing;

a bottom flow adaptor connected to the bottom portion of the main housing arranged and designed to receive the water and sand in the interior cavity;

a gas separator connected to the upper portion of the main housing, the gas separator comprising a second screen having a plurality of perforations having a diameter such that gas particles flow outwardly through the second screen perforations and sand and other small sediment remains within the second screen;

a three-phase separator configured for receiving the gas particles separated in the gas separator and exiting the primary separator through a gas line; and

a fluid-sand clean-up line configured for removing separated liquid and solid matter exiting the primary separator.

15. The flowback system of claim 14 , wherein the primary separation assembly further comprises a baffle within the interior cavity at the second end of the housing, wherein the baffle is arranged and designed to enhance separation of the production stream into its constituents.

16. The flowback system of claim 15 , wherein the baffle is sized to have an outer diameter that is less than an inner diameter of the main housing thereby forming an upper passageway and a lower passageway therebetween.