US20110005757A1 - Device and method for flowing back wellbore fluids - Google Patents

Abstract

A method for heating flowing back wellbore fluids or heating fluids to treat wellbores or pipelines having a tubing string is disclosed. The wellbore will intersect a hydrocarbon reservoir. The method will include providing a diesel engine that produces heat as a result of its operation. The engine will in turn produce a gas exhaust, a water exhaust, and a hydraulic oil exhaust. The method would further include channeling the exhaust to a series of heat exchangers. The method may further include flowing a wellbore fluid into the heat exchangers and heating the wellbore fluid in the series of heat exchangers by heat transfer from the exhaust to the wellbore fluid.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS
• Reference is made to U.S. Pat. No. 6,073,695, issued on Jun. 13, 2000, which is incorporated in its entirety by reference thereto herein.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
• Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
• Not applicable
BACKGROUND OF THE INVENTIONField of the Invention
• This invention relates to an apparatus and method for treating the flowback of wellbore fluids. This invention relates to an apparatus and method for heating the fluids flowing from a wellbore to break emulsions and gas hydrates or any obstructions that would have formed due to the cooling of the fluid as it flows from the wellbore. The invention also relates to an apparatus and method for treating the flowback of wellbore fluids as well as the treatment of pipelines and wellbores.
• In order to heat these types of compounds, operators utilize an open or enclosed flame. However, government regulations have either banned or limited the use of open or enclosed flames on offshore locations and some land locations. Thus, there is a need for a thermal fluid unit that will treat a wellbore fluid without the need for having an open flame. There is also a need for a method of treating wellbore fluid with this heat
BRIEF SUMMARY OF THE INVENTION
• A method of heating a fluid flowing from a wellbore and injecting heated fluid into a wellbore or pipeline having a tubing string is disclosed. The wellbore will intersect a hydrocarbon reservoir. The method will comprise providing a diesel engine that produces heat as a result of its operation. The engine will in turn produce a gas exhaust, a water exhaust, and a hydraulic oil exhaust. These three exhaust or any combination of the three can be used to transfer heat to a heat exchanger.
• The invention also relates to an apparatus and method for treating the flowback of wellbore fluids as well as the treatment of pipelines and wellbores.
• The method would further include channeling the gas exhaust to a gas exhaust heat exchanger. The method may also include producing a hydraulic oil exhaust from the diesel engine and channeling the hydraulic oil exhaust to a hydraulic oil heat exchanger. Next, the wellbore fluid is directed into the hydraulic oil heat exchanger, and the compound is heated in the hydraulic oil heat exchanger.
• In this process, the water exchanger has been removed. The purpose of removing the water exchanger is to achieve higher temperature without overheating the engine. This provides a much more efficient unit.
• The method may further comprise flowing the wellbore fluid into the gas exhaust heat exchanger and heating the wellbore fluid in the gas exhaust heat exchanger. The operator may then flow the wellbore fluid into their upstream facilities. Any combination of these three can be used to transfer heat from the diesel engine to the exchanger thus heating the wellbore fluid.
• A second method for heating a fluid flowing from a wellbore and injecting heated fluid into a wellbore or pipeline having a tubing string is enclosed. The wellbore will intersect a hydrocarbon reservoir. The method will comprise providing a diesel engine that produces heat as a result of its operation. The method is similar to that of the first except the heat generated by the diesel engine is used to heat a fluid circulated from a reservoir on the unit. This heated, circulated fluid is then used to heat a separate heat exchanger. The purpose of this isolated heat exchange system is to provide the flowback operations with two barriers of protection before wellbore fluid is exposed to the extreme heat of the engine gas exchanger.
• Also disclosed herein is an apparatus for heating a wellbore fluid flowing from an oil and gas wellbore and injecting heated fluid into a wellbore or pipeline. The apparatus comprises a diesel engine that produces a heat source while in operation. The engine has a gas exhaust line, and a gas heat exchanger means, operatively associated with the gas exhaust line, for exchanging the heat of the gas with a set of gas heat exchange coils.
• Also included will be a wellbore fluid supply reservoir, with the wellbore fluid supply reservoir comprising a first fluid feed line means for supplying the fluid to the water heat exchanger means. Also included will be a second fluid feed line means for supplying the fluid to the gas heat exchanger means so that heat is transferred to the fluid.
• The engine will also include a hydraulic oil line, and the apparatus further comprises a hydraulic oil heat exchanger means, operatively associated with the hydraulic oil line, for exchanging the heat of the hydraulic oil with a set of hydraulic oil heat exchange coils. The fluid supply reservoir further comprises a third fluid feed line means for supplying the fluid to the hydraulic oil heat exchanger means so that the fluid is transferred the heat.
• In one embodiment, the gas exhaust line has operatively associated there with a catalytic converter member and the gas heat exchanger means has a gas output line containing a muffler to muffle the gas output.
• The apparatus may also contain a hydraulic oil line that has operatively associated there with a hydraulic oil pump means for pumping hydraulic oil from the engine into the hydraulic oil heat exchanger and further associated therewith a hydraulic back pressure control means for controlling the back pressure of the engine.
• An advantage of the present invention includes that it effectively heats fluids flowing from a wellbore this heat will break emulsions and gas hydrates that occur from cooling of the fluid. Another advantage is that fluids are heated in a single pass with continuous flow at temperatures of 140 degrees Fahrenheit up to and exceeding 300 degrees Fahrenheit without the aid of an open or enclosed flame.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
• For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
• FIG. 1 illustrates a schematic illustration of the prior art which covers the subject matter of the present invention;
• FIG. 2 is a first embodiment of the present invention in schematic illustration;
• FIG. 3 is a second embodiment of the system of the present invention in schematic illustration;
• FIG. 4 illustrates a diagram of the fluids flowing back from a wellbore; and
• FIG. 5 illustrates a diagram of heating a fluid and injecting it into a pipeline or wellbore.
DETAILED DESCRIPTION OF THE INVENTION
• Prior to a discussion of the system of the present invention, reference is made to the prior art, which is disclosed inFIG. 1 herein. As illustrated inFIG. 1, thesystem10 in the prior art of the type of systems related to the present invention. As seen inFIG. 1, the fluid (Arrow12) to be heated is fed into a 4 inch by 3 inchcentrifugal pump14 and pumped through a 2inch line16 into thewater heat exchanger18. Thewater heat exchanger18 is heated by water from thediesel engine20. Heat is generated as a function of the engines operation and the heat is transferred to water, thereby cooling theengine20. The water is then pumped fromengine20 by awater pump22 into thewater heat exchanger18 where the water comes in contact with tubes in the exchanger for carrying the fluid to be heated, and transfers the heat from the water to the tubes, thereby heating the fluid. The engine water then exits theexchanger18 and encounters atemperature control valve24 which can either send the water to theengine20, if it is cool enough, or divert it to aradiator26 to remove more heat from the water and render it cooler.
• The fluid to be heated then exits thewater exchanger18 and enters thehydraulic oil exchanger28. Thehydraulic oil exchanger28 is heated by oil kept in ahydraulic oil tank30. The oil is then pumped by ahydraulic oil pump32, which shears the oil and increases the temperature in the oil, into theheat exchanger28. The oil comes in contact with tubes in the exchanger28 (carrying the fluid to be heated) and transfers the heat to the tubes, thereby heating the fluid. The hydraulic oil then exits theexchanger28 and encounters atemperature control valve34 which can either send the oil to thetank30, if it is cool enough, or divert it to an additional heat exchanger36 to lose additional heat and be rendered cooler before entering thetank30.
• The fluid to be heated then exits theoil exchanger28 and enters theengine exhaust exchanger38. Theengine exhaust exchanger38 is heated by exhaust gas from thediesel engine20. Heat is generated as a function of the engines operation and is discharged into the engineexhaust heat exchanger38. The gas comes in contact with tubes in the exchanger38 (carrying the fluid to be heated) and transfers the heat to the tubes, thereby heating the fluid. The engine gas exhaust then exits theexchanger38 and is vented to the atmosphere at40. The heated process fluid then exits theunit10.
• FIG. 2 illustrates a first embodiment of the system of the present of the present invention by the numeral100. As seen inFIG. 2, the fluid to be heated is fed into a 4 inch by 3 inchcentrifugal pump114 and pumped through a 2inch line112 into thehydraulic oil exchanger118. Thehydraulic oil exchanger118 is heated by oil kept in ahydraulic oil tank120. The oil is then pumped by ahydraulic oil pump122, which shears the oil and increases the temperature in the oil, into theheat exchanger118. The oil comes in contact with tubes in theexchanger118, while carrying the fluid to be heated, and transfers the heat to the tubes, thereby heating the fluid to a temperature of between 40 and 300 degrees F. The hydraulic oil then exits theexchanger118 and encounters atemperature control valve124 which can either send the oil to thetank120, if it is sufficiently cool, or divert it to asecond heat exchanger126 to lose additional heat and be rendered cooler, before entering thetank120.
• The fluid to be heated then exits theoil exchanger118 and enters theengine exhaust exchanger128. Theengine exhaust exchanger128 is heated by exhaust gas from thediesel engine130. Heat is generated as a function of the engines operation and is discharged into the engineexhaust heat exchanger128. The gas comes in contact with tubes in the exchanger128 (carrying the fluid to be heated) and transfers the heat to the tubes, thereby heating the fluid. The engine gas exhaust then exits theexchanger128 and is vented to the atmosphere at132 at a temperature of between 40 and 300 degrees F. The heated process fluid then exits theunit100.
• FIG. 3 illustrates a second embodiment of the system of the present of the present invention by thenumber200. As seen inFIG. 3, the circulating fluid to be heated is fed from a heatingfluid holding tank202 into a 4 inch by 3 inchcentrifugal pump204 and pumped through a 2inch line204 and enters thehydraulic oil exchanger206. Thehydraulic oil exchanger206 is heated by oil kept in ahydraulic oil tank208. The oil is then pumped by ahydraulic oil pump210, which shears the oil and increases the temperature in the oil, into theheat exchanger206. The oil comes in contact with tubes in theexchanger206, which is carrying the fluid to be heated, and transfers the heat to the tubes, thereby heating the fluid. The hydraulic oil then exits theexchanger206 and encounters atemperature control valve212 which can either send the oil to thetank208, if it is sufficiently cool, or divert it to aheat exchanger214 to lose additional heat and cool off before entering thetank208.
• The circulating fluid to be heated then exits theoil exchanger206 and enters theengine exhaust exchanger216. Theengine exhaust exchanger216 is heated by exhaust gas from thediesel engine218. Heat is generated as a function of the engines operation and is discharged into the engineexhaust heat exchanger216. The gas comes in contact with tubes in the exchanger216 (carrying the fluid to be heated) and transfers the heat to the tubes, thereby heating the fluid. The engine gas exhaust then exits the exchanger and is vented to the atmosphere at218.
• The heated circulating fluid then enters the processfluid heat exchanger220. Theprocess fluid exchanger220 is heated by the circulating fluid exiting from theexhaust box216. The heated circulating fluid comes in contact with tubes in the exchanger220 (carrying the fluid to be heated) and transfers the heat to the tubes, thereby heating the fluid. The circulating fluid then exits theexchanger220 and returns to the heatedfluid holding tank202.
• The process fluid enters the unit and is pumped by acentrifugal pump222 to the processfluid heat exchanger220. The fluid passes through the tubes in theexchanger220 which has been heated.
• FIG. 4 illustrates the steps in the process of flowing the fluids back from thewellbore230. As illustrated inFIG. 4, the fluid (Arrow232) flows from ahydrocarbon reservoir234. The fluid232 then flows through a set oftubulars236 located in thewellbore230 and exits through awellhead238. Thewellbore fluid232 flows into thethermal unit240 where it is heated.
• FIG. 5 illustrates next the heating of the fluid232, and injecting it into a pipeline orwellbore230. The fluid232 is pumped from a tank242 into thethermal unit240 where it is heated. The fluid232 is then pumped through awellhead238 into thewellbore230 containing thetubulars236. Theheated fluid232 is then used to treat a wellbore or pipe line. The fluid heated by thethermal unit240 is heated to a temperature of between 40 and 300 degrees F. The wellbore is intersected by a hydrocarbon reservoir244.
• The following is a list of parts and materials suitable for use in the present invention.

• PARTS LIST

  Part Number	Description

  10	system/unit
  12	arrow
  14	centrifugal pump
  16	line
  18	water heat exchanger
  20	diesel engine
  22	water pump
  24	temperature control valve
  26	radiator
  28	hydraulic oil exchanger
  30	hydraulic oil tank
  32	hydraulic oil pump
  34	temperature control valve
  36	additional heat exchanger
  38	engine exhaust exchanger
  40	atmosphere
  100	system/unit
  114	centrifugal pump
  118	hydraulic oil exchanger
  120	hydraulic oil tank
  122	hydraulic pump
  124	temperature control valve
  126	second heat exchanger
  128	engine exhaust exchanger
  130	diesel engine
  132	atmosphere
  200	system/unit
  202	holding tank
  204	centrifugal pump
  206	hydraulic oil exchanger
  208	hydraulic oil tank
  210	hydraulic oil pump
  212	temperature control valve
  214	heat exchanger
  216	engine exhaust heat exchanger/box
  218	diesel engine
  220	fluid heat exchanger
  222	centrifugal pump

• All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.
• The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.

Claims (11)

1. A method of heating fluid flowing out of a wellbore comprising:

providing an engine;

producing a gas exhaust from said engine;

producing a water exhaust from said engine;

providing a hydraulic oil pump operatively connected to said engine;

providing hydraulic oil to the hydraulic oil pump for pumping said hydraulic oil;

channeling said gas exhaust to a gas exhaust heat exchanger;

channeling said water exhaust to a water exhaust heat exchanger;

providing a wellbore fluid;

channeling said hydraulic oil to a hydraulic oil heat exchanger;

injecting said wellbore fluid into said water exhaust heat exchanger, thereby heating said wellbore fluid;

injecting said wellbore fluid into said hydraulic oil heat exchanger; and

injecting said wellbore fluid into said gas exhaust heat exchanger got heating said wellbore fluid to a desired temperature.

2. The method inclaim 1, wherein the engine is a diesel or other hydrocarbon fuel driven engine.

3. The method inclaim 1, further comprising the step of providing an hydraulic oil back pressure controller, controlling the back pressure on an hydraulic oil pump outlet.

4. The method inclaim 1 wherein the heated wellbore fluid is between 40° F. and 300° F.

5. The method inclaim 1 wherein, the heated wellbore fluid breaks down emulsions formed due to the cooling of the fluid during flowback from the wellbore.

6. A method of heating fluid flowing out of a wellbore comprising the steps of:

providing an engine;

producing a gas exhaust from said engine;

providing a hydraulic oil pump operatively connected to said engine;

providing hydraulic oil to an hydraulic oil pump, pumping said hydraulic oil;

providing hydraulic oil back pressure controller, thereby controlling the back pressure on the hydraulic oil pump outlet;

channeling said gas exhaust to a gas exhaust heat exchanger;

injecting said heating fluid into an hydraulic oil heat exchanger;

injecting said heating fluid into said gas exhaust heat exchanger for heating said heating fluid;

injecting the heated fluid into a heat exchanger whereby the heating fluid is the heating medium for the exchanger; and

injecting the wellbore fluid into the exchanger of the previous step.

7. The method inclaim 6, wherein the engine is a diesel or other hydrocarbon fuel driven engine.

8. The method inclaim 6, further comprising the step of providing an hydraulic oil back pressure controller, controlling the back pressure on an hydraulic oil pump outlet.

9. The method inclaim 6, wherein the heated wellbore fluid is between 40° F. and 300° F.

10. The method inclaim 6, wherein the heated wellbore fluid breaks down emulsions formed due to the cooling of the fluid during flowback from the wellbore.

11. A method of heating fluid and treating a wellbore or pipeline with the heated fluid, comprising the steps of:

providing an engine;

producing a gas exhaust from said engine;

channeling said gas exhaust to a gas exhaust heat exchanger;

injecting said heating fluid into an hydraulic oil heat exchanger;

injecting said heating fluid into said gas exhaust heat exchanger for heating said heating fluid;

injecting the heated fluid into a heat exchanger whereby the heating fluid is the heating medium for the exchanger; and

injecting the fluid into the exchanger of the previous step; and

pumping the fluid into the wellbore for treating the wellbore, or pipeline for treating the pipeline.

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