HORIZONTAL GAS-LIQUID BYPASS SEPARATOR

Abstract

A horizontal gas-liquid bypass separator is provided for use in a hydrocarbon production well borehole to allow gas to pass over the upper portion of a pump inlet in a horizontal portion of a well borehole. The separator includes at least one valve having a body, a conduit extending longitudinally through the body, a channel extending transversely through the body from an outer surface of the body to the conduit, and a plunger positioned within the conduit. The plunger is movable within the channel to selectively seal the conduit relative to the channel, thereby inhibiting gas entry into the conduit when the plunger is moved to a closed position and allowing liquid to flow into the conduit when the plunger is moved to an open position.

Description

HORIZONTAL GAS-LIQUID BYPASS SEPARATOR R7. Ln / Lznz / E / YILI Field of Invention The present description is directed to an apparatus and method for oil injection and production wells and more particularly to the separation of gas and liquid from a hydrocarbon production stream. Background of the Invention An oil well is a borehole in the earth designed to bring petroleum hydrocarbons to the surface. In some versions, an oil well borehole may have a vertical portion extending in a generally vertical direction and a horizontal portion extending in a generally horizontal direction. For example, as shown in FIG. 1, a well borehole (10) may include a generally vertical portion (12) extending downward from the earth's surface (24) and a generally horizontal portion (14) extending outward and transversely to the generally vertical portion (12). A generally curved portion (16) may be placed between the generally vertical portion (12) and the generally horizontal portion (14), which is generally curved to transition the well borehole (10) from the generally vertical portion (12) to the horizontal portion (14). Ref. 327662 generally horizontal (16). A well perforation (10) may include one or more of a generally vertical portion (12), a generally horizontal portion (14) and a generally curved portion (16) that join together to form the well perforation (10). The pressure of the fluids and gases within the wellbore may be insufficient to cause them to flow naturally to the surface. In such circumstances, some form of artificial lift may be necessary to supply fluids from the well to the surface. Such artificial lift in a production well may be achieved by, but is not limited to, an electric submersible pump (ESP), a sucker rod pump, a progressive cavity pump, a plunger lift, and / or a gas injection lift. Referring back to Figure 1, an ESP system may include an electric motor (30) and a pump (42) used to pump oil or other fluids within the wellbore (10). The electric motor (30) may have a rotating rotor contained within a stationary stator.When the motor (30) is running, the rotor can rotate to provide artificial lift within the wellbore (10). Consequently, an ESP system can be configured to move fluids from the horizontal portion (14) and / or the generally curved portion. R7. Ln / Lznz / E / YILI (16) from the well drilling (10) to the surface (24) and / or the wellhead (20) through a pipe string (40) that is discharged to the surface (24). When the product flowing into the wellhead contains free and entrained gas, that gas can enter the pump and reduce its volumetric efficiency. For example, the hydrocarbon production stream may include liquid and gaseous products, which are a natural byproduct of producing wells. As hydrocarbons and water flow through the formation, gases can travel in the flow stream either separated from the liquid products or dissolved within them. Gases are carried into the production tubing and can cause problems for an artificial lift mechanism, such as ESP systems, by reducing the pump's volumetric efficiency. Gas interference occurs when the pump is being filled with a significant amount of free gas that is not separated from the liquid before entering the pump.If the amount of free gas entering the pump can be reduced, the volumetric efficiency of the pump can be improved or the total pumping capacity can be increased. A common attempt to decrease the amount of free gas entering the pump in a horizontal well borehole R7. Ln / Lznz / E / YILI involves running an escape-tube or velocity string into the wellbore below the pump and attempting to extract the fluids directly from the bottom of the horizontal portion. With reference to FIG. 1, a pipe string (40) can be run below the pump (42) through the generally curved portion (16) and / or the horizontal portion (14). In wellbore drilling, a natural separation between the fluid and gas typically occurs, with fluids present near the bottom of the wellbore and gas present near the top. The pipe string is typically installed between the pump suction and the inlet, with one open end positioned in the horizontal portion of the wellbore.In this way, the pipe string can allow gas to be diverted from the upper portion of the open end of the pipe string and allow liquids to enter the pipe string without gas. This is an attempt to increase the fluid velocity as the liquids move toward the pump to increase pump productivity. In some cases, due to the slow liquid filling rate in the horizontal portion of the well or the high percentage of gas in the well product, there may be a mixture of liquid and gas in the horizontal portion of the wellbore, with gas in the upper portion of the horizontal hole and liquid in the lower portion. In this case, the liquid level... R7. Ln / Lznz / E / YILI within the horizontal portion of the wellbore can fall below the open end of the pipe string, which can still allow gas to enter the pump and decrease pump efficiency. Therefore, there remains a need to assist in this process to allow the well string to extract fluid from a horizontal or curved portion of a wellbore to improve pump efficiency and extend the service life of the pump assembly regardless of the artificial lift methodology. Summary of the Invention An exemplary separator for use in well drilling may comprise at least one valve. The at least one valve may comprise a body extending along a longitudinal axis from a first end to a second end of the body, a conduit extending longitudinally through the body from the first end to the second end of the body, a channel extending laterally through the body from an outer surface of the body to the conduit, and a plunger positioned within the channel such that the plunger can be moved inward and outward within the channel to selectively seal the conduit relative to the channel. The plunger can be moved inward, within the channel toward the longitudinal axis, to a closed position such that the plunger R7. Ln / Lznz / E / YILI substantially seals the conduit relative to the channel to inhibit gas from entering the conduit. The plunger can also be moved outward within the channel away from the longitudinal axis to an open position so that the plunger substantially opens the conduit relative to the channel to allow liquid to enter the conduit. An exemplary separator for use in well drilling may comprise a first valve and a second valve coupled together along a longitudinal axis of the separator. Each of the first and second valves may comprise a body extending along the longitudinal axis from a first end to a second end of the body, a conduit extending longitudinally through the body from the first end to the second end of the body, a channel extending laterally through the body from an outer surface of the body to the conduit, and a plunger positioned within the channel such that the plunger can be moved in and out within the channel to selectively seal the conduit relative to the channel.The plunger can be moved inwards within the channel towards the longitudinal axis to a closed position so that the plunger substantially seals the conduit relative to the channel, and the plunger can be moved outwards within the channel away from the longitudinal axis to an open position such that the plunger substantially opens the conduit relative to the channel. The first valve can be rotated relative to the second valve around the longitudinal axis so that the first valve is in the closed position when the second valve is in the open position. An exemplary well drilling assembly may comprise a wellbore having a generally vertical portion and a generally horizontal portion extending transversely with respect to the generally vertical portion, a pipe string extending through at least a portion of the wellbore, an artificial lift having a pump coupled with the pipe string, wherein the pump is configured to pump fluid through the pipe string, and a separator coupled with one end of the pipe string.The separator may comprise at least one valve having a body extending along a longitudinal axis from a first end to a second end of the body, a conduit extending longitudinally through the body from the first end to the second end of the body, wherein the conduit is fluidly coupled with the pipe string, at least one channel extending laterally through the body from an outer surface of the body to the conduit, and a plunger positioned within the at least one body. R7. Ln / Lznz / E / YILI a channel so that the plunger can be moved in and out within at least one channel to selectively seal the conduit with respect to at least one channel. The separator can be placed within a lower portion of the wellbore, wherein the separator is configured to allow gas within the wellbore to bypass an upper portion of the separator, and wherein the separator is configured to allow liquid within the wellbore to flow within a lower portion of the separator and to the pump through the pipe string. The foregoing has broadly described the technical features and advantages of the present invention so that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention, which form the subject matter of the claims, will now be described. Persons skilled in the art should appreciate that the specific conception and embodiment described can readily be used as a basis for modifying or designing other structures to accomplish the same purposes as the present invention. Persons skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the R7. Ln / Lznz / E / YILI appended claims. The novel features believed to be characteristic of the invention, both in its organization and method of operation, together with other objects and advantages, will be better understood from the following description when considered in relation to the accompanying figures. It should be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended to be a definition of the limits of the present invention. Brief Description of the Figures For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying figures, in which: FIG. 1 is a schematic of a well drilling that has a generally vertical portion and a generally horizontal portion; FIG. 2 is a schematic of the well drilling of FIG. 1 having an exemplary horizontal liquid and gas bypass separator positioned within the generally horizontal portion of the well drilling; FIG. 3 is a schematic of the well drilling in FIG. 2 that has a rod pump system for pumping liquid through it; R7. Ln / Lznz / E / YILI FIG. 4 is a front view of the horizontal gas-liquid bypass separator of FIG. 2; FIG. 5 is a left-side perspective view of a first exemplary horizontal gas-liquid bypass separator valve of FIG. 4; FIG. 6 is a right-side perspective view of the valve in FIG. 5; FIG. 7 is a top plan view of the valve in FIG. 5; FIG. 8A is a cross-sectional view of the valve in FIG. 5 taken along line 8A-8A of FIG. 7, showing a valve plunger in a closed position; FIG. 8B is a cross-sectional view of the valve in FIG. 8A, showing the valve plunger in an open position; FIG. 9A is a cross-sectional view of the valve in FIG. 5 taken along line 9A-9A of FIG. 7, showing the valve plunger in the closed position; FIG. 9B is a cross-sectional view of the valve in FIG. 9A, showing the valve plunger in the open position; FIG. 10A is a front view of the horizontal gas-liquid bypass separator of FIG. 4, which «7 LÍV ί7Π7 / E / YΙΛΙ shows a transparent separator body for illustrative purposes; FIG. 10B is an end view of the horizontal gas-liquid bypass separator of FIG. 4, showing the separator body transparent for illustrative purposes; FIG. 11 is a left-facing perspective view of a second exemplary valve that can be incorporated into the horizontal gas-liquid bypass separator of FIG. 4; FIG. 12 is a right-angle perspective view of the valve in FIG. 11; FIG. 13 is a top plan view of the valve in FIG. 11; FIG. 14A is a cross-sectional view of the valve in FIG. 11 taken along line 14A-14A of FIG. 13; FIG. 14B is a cross-sectional view of the valve in FIG. 14A, with the valve rotated about 180 degrees about a longitudinal axis of the valve; FIG. 15A is a cross-sectional view of the valve in FIG. 11 taken along line 15A-15A of FIG. 11; FIG. 15B is a cross-sectional view of the valve in FIG. 15A, with the valve rotated approximately R7. Ln / Lznz / E / YILI degrees around the longitudinal axis of the valve; and FIG. 16 is a schematic of the well drilling in FIG. 2 showing an exemplary horizontal second gas-liquid bypass separator placed within a generally curved portion of the well drilling. Detailed Description of the Invention The preferred configurations of a horizontal gas-liquid bypass separator for a hydrocarbon producing well provide mechanisms to allow gas to pass over the pump inlet in a horizontal portion of a wellbore. These mechanisms use a vent pipe separator to reduce and / or eliminate free gas entering the pump of an artificial lift system. Any type of artificial lift system applicable to any oil producing well can be used, such as a sucker rod pump, rod pumping, electric submersible pumps, progressive cavity pumps, and other suitable methods. I. Exemplary well drilling assembly having a horizontal gas-liquid bypass separator Referring to FIG. 2, a wellbore (10) of an oil well includes a generally vertical portion (12) extending downwards from the surface (24) and a generally horizontal portion (14) extending transversely from the generally vertical portion. RZ LÍV Lznz / E / YILI vertical (12). A generally curved portion (16) is positioned between the generally vertical portion (12) and the generally horizontal portion (14), which is generally curved to extend the wellbore (10) from a generally vertical to a generally horizontal direction. The horizontal portion (14) may include one or more openings (18) to allow gaseous and liquid products to enter the wellbore (10). In the wellbore (10), some gas may naturally separate from the liquid, so that liquids (54) exist near the bottom of the wellbore (10) and gas (52) exists near the top portion of the wellbore (10). In the illustrated embodiment, an ESP system is used as an artificial lift to supply liquids from the well to the surface.The ESP system includes an electric drive (30), or motor, and a submersible pump (42) located inside the wellbore (10). The electric motor (30) may have a rotating rotor contained within a stationary stator. When the motor (30) is operating, the rotor can rotate to provide artificial lift within the wellbore (10). As shown in FIG. 2, a string of pipe (40) is placed above the ESP pump (42) to move liquids (54) from the wellbore (10) to the R7. Ln / Lznz / E / YILI surface (24) and / or the wellhead (20). Another string of tubing (40) is then placed below the pump (42) and extends through the generally vertical portion (12) and the generally curved portion (16), into the generally horizontal portion (14) of the wellbore (10). A horizontal gas-liquid bypass separator (100) is attached to the open end of the tubing string (40) in the generally horizontal portion (14) of the wellbore (10). The separator (100) can then be deployed below a velocity or tubing string in such a way as to increase the fluid velocity through the wellbore tubing to aid production from the low-pressure reservoirs. In some other versions, a rod pump system or other artificial lift system may be used. With reference to FIG. 3, a rod pump system is shown having a beam and crank assembly (60) that creates a reciprocating motion in the pipe string (40) connected to the pump (62). The pump (62) may include a plunger and valve assembly to convert the reciprocating motion into fluid movement within the pipe string (40). Still other suitable configurations for the artificial lift system will become apparent to a person skilled in the art in view of the teachings of this document. «7 LÍV ί7Π7 / E / YΙΛΙ A. Exemplary horizontal liquid-gas bypass separator With reference to Figure 4, a first exemplary horizontal gas-liquid bypass separator (100) is shown, in accordance with the concepts described herein, for use in a hydrocarbon producing well. The separator (100) comprises one or more valves (102a, 102b, 102c, 102d) aligned along a longitudinal axis (A) of the separator (100). Each of the one or more valves (102a, 102b, 102c, 102d) of the separator (100) may be rotationally offset from each other along the longitudinal axis (A). In the illustrated embodiment, four valves (102a, 102b, 102c, 102d) are assembled together along the longitudinal axis (A) such that each valve is rotated approximately 90 degrees with respect to an adjacent valve about the longitudinal axis (A). As shown in FIG.4, a first valve (102a) is positioned at approximately 90 degrees, a second valve (102b) is positioned at approximately 180 degrees, a third valve (102c) is positioned at approximately 270 degrees, and a fourth valve (102d) is positioned at approximately 0 degrees. Still other configurations suitable for assembling one or more valves will be evident to a person experienced in the art in view of the teachings of this document. For example, the separator (100) may include one or more valves (102a, 102b, 102c, 102d) that are rotationally offset from each other by any suitable number of degrees from approximately 0 degrees to approximately 360 degrees. Referring to Figures 5-7, a first exemplary valve (102) is shown in accordance with the concepts described herein for use in the separator (100). Although only one valve (102) is described below, it should be noted that the description of valve (102) may apply to each of the valves (102a, 102b, 102c, 102d) of the separator (100). In the illustrated embodiment, the valve (102) comprises a body (104) defining a conduit (112) extending longitudinally through it from a first end (106) of the valve (102) to a second end (108) of the valve (102). The body (104) of the valve (102) may have a length of approximately 91.44 cm (3 feet) and an outside diameter of approximately 5.08 to approximately 10.16 cm (2 to approximately 4 inches), such as approximately 7.62 cm (3 inches), although other suitable dimensions may be used.The conduit (112) can have a diameter of approximately 25% to approximately 95% of the body diameter (104), such as approximately 33%. For example, the conduit (112) can have a diameter of approximately 2.54 cm (1 inch), although other suitable dimensions may be used. R7. Ln / Lznz / E / YILI The first end (106) may include a groove (114) extending inward from the first end (106) into a portion of the body (104). The second end (108) may include a protrusion (109) extending outward from the second end (108). The protrusion (109) and the groove (114) may be of sufficient size such that the groove (114) is configured to receive a protrusion (109) from an adjacent valve (102) for assembling the valves (102) together. Accordingly, each valve (102) may be selectively mated with another valve (102). In the illustrated embodiment, the groove (114) and the protrusion (109) are threaded so that the groove (114) can be threaded to a protrusion (109) to maintain the rotational position of the groove (114) with respect to the protrusion (109).Other suitable couplings may be used to join adjacent valves (102) together, such as a friction fit, a keyed coupling, etc. The valve (102) may be made of stainless steel or any other suitable material. The valve (102) further comprises a channel (110) extending inward through at least a portion of the body (104) from an outer surface of the valve (102) to the conduit (112). The channel (110) may have a length extending from approximately 50% to approximately 100% of the length of the valve (102), such as from approximately 50% to approximately 67%. In some versions, the channel has a length of approximately 45.72 cm (1.5 ft) to approximately 60.96 cm (2 ft), although other suitable dimensions may be used. The channel (110) may further have a width extending along a portion of the circumference of the body (104). The channel (110) can have a width from approximately 5% to approximately 50% of the body circumference (104), such as approximately 5% to 25%. For example, the channel can have a width of approximately 2.The channel (110) can have a depth from approximately 5% to approximately 50% of the body diameter (104), such as approximately 33%. For example, the channel (110) can have a depth of approximately 2.54 cm (1 inch), although other suitable dimensions can be used. The channel (110) can be rotated about the longitudinal axis of the valve (102) from approximately 0 degrees to approximately 360 degrees, so that the channel (110) can be positioned at approximately 0 degrees, approximately 90 degrees, approximately 180 degrees, and / or approximately 270 degrees. While the illustrated embodiment shows the valve (102) having one channel (112), in some other versions, a valve (102) can have more. R7 Ln / Lznz / E / YILI of a channel (110) extending into the valve (102) that are longitudinally separated along the valve (102) and / or rotationally displaced from each other around the valve (102). With reference to FIGS. 8A-9B, the channel (110) includes an outer opening (111) extending inward from an outer surface of the body (104), a slit (116) extending inward from the outer opening (111), and an inner opening (118) extending inward from the slit (116) to the conduit (112) such that the channel (110) seamlessly connects the conduit (112) to the atmosphere. As is more clearly seen in FIGS. 8A-8B, the slit (116) is longer than both the outer opening (111) and the inner opening (118). Accordingly, a pair of internal stops (105) extend inward at each end of the inner opening (118) between the slit (116) and the conduit (112). A pair of outer stops (107) extend equally inwards at each end of the outer opening (111) between the slit (116) and the outside of the valve (102).In some other versions, the internal stops (105) and / or the external stops (107) may be placed through a central portion of the internal opening (118) and / or the external opening (111) respectively, such that each opening (111, 118) may comprise a plurality of openings. Referring to. R7 Ln / įZРZ / B / YILI as FIGS. 9A-9B, the inner opening (118) is narrower than the outer opening (111). Consequently, the width of the slit (116) can be tapered inwards from the outer opening (111) to the inner opening (118) so that the slit (116) has a V-shaped cross-section. In some other versions, the slit (116) may have other suitable cross-sectional shapes (e.g., rectangular, cylindrical, U-shaped, etc.). Still other suitable configurations for the channel (110) will become apparent to a person skilled in the art in light of the teachings in this document. The valve (102) further comprises a plunger (120) positioned within the slot (116). In the illustrated embodiment, the plunger (120) is generally a cylindrical rod. As more clearly seen in Figs. 8A-8B, the plunger (120) is sized to be shorter than the slot (116) and longer than the outer opening (111) and the inner opening (118). Consequently, the plunger (120) can move freely inward and / or outward within the slot (116) in response to gravitational forces. Therefore, the plunger (120) is held within the slot (116) by inner and outer stops (105, 107). In some versions, the plunger (120) has a length of R7 Ln / Lznz / E / YILI approximately 45.72 to approximately 60.96 cm (1.5 to approximately 2 ft) and an outside diameter of approximately 1.27 cm (0.5 in), although other suitable dimensions may be used. Accordingly, the plunger (120) may have a width of approximately 10% to approximately 99% of the width of the channel (110), such as approximately 50%, although other suitable dimensions may be used. As best seen in Figs. 9A-9B, the plunger (120) has a smaller diameter or width than the outside opening (111) and the slit (116). The plunger (120) also has a larger diameter or width than the inside opening (118). Therefore, when the plunger (120) is placed inwards, inside the groove (116), the plunger (120) is configured to cover and / or seal the inner opening (118).When the plunger (120) is positioned outward within the slot (116), the plunger (120) is configured to uncover and / or open the inner opening (118). This allows the plunger (120) to selectively seal the inner opening (118) when the valve (102) rotates about the longitudinal axis of the valve (102). Referring to FIGS. 2, 4 and 8A-10B, the separator (100) can be used to separate gas from liquid in a horizontal portion (14) of a wellbore (10) to improve efficiency and extend the service life of the R7 Ln / Lznz / E / YILI pump (42). For example, one or more valves (102) can be assembled to form the separator (100). In the illustrated embodiment, four valves (102a, 102b, 102c, 102d) are assembled by threading the protrusion (109) of one valve (102) into a groove (114) of an adjacent valve (102) to maintain the rotational position of the valves (102) relative to each other. Each of the valves (102a, 102b, 102c, 102d) can be offset approximately 90 degrees from each other along the longitudinal axis (A) of the separator (100). The separator (100) can then be placed inside the wellbore (10). When the separator (100) is placed in the wellbore (10), the valves (102) of the separator (100) can be rotated or oriented to any position within the wellbore (10). For illustrative purposes, as shown in FIG.2, the separator (100) is positioned within the generally horizontal portion (14) where the first valve (102a) is positioned at approximately 90 degrees with respect to the longitudinal axis (A), the second valve (102b) is positioned at approximately 180 degrees with respect to the longitudinal axis (A), the third valve (102c) is positioned at approximately 270 degrees with respect to the longitudinal axis (A), and the fourth valve (102d) is positioned at approximately 0 degrees with respect to the longitudinal axis (A). Alternatively, as shown in FIGS.In 10A-10B, the separator (100) is positioned where the first valve (102a) is located at approximately 45 degrees with respect to the longitudinal axis (A), the second valve (102b) is located at approximately 135 degrees with respect to the longitudinal axis (A), the third valve (102c) is located at approximately 225 degrees with respect to the longitudinal axis (A), and the fourth valve (102d) is located at approximately 315 degrees with respect to the longitudinal axis (A). Referring back to FIG. 2, the longitudinal axis (A) of the separator (100) is positioned substantially parallel to the longitudinal axis of the generally horizontal portion (14) of the wellbore (10). In some other versions, the separator (100) is positioned transversely with respect to the longitudinal axis of the generally horizontal portion (14) of the wellbore (10).The first end (106) of the first valve (102a) can be coupled to an open end of the pipe string (40) to smoothly connect each conduit (112) of the valves (102a, 102b, 102c, 102d) to the pipe string (40). The second end (108) of the fourth valve (102d) can be sealed or covered to prevent gas from within the wellbore (10) from entering the conduit (112) of the fourth valve (102d). Therefore, at least a lower portion of the separator (100) can be submerged within the liquid (54) of the generally horizontal portion (14) of the «7 LÍV ί7Π7 / E / YΙΛΙ well drilling (10). When the artificial lift pump (42) is actuated, the valves (102a, 102b, 102c, 102d) having the channel (110a, 110b, 110c, HOd) placed in a downward position (e.g., between approximately 91 degrees and approximately 269 degrees, such as approximately 180 degrees) allow gravity to move the plunger (120) within the channel (110a, 110b, 110c, HOd) outward to open the channel (110a, 110b, 110c, HOd) and allow the fluid (54) within the wellbore (10) to flow through the conduit (112) of the valves (102a, 102b, 102c, 102d) and into the pump inlet through the velocity chain (40).The valves (102a, 102b, 102c, 102d), having the channel (110a, 110b, 110c, HOd) positioned upwards (e.g., between approximately 270 degrees and approximately 90 degrees, such as approximately 0 degrees), allow gravity to move the plunger (120) within the channel (110a, 110b, 110c, HOd) inwards, thereby blocking the channel (110a, 110b, 110c, HOd) and preventing gas (52) from entering the conduit (112) of the valves (102a, 102b, 102c, 102d). Consequently, the gas (52) moves through the upper portion of the separator (100) to divert the pump inlet. This prevents free gas from entering the pump inlet to increase pump efficiency (42). Referring to FIGS. 8A and 9A, when the channel R7 Ln / Lznz / E / YILI (110) of the valve (102) is placed in an upward position, gravitational forces can act on the plunger (120) of the valve (102) to move the plunger (120) inward, into the groove (116) of the valve (102). The side surfaces of the groove (116) can direct the plunger (120) toward the central portion of the groove (116) so that the plunger (120) can cover and / or seal the inner opening (118) of the valve (102). With the inner opening (118) of the valve (102) covered and / or sealed, the plunger (120) can prevent gas (52) from the wellbore (10) from entering the conduit (112) of the valve (102). Therefore, with reference to FIGS. 10A-10B, the first and fourth valves (102a, 102d) are placed in an upward position so that the plungers (120a, 120d) are moved inwards to prevent the gas (52) from entering the duct (112) of the separator (100). With reference to FIGS. 8B and 9B, when the channel (110) of the valve (102) is positioned downwards, gravitational forces can act on the plunger (120) of the valve (102) to move the plunger (120) outwards into the groove (116) of the valve (102). In this way, the plunger (120) can uncover and / or open the inner opening (118) of the valve (102). With the inner opening (118) of the valve (102) uncovered and / or unsealed, the plunger (120) can allow fluid (54) from the well drilling (10) to enter the conduit (112) of the valve (102). For example, as shown by arrow (130), the fluid (54) is allowed to flow into the outer opening (111) of the channel (110) and around the plunger (120). The fluid (54) can then flow through the slit (116) and the inner opening (118), as shown by arrow (132), and into the conduit (112). Referring to FIGS.10A-10B, the second and third valves (102b, 102c) are positioned downwards so that the plungers (120b, 120c) are moved outwards to allow the liquid (54) to enter the duct (112) of the separator (100). Referring again to FIGS. 8B and 9B, the liquid (54) can then be pumped by the artificial lift mechanism through the conduit (112), as shown by arrow (134), and out of the conduit (112), as shown by arrow (136). Consequently, the liquid (54) can flow through the next adjacent valve (102) and / or through the tubing string (40) to the surface (24). The separator (100) thus allows the gas (52) to pass over the upper portion of the separator (100) in a generally horizontal portion (14) of a wellbore (10), while allowing the liquid (54) to flow through the separator (100) to the pump (42). R7 Ln / Lznz / E / YILI may use other configurations and methods suitable for operating the separator (100), as will become evident to a person experienced in the technique from the teachings of this document. For example, the separator (100) may include any suitable number of valves (102) coupled together to form the separator (100). Each of these valves may have any suitable number of channels (110) that can be positioned around the body (104) of the separator (100) in any suitable circumferential and / or longitudinal pattern. Accordingly, a single separator (100) may be placed within a wellbore (10), and / or multiple separators (100) may be used within the wellbore (10). Such separators (100) could be assembled together and / or spaced at various positions along the pipe string (40). B. Exemplary horizontal liquid-gas bypass separator having a ball piston and seat. Referring to FIGS. 11-13, a second exemplary valve (202) is shown, in accordance with the concepts described herein, for use in the separator (100). Although only one valve (202) is described below, it should be noted that the valve (202) may be incorporated as one or more valves (102a, 102b, 102c, 102d) of the separator (100). The valve (202) is similar to the valve (102) except that the valve (202) includes a plunger (220) having a ball and seat configuration instead of a rod configuration. In the illustrated embodiment, the valve (202) comprises a body (204) defining a conduit (212) extending longitudinally therethrough from a first end (206) of the valve (202) to a second end (208) of the valve (202). The first end (206) may include a groove (214) extending inward from the first end (206) into a portion of the body (204). The second end (208) may include a protrusion (209) extending outward from the second end (208). The protrusion (209) and the groove (214) may be of sufficient size such that the groove (214) is configured to receive a protrusion (209) from an adjacent valve (202) for assembling the valves (202) together. Accordingly, each valve (202) can be selectively coupled with another valve (202).In the illustrated embodiment, the groove (214) and the protrusion (209) are threaded so that the groove (214) can be threaded to a protrusion (209) to maintain the rotational position of the protrusion (214) relative to the protrusion (209). Other suitable couplings, such as a friction fit, a keyed coupling, etc., may be used to assemble adjacent valves (202) together. The valve (202) may be made of stainless steel or any other suitable material. The valve (202) further comprises at least one channel (210a, 210b, 210c, 210d) extending inward through at least a portion of the body (204) from an outer surface of the valve (202) to the conduit (212). Referring to Figures 14A-15B, each channel (210a, 210b, 210c, 210d) is formed by a tube (213) extending inward from the body (204) of the valve (202). In the illustrated embodiment, each tube (213) is generally cylindrical, although any other suitable shape may be used. An inner portion of each tube (213) includes a tapered portion (217) that narrows inward such that an end surface (215) of the tapered portion (217) defines an inner opening (219). Therefore, the inner opening (219) has a smaller diameter than the channel (210). In the illustrated embodiment, four channels (210a, 210b, 210c, 210d) are shown spaced longitudinally and circumferentially around the body (204).For example, a first channel (210a) is positioned at approximately 0 degrees about the longitudinal axis of the valve (202), a second channel (210b) is positioned distally relative to the first channel (210a) at approximately 90 degrees about the longitudinal axis of the valve (202), a third channel (210c) is positioned. R7 Ln / Lznz / E / YILI distally with respect to the second channel (210b) at approximately 180 degrees around the longitudinal axis of the valve (202), and a fourth channel (210d) is positioned distally with respect to the third channel (210c) at approximately 270 degrees around the longitudinal axis of the valve (202). In some other versions, the valve (202) may include more or fewer channels (210a, 210b, 210c, 210d) and / or one or more channels (210a, 210b, 210c, 210d) may be longitudinally and / or laterally aligned with each other. Each channel (210a, 210b, 210c, 210d) may have a width of approximately 5% to approximately 50% of the circumference of the body (204), such as approximately 5% to 25%. Each channel (210a, 210b, 210c, 210d) may have a width of approximately 2.54 cm (1 inch) to approximately 7.62 cm (3 inches), although other suitable dimensions may be used. Each tube (213) may have a depth of approximately 5% to approximately 50% of the body diameter (204), such as approximately 33%. Each tube (213) may have a depth of approximately 1 inch (2.54 cm), although other suitable dimensions may be used.Consequently, each tube (213) can be rotated around the longitudinal axis of the valve (202) from approximately 0 degrees to approximately 360 degrees, so that the tube (213) can be positioned at approximately 0. R7. Ln / ί7Π7 / E / YΙΛΙ degrees, approximately 90 degrees, approximately 180 degrees and / or approximately 270 degrees. As best seen in FIGS. 11-13 and 15A-15B, each channel (210a, 210b, 210c, 210d) includes at least one stop (211a, 211b, 211c, 211d) extending across an upper portion of the channel (210a, 210b, 210c, 210d). The stop (211a, 211b, 211c, 211d) is narrower than the diameter of the channel (210a, 210b, 210c, 210d). The valve (202) further comprises a plunger (220a, 220b, 220c, 220d) positioned within each channel (210a, 210b, 210c, 210d). In the illustrated embodiment, the piston (220a, 220b, 220c, 220d) is a generally spherical ball. As best seen in Figs. 14A-15B, each piston (220a, 220b, 220c, 220d) is sized to have a diameter smaller than the channel (210a, 210b, 210c, 210d) and a diameter larger than the inner opening (219). Consequently, the piston (220a, 220b, The piston (220a, 220b, 220c, 220d) can move freely in and / or out within the channel (210a, 210b, 210c, 210d) due to gravitational forces. The piston (220a, 220b, 220c, 220d) is contained within the channel (210a, 210b, 210c, 220d). 210d) by the stop (211a, 211b, 211c, 211d) in an outer portion of the channel (210a, 210b, 210c, 210d) and by the conical portion (217) in an inner portion of the channel (210a, 210b, 210c, 210d). In some versions, the piston (220a, 220b, 220c, 220d) has an outer diameter of approximately R7 Ln / Lznz / E / YILI .27 cm (0.5 inches), although other suitable dimensions may be used. As best seen in Figs. 15A-15B, when the plunger (220a, 220b, 220c, 220d) is placed inwardly within the channel (210a, 210b, 210c, 210d), the plunger (220a, 220b, 220c, 220d) is configured to cover and / or seal the inner opening (219). When the plunger (220a, 220b, 220c, 220d) is positioned outward within the channel (210a, 210b, 210c, 210d), the plunger (220a, 220b, 220c, 220d) is configured to uncover and / or open the inner opening (219). This allows the plunger (220a, 220b, 220c, 220d) to selectively seal the inner opening (219) when the valve (202) rotates about its longitudinal axis. With reference to FIGS. 2 and 14A-15B, one or more valves (202) may be incorporated into the separator (100) to separate the gas from the liquid in a horizontal portion (14) of a wellbore (10) to improve efficiency and extend the service life of the pump (42). For example, a valve (202) having a channel (210a, 210b, 210c, 210d) positioned upwards (for example, between approximately 270 degrees and approximately 90 degrees, such as approximately 0 degrees) can inhibit gas (52) within the wellbore (10) from entering the separator (100), whereas valves (202) having the channel (210a, 210b, 210c, 210d) positioned downwards (for example, between approximately 91 degrees and approximately 269 degrees, such as approximately 180 degrees) can allow liquid (54) within the wellbore (10) to enter the separator (100). Referring to FIGS.14A and 15A For illustrative purposes, when the first channel (210a) of the valve (202) is placed in an upward position, gravitational forces can act on the plunger (220a) of the valve (202) to move the plunger (220a) inward into the first channel (210a). The tapered portion (217) of the tube (213) can direct the plunger (220a) toward the central portion of the first channel (210a) so that the plunger (220a) can cover and / or seal the inner opening (219) of the valve (202). With the inner opening (219) of the valve (202) covered and / or sealed, the plunger (220a) can prevent gas (52) from the well drilling (10) from entering the conduit (212) of the valve (202) through the first channel (210a). Referring to FIG. 14B, the first channel (210a) of the valve (202) can be rotated to a downward position so that gravitational forces can act on the plunger (220a) of the valve (202) to move the plunger (220a) outward within the first channel (210a) to the stop (211a). In this way, the plunger (220a) can uncover and / or open the inner opening (219) of the valve (202). With the inner opening (219) of the valve (202) uncovered and / or unsealed, the plunger (220a) can allow fluid (54) from the well drilling (10) to enter the conduit (212) of the valve (202) through the first channel (210a). For example, as shown by arrow (230), the fluid (54) is allowed to flow around the stop (211a) and the plunger (220a), into the first channel (210a). The fluid (54) can then flow through the first channel (210a) and the inner opening (219), as shown by arrow (232), and into the conduit (212).The fluid (54) can then be pumped by the artificial lift mechanism through the conduit (212), as shown by arrow (234), and out of the conduit (212), as shown by arrow (236). Consequently, the fluid (54) can flow through the next adjacent valve (202) and / or through the pipe string (40) to the surface (24). Additionally or alternatively, the valve (202) can be rotated within the wellbore (10) to place one or more channels (210a, 210d) in the up position and one or more channels (210b, 210c) in the down position. For example, as shown in FIG. 15B, the first and fourth channels (210a, 210d) are in the up position and the second and third channels (210b, 210c) are in the down position. Consequently, the plungers (220a, 220d) of the first and fourth channels (210a, 210d) can be moved inward to substantially seal R7 Ln / Lznz / E / YILI the respective inner opening (219) of the channels (210a, 210d). The plungers (220b, 220c) of the second and third channels (210b, 210c) can be moved outward to uncover the inner opening (219) of the respective channels (210b, 210c). This allows liquid (54) to enter the second and third channels (210b, 210c), while the first and fourth channels (210a, 210d) are sufficiently sealed to allow gas (52) to pass over the upper portion of the valve (202). Other suitable configurations and methods may be used to operate the valve (202), as will become apparent to a person skilled in the art in view of the teachings of this document. For example, the separator (100) may include any suitable number of valves (202) coupled together to form the separator (100). Each of these valves may have any suitable number of channels (210) that can be positioned around the body (204) of the separator (100) in any suitable circumferential and / or longitudinal pattern. Accordingly, a single separator (100) may be placed within a wellbore (10), and / or multiple separators (100) may be used within the wellbore (10). Such separators (100) could be assembled together and / or spaced at various positions along the pipe string (40). II. Exemplary well drilling assembly that has R7 Ln / ίZΖΠZΖ / Β / YΙΛΙ a horizontal gas-liquid bypass separator in an angular position In some versions, at least a portion of the separator (100) may be positioned within the generally vertical portion (12), the generally curved portion (16), and / or the generally horizontal portion (14). For example, the separator (100) may be positioned at an angle within the wellbore (10). With reference to FIG. 16, a second example of a separator (300) is shown, which is similar to the separator (100) described above. The separator (300) includes one or more valves (302) assembled together with each channel (310) of the valves (302) rotationally offset from each other. In the illustrated embodiment, the separator (300) is positioned within the wellbore (10) with a longitudinal axis (A) of the separator (300) at an angle (a) transverse to a longitudinal axis (B) of the generally horizontal portion (14) of the wellbore (10).The angle (a) can be any sufficient angle that allows the plunger (120, 220) to move within the channel (310) of the valve (302) in response to gravitational forces. For example, the separator (300) can be positioned at an angle (a) from approximately 0 degrees to approximately 90 degrees, such as from approximately 0 degrees to approximately 45 degrees. In the illustrated embodiment, the separator (300) therefore extends to a. R7 Ln / Lznz / E / YILI through the generally curved portion (16) of the wellbore (10). In some other versions, the separator (300) may be placed in one or more of the generally vertical portion (12), the generally curved portion (16) and / or the generally horizontal portion (14) at an angle (a). Still other suitable configurations for the separator (300) will become evident to a person experienced in the art in view of the teachings of this document. For example, each valve (302) of the separator (300) may be separated from each other by the tubing string (40) and / or other suitable tubing placed between the valves (302) to couple the valves (300) together. Consequently, each valve (302) may be positioned at an angle (a) within the wellbore (10) such that each valve (302) may be positioned at a different angle (a) than the other valves (302) of the separator (300). Thus, the separator (300) may be positioned to extend through the wellbore (10) in one or more of the generally vertical portion (12), the generally curved portion (16), and / or the generally horizontal portion (14), with each valve (302) positioned at an angle (a). Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions, and alterations may be made herein without departing from the spirit and scope of the invention as defined in the appended claims. Furthermore, the scope of this application is not intended to be limited to the particular embodiments of the process, machine, manufacture, material composition, means, methods, and steps described herein. As a person skilled in the art will readily appreciate from the description of the present invention, processes, machines, manufacture, material compositions, means, methods, or steps, currently existing or subsequently developed, that substantially perform the same function or achieve substantially the same result as the corresponding embodiments described herein may be used in accordance with the present invention.Therefore, the attached claims are intended to include within their scope such processes, machines, manufacturing, material compositions, means, methods or steps. It is hereby stated that, as of this date, the best method known to the applicant for putting the aforementioned invention into practice is the one that is clear from the present description of the invention.

Claims

CLAIMS Having described the invention as above, the following claims are claimed as property:

1. A separator for use in well drilling, characterized in that it comprises at least one valve, wherein the at least one valve comprises: a body extending along a longitudinal axis from a first end to a second end of the body; a conduit extending longitudinally through the body from the first end to the second end of the body; an elongated channel extending laterally through the body from an outer surface of the body to the conduit and longitudinally along the length of the body; a pair of internal stops positioned at each end of the elongated channel adjacent to the conduit; a pair of external stops positioned at each end of the elongated channel adjacent to the outer surface of the body;and a cylindrical plunger positioned within the elongated channel such that the plunger can be moved inwards and outwards within the elongated channel to selectively seal the conduit with respect to the elongated channel, wherein the cylindrical plunger is longer than the length of the elongated channel so that the pair of internal stops engage with the ends of the cylindrical plunger; wherein the plunger can be moved inwards within the elongated channel towards the longitudinal axis to a closed position so that the plunger substantially seals the conduit relative to the elongated channel to inhibit the entry of gas into the conduit, wherein the plunger can be moved outwards within the elongated channel away from the longitudinal axis to an open position so that the plunger substantially opens the conduit relative to the elongated channel to allow liquid to enter the conduit.

2. The separator according to claim 1, characterized in that the piston can be moved in response to gravitational forces, such that the piston moves to the closed position when the valve is oriented to an upward position with the elongated channel generally extending upwards, and such that the piston moves to the open position when the valve is oriented to a downward position with the elongated channel generally extending downwards.

3. The separator according to claim 1, characterized in that the piston is configured to cover b / Ln / ί7Π7 / E / YΙΛΙ substantially the elongated channel when the piston is placed in the closed position.

4. The separator according to claim 1, characterized in that the channel includes a conical portion that narrows inwards from an outer portion of the elongated channel to an inner portion of the channel.

5. The separator according to claim 1, characterized in that the valve includes a plurality of elongated channels extending through the body, wherein the plurality of elongated channels are circumferentially separated from each other.

6. The separator according to claim 5, characterized in that multiple separators are joined end to end.

7. A separator assembly for use in a well drilling, characterized in that it comprises: a first valve segment and a second valve segment coupled together along a longitudinal axis of the separator assembly, wherein each of the first and second valve segments comprises: a body extending along the longitudinal axis from a first end to a second end of the body, a conduit extending longitudinally through the body from the first end to the second end R7 Ln / Lznz / E / YILI of the body;a channel extending laterally through the body from an outer surface of the body to the conduit, and a plunger positioned within the channel such that the plunger can be moved inward and outward within the channel to selectively seal the conduit with respect to the channel, wherein the plunger can be moved inward within the channel toward the longitudinal axis to a closed position such that the plunger substantially seals the conduit with respect to the channel, wherein the plunger can be moved outward within the channel away from the longitudinal axis to an open position such that the plunger substantially opens the conduit with respect to the channel; wherein the first valve is rotationally offset with respect to the second valve about the longitudinal axis such that the first valve is placed in the closed position when the second valve is placed in the open position.

8. The separator assembly according to claim 7, characterized in that the first valve comprises an inwardly extending groove within the first end of the body, wherein the second valve comprises an outwardly extending protrusion R7 Ln / ί7Π7 / E / YΙΛΙ from the second end of the body, wherein the groove of the first valve is of sufficient size to receive the protrusion of the second valve.

9. The separator assembly according to claim 8, characterized in that the groove of the first valve is threaded and secured to the protrusion of the second valve to maintain the position of the first valve with respect to the second valve.

10. The separator assembly according to claim 7, characterized in that the second valve is rotated approximately 90 degrees with respect to the first valve about the longitudinal axis.

11. The separator assembly according to claim 7, characterized in that the first valve is positioned upwards with the channel of the first valve generally extending upwards so that the plunger of the first valve is in the closed position, wherein the second valve is positioned downwards with the channel of the second valve generally extending downwards so that the plunger of the second valve is in the open position.

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