Three-Concentric Tube Gas-Liquid Separator for ESP and Beam Pump Systems
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Solution Overview
Problem
In hydrocarbon production, especially in low-pressure depleted reservoirs, horizontal wells face challenges in efficiently pumping low volume and low pressure liquids due to gas interference, which reduces pumping efficiency and increases wear on pumps, as existing gas separators are ineffective in handling high foam volumes within the limited casing annulus.
Innovation Solution
A three-concentric tube gas-liquid separator/connector device is used to separate gas from liquid, allowing gas to rise to the surface while liquid falls back into the pump intake, enabling the combination of electric submersible pumps and beam pumps or progressive cavity pumps to enhance production efficiency and reduce pump wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional gas separator is used in the limited casing annulus, then gas separation is attempted, but the separator becomes ineffective in handling high foam volumes and reduces pumping efficiency
Solution Approach 1:
The patent transitions from a horizontal annular separator to a vertical three-concentric-tube separator configuration. The inner tube carries liquid downward to the pump, the middle tube allows gas to rise to the surface, and the outer tube provides structural support and additional flow paths. This vertical dimensionality change enables effective gas-liquid separation in the limited wellbore space while maintaining pumping efficiency.
Solution Approach 2:
The separator divides the fluid flow into three distinct segments using concentric tubes: liquid flow through the inner tube, gas flow through the middle tube annulus, and structural/support flow through the outer tube annulus. This segmentation allows simultaneous handling of high foam volumes and efficient liquid pumping by directing each phase through its own dedicated pathway.
2Reliability
If gas is allowed to enter the pump intake, then gas interference increases, but preventing gas separation increases device complexity
Solution Approach 1:
The separator employs a nested three-concentric-tube structure where the inner tube is positioned within the middle tube, which is positioned within the outer tube. This nesting arrangement achieves comprehensive gas-liquid separation and pump protection while minimizing the overall footprint and complexity by efficiently utilizing vertical wellbore space.
3Productivity
If multiple artificial-lift technologies are combined, then production efficiency increases, but system complexity and pump wear increase
Solution Approach 1:
The separator extracts gas from the produced fluid stream before it reaches the pump intake by directing gas upward through the middle tube annulus to the surface, while liquid continues downward through the inner tube to the pump. This extraction of harmful gas phase protects the pump from gas interference and foam-related wear, extending service intervals even when multiple artificial-lift technologies are combined.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution increases the rate of hydrocarbon production by ensuring only liquid enters the pump intake, reducing gas interference, and allows for the effective use of multiple artificial-lift technologies, thereby maximizing flow rates and minimizing pump wear and service intervals.
Implementation Method 1
The relatively large space between the inside tube and the outside tube allows for the gas to separate from the liquid. The gas continues to rise to the surface in the tubing-casing annulus. The liquid now can enter, by gravity, the third tube that is placed outside the inner tube
Data Source
AI summary
The present invention provides a gas-liquid separator/connector having three concentric tube device made such that flow of fluids from a ESP enters the bottom and are diverted into the largest of the three concentric tubes located as the outside tube. The relatively large space between the inside tube and the outside tube allows for the gas to separate from the liquid. The gas continues to rise to the surface in the tubing-casing annulus. The liquid now can enter by gravity the third tube that is placed outside the inner tube (the tubing) and the large external tube. This third concentric tube is not as long as the large outer tube and is connected at the bottom to become the entrance to the pump intake for the beam pump or PCP. The pump intake for the beam pump or PCP is a part of the smallest inner tube of the connector.