Downhole Cyclone Separator for Gas-Liquid Phase Management
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Solution Overview
Problem
In wells with high gas oil ratio and high water cut, the efficiency of hydrocarbon production is decreased due to gas accumulation in electrical submersible pumps, leading to gas locking and reduced fluid production, with existing methods failing to effectively manage free gas and prevent overheating.
Innovation Solution
A cyclone separator system is implemented within the well, featuring a rotating screw with angled thread surfaces to separate gas and liquid phases, directing the liquid stream radially outward and the gas stream radially inward, preventing gas lock on the pump and liquid loading on the gas string, thereby enhancing downhole separation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gas is re-dissolved into liquid phase to avoid gas locking, then gas lock prevention is improved, but free gas management becomes insufficient leading to pump overheating and burning
Solution Approach 1:
The patent divides the production string into separate gas and liquid phases using a gas-liquid separator. The separator segments the single-phase flow into distinct gas and liquid streams, allowing independent management of each phase. Gas is directed to a gas string while liquid is pumped through a liquid string, preventing gas accumulation in the pump and eliminating the need for gas re-dissolution.
Solution Approach 2:
The patent extracts the gas phase from the liquid phase using a downhole gas-liquid separator. By taking out the free gas from the production stream before it reaches the pump, the system eliminates the harmful effect of gas accumulation while maintaining continuous liquid production. The extracted gas is routed separately through a dedicated gas string to the surface.
2Productivity
If electrical submersible pump is used to retrieve production zone fluid, then artificial lift is achieved, but gas accumulation causes decreased production efficiency and pump shutdown
Solution Approach 1:
The patent performs preliminary separation of gas and liquid phases using a downhole gas-liquid separator positioned before the electrical submersible pump. By separating the phases in advance, the system prevents gas accumulation in the pump intake, ensuring continuous reliable operation. The separator acts as a preliminary treatment stage that protects the pump from gas locking conditions.
3Device complexity
If single production string is used, then device complexity is reduced, but gas-liquid separation efficiency decreases leading to pump gas lock
Solution Approach 1:
The patent segments the production system into separate gas and liquid pathways using a gas-liquid separator and dual strings. This segmentation allows efficient phase separation while managing the complexity through modular design. The separator is a single downhole device that creates two independent flow paths, maintaining reliability without excessive complexity.
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
The cyclone separator system significantly reduces the risk of gas lock in the electrical submersible pump, increases hydrocarbon production efficiency, and reduces liquid loading on the gas string, allowing for more effective gas and liquid phase separation and production.
Implementation Method 1
A cyclone separator is within the well. The cyclone separator has a rotating screw with thread surfaces open to an inner diameter surface of the well, the rotating screw positioned between a lower end of the gas production tubular and the electrical submersible pump, the thread surfaces angled to direct a liquid stream axially downward and radially outward towards the inner diameter surface of the well. A central passage extends through the rotating screw and is oriented to direct a gas stream towards the lower end of the gas production tubular.
Data Source
AI summary
Systems and methods for producing hydrocarbons from a subterranean well include a fluid production tubular and a gas production tubular extending separately into the well. An electrical submersible pump is in fluid communication with the fluid production tubular. A cyclone separator is within the well. The cyclone separator has a rotating screw with thread surfaces open to an inner diameter surface of the well. The rotating screw is positioned between a lower end of the gas production tubular and the electrical submersible pump. The thread surfaces are angled to direct a liquid stream axially downward and radially outward towards the inner diameter surface of the well. A central passage extends through the rotating screw and is oriented to direct a gas stream towards the lower end of the gas production tubular.