Downhole Cyclonic Sand Separation with Progressing Cavity Pump
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Solution Overview
Problem
Excessive sand production in subterranean hydrocarbon wells plagues the petroleum industry, causing equipment erosion, reduced productivity, and flow capacity issues, as current sand control methods often compromise fluid flow.
Innovation Solution
Implementing a centrifugal separation system within the wellbore using a tangential perforation design or screen system to create a cyclonic flow pattern, separating sand from oil and gas, and utilizing a progressing cavity pump to collect and remove the sand, thereby enhancing the operating life of downhole and surface equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sand control methods such as sand screens, slotted liners, or gravel-pack schemes are used, then sand production is minimized, but overall flow capacity of formation fluids is reduced
Solution Approach 1:
The wellbore is segmented into separate flow paths: one for de-sanded fluid (through production tubing) and one for sand removal (through sand discharge tube). This segmentation allows simultaneous sand control and maintained flow capacity by preventing sand from entering the production stream while maintaining formation fluid flow pathways.
Solution Approach 2:
Sand is extracted from the formation fluid stream through centrifugal separation before the fluid enters the production tubing. The sand is removed and discharged separately through a dedicated sand discharge tube, preventing it from plugging equipment while maintaining fluid flow capacity.
2Productivity
If sand production is allowed to occur, then formation fluid flow capacity is maintained, but equipment erosion and productivity loss increase
Solution Approach 1:
Centrifugal separation is performed preliminarily within the wellbore before fluids reach surface equipment. The cyclonic separator creates a spiral flow pattern that separates sand from fluids downhole, preventing sand from causing equipment erosion upstream while maintaining flow capacity.
Solution Approach 2:
A centrifugal separation system acts as an intermediary between the formation and surface equipment. The system includes a cyclonic separator and progressing cavity pump that intercept sand particles, preventing them from reaching and eroding expensive surface facilities while allowing formation fluids to flow freely.
3Reliability
If a centrifugal separation system with progressing cavity pump is implemented, then sand is removed while maintaining flow capacity, but device complexity increases
Solution Approach 1:
The system uses hydraulic principles through the progressing cavity pump to move sand-laden fluid through the separation system. The pump creates progressive cavities that mechanically transport sand particles through the wellbore to the discharge point, providing reliable sand removal without complex mechanical moving parts that would increase maintenance 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
This method effectively minimizes sand-related losses, improves oil and gas recovery, and extends the lifespan of equipment by maintaining fluid flow capacity while allowing for sand removal from both consolidated and unconsolidated formations.
Implementation Method 1
Within a wellbore, the centrifugal separation can be performed by generating a spiral or cyclonic flow pattern. Because of the spiral flow pattern of the oil, gas, or water carrying the sand within wellbore, sand as a heavier component would flow outward along the well sides
Implementation Method 2
the centrifugal separation can be performed by generating a spiral or cyclonic flow pattern. Such flow pattern can be generated by using a tangential perforation design or a specially designed screen system
Implementation Method 3
The separated sand would fall down the wellbore through a one-way flip valve and be collected in a sand chamber. The lower-end of the sand chamber can release the collected sand towards the intake side of a progressing cavity pump for removal to the surface
Data Source
AI summary
Systems and methods for removing sand from fluid in a subterranean hydrocarbon development well include producing a cyclonic flow pattern of a sandy fluid of the subterranean well within a wellbore of a subterranean well with tangentially formed openings along a fluid flow path of the sandy fluid. The cyclonic flow pattern causes sand traveling in the sandy fluid to fall downhole as separated sand, and causes a de-sanded fluid stream to be directed uphole towards a production tubing. The de-sanded fluid stream is produced through the production tubing. The separated sand is collected proximate to a suction end of a progressing cavity pump. The progressing cavity pump is operated so that the separated sand flows through the progressing cavity pump and out a discharge end of the progressing cavity pump, to produce the separated sand through a sand discharge tube.