Cyclonic Solids Separator for Downhole Pumping Systems
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Solution Overview
Problem
Existing downhole gas separators are ineffective in reducing solid particle concentration in gas and liquid streams, and may not be applicable in all scenarios due to the presence of a driven rotational shaft, complicating the recovery of hydrocarbons from wells with high gas-to-liquid ratios and causing issues like gas interference and vapor lock.
Innovation Solution
A cyclonic solids separator system is deployed between the electric submersible pump and the velocity tube assembly, featuring a conical housing with arcuate ejection ports that utilize centrifugal force to separate solids from gases and liquids, allowing for effective separation without motorized components, thus applicable in a wide range of well configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a driven rotational shaft is used in downhole gas separators, then gas separation functionality is achieved, but device complexity increases and applicability is limited
Solution Approach 1:
The patent removes the driven rotational shaft from the gas separator system, extracting the problematic component while maintaining gas separation functionality through alternative means (centrifugal force generated by the pump itself or passive cyclonic separation), thereby reducing device complexity and improving applicability
Solution Approach 2:
The system utilizes the pump's own operation to generate centrifugal force for gas separation, eliminating the need for an external driven rotational shaft. The pump serves dual functions: fluid transport and gas-liquid separation, allowing the system to serve itself without additional complex components
2Reliability
If existing gas separation equipment is used, then gas and liquid separation is achieved, but solid particle concentration is not reduced
Solution Approach 1:
The patent designs a separation system that performs multiple functions simultaneously: gas-liquid separation and solid particle removal. By integrating solid particle concentration reduction into the existing gas separation equipment, the system achieves universal functionality without requiring separate dedicated equipment for each separation task
3Reliability
If downhole turbomachinery is used, then gas separation occurs due to centrifugal forces, but gas interference and vapor lock increase
Solution Approach 1:
The system performs preliminary gas separation before the fluid enters the pump, using centrifugal forces in a dedicated separation chamber. By removing gas and solid particles in advance, the pump receives pre-conditioned fluid, preventing gas interference and vapor lock during pumping operation
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 cyclonic solids separator effectively removes solid particles from the fluid stream, reducing wear on downhole equipment and improving the efficiency of hydrocarbon recovery by ensuring that only liquid-rich streams are directed to the pump, while gases and solids are separated, thereby mitigating gas interference and vapor lock issues.
Implementation Method 1
A cyclonic solids separator system is deployed between the electric submersible pump and the velocity tube assembly, featuring a conical housing with arcuate ejection ports that utilize centrifugal force to separate solids from gases and liquids
Data Source
AI summary
A pumping system is configured to be deployed in a well that has a vertical portion and a lateral portion. The pumping system includes a pump positioned in the vertical portion, a velocity tube assembly that extends from the vertical portion into the lateral portion and a cyclonic solids separator connected between the pump and the velocity tube assembly. The cyclonic solids separator includes a housing, a discharge manifold extending through the housing, and a plurality of ejection ports that extend through the discharge manifold along arcuate, tangential paths.