Downhole Desander Dip Tube for Gas-Lock and Solids Separation
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Solution Overview
Problem
Current wellbore fluid pumping systems are prone to gas-locking due to the production of large gas pockets and solids, which inhibit pumping efficiency and liquid returns.
Innovation Solution
A downhole solids separation system comprising a stack of solids separators and a dip tube configuration that utilizes a restricted opening and a kill zone to separate solids from fluids, allowing continuous flow and deposition of solids into mud joints, while fluids are processed through gas separators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pumping wellbore fluids is performed without solids separation, then pumping operation can be maintained, but gas-locking occurs and pumping efficiency is reduced
Solution Approach 1:
The solids separator is installed in the wellbore above the pump to perform solids separation before the fluid enters the pump. This preliminary action removes sand and other solids from the produced fluid, preventing gas-locking and ensuring only liquid enters the pump, thereby maintaining pumping efficiency and reliability
2Productivity
If solids are not separated from production fluids, then fluid production continues, but solids limit pump efficiency and cause well locking
Solution Approach 1:
The solids separator extracts sand and other solids from the produced fluid stream using centrifugal force and gravitational separation. By removing these harmful solids before the fluid reaches the pump, the system ensures that only liquid enters the pump, maximizing liquid returns and preventing well locking
3Reliability
If a separate downhole solids removal apparatus is added, then solids separation is achieved, but device complexity increases
Solution Approach 1:
The solids separator utilizes the natural hydraulic flow of produced fluid through the wellbore and employs centrifugal force generated by the flowing fluid to separate solids from liquid. This hydraulic-based separation mechanism eliminates the need for complex mechanical moving parts, motors, or external power sources, thereby achieving reliable solids separation while maintaining relatively simple device structure
Solution Approach 2:
The solids separator is designed to operate autonomously using the kinetic energy and flow characteristics of the produced fluid itself. The device self-regulates the separation process without requiring external control systems, actuators, or power sources, thereby reducing device complexity while maintaining effective solids separation functionality
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 system effectively separates solids from fluids, preventing gas-locking and enhancing pumping efficiency by ensuring only liquids are pumped, thereby improving well operation and liquid returns.
Implementation Method 1
a downhole solids separation system comprising a stack of solids separators and a dip tube configuration that utilizes restricted openings and a 'kill zone' to separate solids from fluids
Implementation Method 2
separate solids from fluids, allowing continuous flow and deposition of solids into a closed chamber below the packer
Data Source
AI summary
A downhole solids separator having: a plurality of solids separation modules, a production tube disposed therein, one or more limited entry ports in the production tube, placed in each of the modules, an intake port in the lower half of each module opening into a wellbore annulus, the intake port below the limited entry port of the module, a closed chamber for collecting solids, isolated from the well bore, the closed chamber below modules, a solids conveying conduit from at least one module, opening into the closed chamber, an opening restricted to less than the size of the production tube in the conduit near the bottom of the module, an opening in the production tube in the closed chamber, where the production tube opening and conduit opening are configured to effect a drop fluid velocity into production tube to a level insufficient to carry solids into the production tube.