Downhole Flow Diverter for Compact Gas Separation and Pump Protection
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Solution Overview
Problem
Reservoir fluids containing entrained gases and solids interfere with downhole pump operation, leading to sluggish flow and mechanical component erosion, and existing separators occupy significant space and are costly.
Innovation Solution
A flow diverter system within the wellbore string that separates reservoir fluids into gas-depleted and gas-enriched streams using buoyancy forces, diverting the gas-depleted fluid to the pump suction via a configuration of branches or vanes to minimize alignment and bends, reducing erosion and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional separators are used to separate gaseous material from reservoir fluid, then gas separation is achieved, but the separator occupies significant space within the wellbore and increases material and manufacturing costs
Solution Approach 1:
The flow diverter is segmented into multiple flow diverting conductor branches, each independently conducting portions of gas-depleted reservoir fluid. This segmentation allows the system to achieve effective gas separation while occupying less space than a single large separator, as each branch can be compact and the combined structure utilizes wellbore space more efficiently.
Solution Approach 2:
The invention transitions from a horizontal separator design to a vertical flow diverter configuration within the wellbore string. By utilizing the vertical dimension and the natural buoyancy forces acting upward in the wellbore, the system achieves gas separation without requiring the horizontal space that traditional separators demand, thereby reducing the volume occupied within the constrained wellbore environment.
2Reliability
If traditional separators are used to separate gaseous material from reservoir fluid, then gas separation is achieved, but material and manufacturing costs increase
Solution Approach 1:
The flow diverter structure serves multiple functions: it separates gas-depleted reservoir fluid from gas-enriched reservoir fluid using buoyancy forces, directs the separated fluids to appropriate zones, and protects the pump from gas interference. This multi-functionality eliminates the need for separate dedicated separator equipment, thereby reducing material and manufacturing costs while maintaining effective gas separation.
Solution Approach 2:
The flow diverter utilizes the natural buoyancy forces of the reservoir fluid to achieve gas separation without requiring additional energy input or complex mechanical mechanisms. The system self-regulates the separation process based on density differences between gas and liquid phases, reducing the need for expensive powered separation equipment and simplifying manufacturing requirements.
3Ease of operation
If reservoir fluid containing entrained gas is pumped directly, then pump operation is simple, but gas interference causes sluggish flow and interferes with pump operation
Solution Approach 1:
The flow diverter performs preliminary gas separation before the reservoir fluid reaches the pump by utilizing buoyancy forces in the vertical wellbore string. Gas-depleted reservoir fluid is directed to the pump suction zone while gas-enriched fluid is directed away, preventing gas interference with pump operation and maintaining optimal flow rates without complex pump controls or modifications.
4Ease of operation
If reservoir fluid containing solids is pumped directly, then pump operation is simple, but solids cause erosion of mechanical components
Solution Approach 1:
The flow diverter extracts and separates gas-depleted reservoir fluid from the overall reservoir fluid stream before it reaches the pump. By removing the gas phase that would otherwise interfere with pump operation and potentially trap solids, the system protects pump mechanical components from erosion caused by gas-solid interactions while maintaining simple pump 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
Enhances hydrocarbon production by efficiently separating gases and solids, minimizing interference with pump operation and reducing material costs.
Implementation Method 1
the reservoir fluid flow is separated into at least a downwardly-flowing gas-depleted reservoir fluid and an upwardly flowing gas-enriched reservoir fluid, wherein the separation includes separation in response to buoyancy forces within the gas separation zone
Data Source
AI summary
There is provided a flow diverter for integration within a production string that is emplaced within a wellbore for effecting separation of reservoir fluid into gas-depleted reservoir fluid and gas-enriched reservoir fluid. The flow diverter is configured for, amongst other things, mitigating corrosion and erosion phenomena.