Downhole Fluid Separator for Gas-Liquid Phase Separation
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Solution Overview
Problem
Existing downhole artificial lift systems face inefficiencies and frequent pump failures due to the presence of free gas, leading to increased operating costs and reduced reservoir productivity, as conventional separators are limited in length, reliability, and compatibility with various lift systems.
Innovation Solution
A downhole fluid separation tool with tubular conduits and separation devices, such as baffles, that separates mixed-phase fluids into gas and liquid phases within the wellbore, allowing only liquid to be delivered to the artificial lift device, reducing gas locking and enabling reuse across different wellbores with minimal moving parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional separators are used in downhole artificial lift systems, then gas separation is achieved, but the separator length is limited and reliability is reduced due to frequent pump failures from gas locking
Solution Approach 1:
The invention extracts and removes free gas from the fluid stream before it enters the pump intake. The separator device separates the mixed-phase fluid into gas and liquid phases, extracting the harmful gas phase and directing it away from the pump, while only liquid enters the pump intake. This eliminates gas locking and improves pump reliability.
Solution Approach 2:
The separator divides the wellbore flow into separate gas and liquid pathways. The device segments the mixed-phase fluid flow, with gas rising through a gas outlet and liquid flowing through a liquid outlet to the pump. This segmentation prevents gas from entering the pump and causing failures.
2Reliability
If conventional separators are used, then gas separation is achieved, but operating costs increase due to frequent workover operations for pump replacements
Solution Approach 1:
By extracting free gas from the fluid stream before pump intake, the separator prevents gas locking that would otherwise cause pump failures requiring expensive workover operations. The continuous removal of gas ensures sustained pump operation and reduces maintenance frequency.
3Adaptability or versatility
If conventional separators are used, then gas separation is achieved, but adaptability to different artificial lift systems is limited
Solution Approach 1:
The separator is designed as a universal device that can be integrated with various artificial lift systems including rod-driven pumps, progressive cavity pumps, and electric submersible pumps. The separator's configuration adapts to different well conditions and lift mechanisms, providing broad compatibility without requiring system-specific complex designs.
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 tool effectively reduces pump failures and operating costs by ensuring only liquid is delivered to the pump, enhancing reliability and allowing for multiple wellbore use, thereby improving hydrocarbon recovery and reservoir productivity.
Implementation Method 1
gas separating by gravity flowing upward while the liquid flows downward
Data Source
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AI summary
A downhole fluid separator includes a first tubular including a volume defined between an open, uphole end of the first tubular opposite an open, downhole end of the first tubular, the volume of the first tubular including a fluid pathway configured to receive a mixed-phase fluid from an annulus of a wellbore and provide separate flows of a gas and a liquid to the uphole end of the first tubular; a second tubular including a volume configured to receive at least a portion of a downhole artificial lift device through an open, uphole end of the second tubular opposite a closed, downhole end of the second tubular, and an adjustable opening formed in a portion of the second tubular at a location between the uphole and downhole ends and configured to selectively receive the flow of the liquid into the volume of the second tubular; and an actuatable wellbore seal positioned around each of the first and second tubulars and between the first and second tubulars, downhole of the adjustable opening, and between the uphole ends and the downhole ends of the respective first and second tubulars.