Downhole Gas Separator With Flow-Regulating Device
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Solution Overview
Problem
Existing downhole gas separators in hydrocarbon wells are inefficient in separating gas from liquid, leading to decreased operational efficiency of artificial lift systems and potential pump ineffectiveness due to gas entry, necessitating improved separation methods.
Innovation Solution
The implementation of downhole gas separators with an elongate outer housing, fluid inlet and gas outlet ports, and a flow-regulating device that restricts gas outlet flow during intake strokes and permits it during exhaust strokes, optimizing the separation process by utilizing an elongate dip tube and selective fluid communication to enhance separation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional downhole gas separator is used, then the structure is simple, but the gas separation efficiency is low allowing gas to enter the reciprocating pump
Solution Approach 1:
The patent applies dynamics by making the gas outlet port selectively communicative through a flow-regulating device that responds to pressure differentials during reciprocating pump strokes. The gas outlet port dynamically opens during exhaust strokes when pressure favors gas exit, and closes during intake strokes when pressure would otherwise allow liquid ingress, thus adapting the separator's behavior to the operational cycle to improve gas separation efficiency without requiring complex external control systems
Solution Approach 2:
The patent applies nesting by placing the flow-regulating device within the enclosed volume of the outer housing, and positioning the dip tube to extend within the enclosed volume with its distal end proximal to the gas outlet port. This nested arrangement integrates multiple functions (separation, flow regulation, selective communication) within a compact structure, improving gas separation efficiency without proportionally increasing overall device complexity
2Reliability
If the gas outlet port remains open continuously, then gas can escape freely, but liquid hydrocarbon may also enter the gas outlet during pump intake strokes
Solution Approach 1:
The patent applies periodic action by making the gas outlet port selectively communicative only during specific phases of the reciprocating pump cycle (exhaust strokes) when pressure conditions favor gas exit. The flow-regulating device creates periodic opening and closing of the gas outlet port synchronized with pump operations, preventing liquid ingress during intake strokes while maintaining gas separation throughput during exhaust strokes
Solution Approach 2:
The patent applies self-service by designing the flow-regulating device to automatically respond to pressure differentials without external control. The device self-regulates the gas outlet port communication based on inherent pressure changes during pump strokes, preventing liquid ingress while maintaining gas escape capability through passive, autonomous 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
This configuration significantly improves the operational efficiency of artificial lift systems by effectively restricting gas entry into the reciprocating pump while allowing liquid hydrocarbon flow, thereby increasing the overall production efficiency and design flexibility.
Implementation Method 1
the gas outlet port is configured to selectively provide fluid communication between the enclosed volume and an external region... a flow-regulating device that is configured to restrict fluid flow through the gas outlet during at least a portion of each intake stroke of a reciprocating pump and to permit the fluid flow during at least a portion of each exhaust stroke
Implementation Method 2
an elongate dip tube that extends within the enclosed volume... an elongate outer housing that defines an enclosed volume, a fluid inlet port, and a gas outlet port
Data Source
AI summary
Downhole gas separators, artificial lift systems including the downhole gas separators, hydrocarbon wells including the artificial lift systems, and methods of separating a gas from a liquid hydrocarbon within a hydrocarbon well. The downhole gas separators include an elongate outer housing that defines an enclosed volume, a fluid inlet port, and a gas outlet port. The downhole gas separators further include an elongate dip tube that extends within the enclosed volume, and the gas outlet port is configured to selectively provide fluid communication between the enclosed volume and an external region.