Downhole Separator Layout for Gas and Solids Removal
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Solution Overview
Problem
Reservoir fluids containing entrained gases and solids hinder efficient hydrocarbon production by interfering with pump operation, leading to sluggish flow and mechanical erosion, and existing separators are bulky and costly.
Innovation Solution
A downhole separator within the wellbore string that utilizes buoyancy forces and gravity separation to separate reservoir fluids into gas-depleted and gas-enriched flows, incorporating a flow diverter, filter-communicating flow conductor, solids filtering apparatus, and permeate/discharge communicators to manage solids and gases effectively.
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 separator is divided into multiple functional zones including a gas separation zone, a flow diverter, a solids filtering apparatus, and discharge communicators. Each zone performs a specific separation function, allowing the system to achieve effective gas and solids separation while maintaining a compact overall structure that fits within the wellbore constraints
Solution Approach 2:
The flow diverter and solids filtering apparatus are positioned within the wellbore string passage, nesting multiple separation functions within the existing wellbore structure. The permeate discharging communicator and retentate discharging communicator are integrated into the flow conductor, creating a nested configuration that maximizes space utilization
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 separator structure performs multiple functions including gas separation, flow diversion, solids filtering, and fluid discharge through integrated components. The flow diverter simultaneously directs gas-depleted fluid and manages flow distribution, while the solids filtering apparatus handles both filtration and discharge functions, reducing the need for separate dedicated components and lowering manufacturing costs
Solution Approach 2:
Multiple separation and discharge functions are merged into a single integrated structure. The permeate discharging communicator and retentate discharging communicator are combined within the flow conductor, and the solids filtering apparatus is integrated with the gas separation zone, creating a unified separator system that reduces material requirements and simplifies manufacturing
3Productivity
If reservoir fluids containing entrained gases are pumped directly, then production continues, but pump operation is interfered with causing sluggish flow
Solution Approach 1:
Gas separation is performed preliminarily within the wellbore string passage before the fluid reaches the pump. The gas separation zone and flow diverter remove gaseous material in advance, ensuring that only gas-depleted reservoir fluid enters the pump, thereby preventing pump interference and maintaining optimal flow speed and production continuity
4Productivity
If reservoir fluids containing solids are pumped directly, then production continues, but mechanical components suffer erosion
Solution Approach 1:
Solids separation is performed preliminarily within the wellbore string passage before the fluid reaches the pump. The solids filtering apparatus and retentate discharging communicator remove solid particles in advance, ensuring that only solids-depleted reservoir fluid enters the pump, thereby preventing mechanical erosion and maintaining production continuity
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 downhole separator efficiently separates gases and solids from reservoir fluids, enhancing production efficiency by minimizing mechanical interference and reducing space and material costs.
Implementation Method 1
the separation includes separation in response to buoyancy forces within a gas separation zone
Implementation Method 2
the downwardly-flowing reservoir fluid-derived flow becomes disposed in mass transfer communication apparatus with the solids filtering apparatus, with effect that the downwardly-flowing reservoir fluid-derived flow is separated into a first solids-depleted reservoir fluid-derived flow and a downwardly-flowing solids-enriched reservoir fluid-derived flow
Implementation Method 3
the solids-enriched reservoir fluid-derived flow becomes emplaced in a solids settling zone, and while disposed in the solids settling zone, the solids-enriched reservoir fluid-derived flow becomes depleted in solid material in response to gravity separation
Data Source
AI summary
There is provided a system for producing hydrocarbon material from a subterranean formation. The system includes a separator for separating gaseous material from reservoir fluid obtained from the subterranean formation. The system is configured to mitigate interference to the separation.