Gas Separator Assembly Artificial Sump Design
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Solution Overview
Problem
Existing gas separators in hydrocarbon wells face issues with gas interference, gas-locking, and potential damage to downhole equipment, leading to downtime and reduced production efficiency, especially in horizontal wells where space within the casing is limited and access for tools is difficult.
Innovation Solution
A gas separator assembly is introduced that creates an artificial sump inside the existing production casing, featuring a primary passage and a secondary passage with ports and a barrier to direct fluids and gas flow, allowing for effective separation of gas and liquid without incremental drilling costs or operational issues, and enabling the use of downhole pumps without interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sump or extended section is drilled post completion to achieve effective gas separation, then gas separation effectiveness is improved, but drilling and completion costs increase and wellbore stability risks arise
Solution Approach 1:
The gas separator assembly is nested within the existing production casing, with an inner casing member containing a primary passage and an outer casing member containing a secondary passage. The barrier is nested within the primary passage to define the sump area. This nesting approach achieves effective gas separation without requiring additional drilling or extending the wellbore, thereby avoiding incremental drilling costs and wellbore stability risks while maintaining reliable gas-liquid separation.
2Reliability
If conventional gas separators are used in horizontal wells with limited casing space, then gas separation is attempted, but gas interference and gas-locking occur leading to equipment damage and downtime
Solution Approach 1:
The gas separator assembly divides the flow path into distinct segments: a primary passage for liquid flow to the pump, a secondary passage for gas separation, and a sump area for liquid accumulation. The barrier segments the primary passage to create the sump. This segmentation allows gas and liquid to follow separate paths, preventing gas interference and gas-locking that plague conventional separators in horizontal wells, while maintaining reliable gas separation performance.
3Reliability
If the primary passage ID is reduced to accommodate separation equipment, then gas separation capability is improved, but access for other downhole tools becomes difficult
Solution Approach 1:
The gas separator assembly is nested within the existing production casing, with the inner casing member's primary passage having an interior diameter equal to or greater than the remainder of the production casing. This nesting configuration provides gas separation capability while maintaining full access for other downhole tools through the primary passage, as the passage diameter is not reduced.
4Reliability
If a barrier is installed in the primary passage to define sump area, then gas-liquid separation is improved, but insertion and removal of the barrier becomes awkward and difficult
Solution Approach 1:
The barrier is designed as a movable, settable element within the primary passage rather than a fixed permanent structure. It can be inserted, set, and removed using standard downhole tools through the primary passage. This dynamic design maintains reliable gas-liquid separation when set, while allowing easy installation and removal when needed for maintenance or tool access.
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 solution allows for efficient separation of gas and liquid, minimizing downtime and maintaining well integrity, while allowing for easy passage of other tools and equipment, as the artificial sump provides extended residence time for gas separation and ensures that only liquid is pumped, enhancing production efficiency and reducing the risk of equipment damage.
Implementation Method 1
a barrier arranged to be supported in the primary passage to seal the primary passage at a location between said at least one first port and said at least one second port so as to define a sump area in the primary passage between the barrier and said at least one first port
Data Source
AI summary
A gas separator assembly generates an artificial sump in a production casing receiving a production tubing string with a downhole pump at the bottom end thereof. The assembly includes an inner casing in series with the production casing of the well and an outer casing supported externally of the inner casing. First and second ports at opposing top and bottom ends of the outer casing communicate from a primary passage in the inner casing to a secondary passage between the inner and outer casings. A barrier supported in the primary passage between the first and second ports diverts flow through the secondary passage and effectively defines the sump area in the primary passage between an inlet of the downhole pump adjacent the barrier and the first port thereabove.