Helical Flow Gas Separator for Downhole Pump Gas Interference
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Solution Overview
Problem
Existing petroleum well systems face reduced volumetric efficiency due to entrained and free gas entering the pump, which affects production efficiency and downhole equipment life.
Innovation Solution
A separator apparatus using an outer and inner tube with a helical auger to separate gas from liquid, where the auger creates a pathway for gas to flow into the inner conduit while liquid continues through the outer conduit, directing gas away from the pump.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If gas is not separated before entering the pump, then the system structure remains simple, but the volumetric efficiency of the pump is reduced
Solution Approach 1:
The separator employs a nested tubular structure with an inner tube containing a helical auger positioned within an outer tube. The auger rotates within the inner tube, creating a centrifugal field that separates gas and liquid phases. This nested configuration achieves effective gas-liquid separation while maintaining a compact footprint suitable for downhole installation, thus improving volumetric efficiency without proportionally increasing overall system complexity.
Solution Approach 2:
The helical auger acts as an intermediary mechanism between the incoming gas-liquid mixture and the pump. By rotating the auger, it generates centrifugal force that mediates the separation process, directing gas phase through the inner tube while liquid phase flows along the outer annular region. This intermediary mechanism enables phase separation before pump intake, improving volumetric efficiency while keeping the separator structure relatively simple.
2Productivity
If a separator is added to remove gas before the pump, then the volumetric efficiency improves, but the device complexity increases
Solution Approach 1:
The separator employs a nested tubular structure with an inner tube containing a helical auger positioned within an outer tube. The auger rotates within the inner tube, creating a centrifugal field that separates gas and liquid phases. This nested configuration achieves effective gas-liquid separation while maintaining a compact footprint suitable for downhole installation, thus improving volumetric efficiency without proportionally increasing overall system complexity.
Solution Approach 2:
The helical auger serves multiple functions: it rotates to generate centrifugal force for phase separation, it acts as a mechanical driver when rotated by an external motor, and it provides structural support for the inner tube assembly. This multi-functionality reduces the need for additional components, achieving effective separation while limiting the increase in device complexity.
3Duration of action of moving object
If free gas enters the pump, then the system operation remains continuous, but the downhole equipment life is reduced
Solution Approach 1:
The separator performs preliminary gas-liquid separation before the mixture enters the pump. By removing free gas phase in advance through centrifugal separation generated by the rotating auger, the pump receives primarily liquid phase, preventing gas-related damage and extending equipment life while maintaining continuous operation and production efficiency.
Solution Approach 2:
The separator converts the harmful effect of free gas entering the pump into a beneficial separation process. By utilizing the centrifugal force generated by the rotating auger, the system naturally separates gas and liquid phases, with gas being directed away from the pump intake. This transforms what would be a harmful condition into an effective separation mechanism, protecting equipment while maintaining production.
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
Improves volumetric efficiency by reducing gas interference in the pump, enhancing production and extending the life of downhole equipment.
Implementation Method 1
Helical flow gas separator
Implementation Method 2
The auger creates a pathway for gas to flow into the inner conduit while liquid continues through the outer conduit
Data Source
AI summary
A separator in a wellbore for separating liquid and gas in a petroleum production stream is described. The separator is formed by an outer tube defining an outer conduit extending from a lower end to an upper end of the outer tube. An inner tube is positioned concentrically within the outer tube, wherein the inner tube defines an inner conduit extending from a lower end to an upper end of the inner tube. The inner conduit includes a cap at its lower end and a plurality of openings connecting the outer conduit and the inner conduit. A helical auger extends between the inner tube and the outer tube, the helical auger defining a pathway between the outer tube and the inner tube such that the gas in the production stream passes through the openings in the inner tube while the fluid passes through the outer conduit to a pump.