Horizontal Bypass Separator Plunger Valve Gas Liquid Separation
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Solution Overview
Problem
In petroleum wells, the presence of free gas in the hydrocarbon production stream reduces the volumetric efficiency of artificial lift systems like ESPs, as gas interferes with the pumping process, leading to decreased efficiency and potential damage to the pump.
Innovation Solution
A horizontal gas and liquid bypass separator is introduced, featuring valves with a plunger mechanism that allows gas to bypass the pump intake while allowing liquid to flow through, preventing free gas from entering the pump and enhancing pump efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a tail-pipe type tubing string is used to draw liquids directly off the bottom of the horizontal portion, then liquid velocity increases and pump productivity improves, but free gas can still enter the pump when liquid level falls below the tubing string open end, reducing pump efficiency
Solution Approach 1:
The separator divides the single tubing string into multiple segmented pathways: a liquid pathway with restricted flow and a gas pathway with unrestricted flow. This segmentation allows liquid and gas to be separated at the separator, with liquid forced through the restricted pathway to maintain velocity while gas bypasses through the unrestricted pathway, preventing gas from entering the pump.
Solution Approach 2:
The separator extracts free gas from the hydrocarbon production stream before it reaches the pump. By removing the harmful gas component from the liquid stream, the pump receives only liquid, maintaining its efficiency and productivity without the detrimental effects of gas interference.
2Reliability
If the liquid level in the horizontal portion falls below the open end of the tubing string, then gas can enter the pump and decrease efficiency, but increasing tubing string length or adjusting liquid level monitoring adds system complexity
Solution Approach 1:
The separator utilizes the natural density difference between gas and liquid phases to automatically separate them without requiring external power, control systems, or complex monitoring devices. The restricted liquid pathway and unrestricted gas pathway create automatic phase separation based on hydrostatic pressure and density, providing a passive, self-regulating solution that protects pump efficiency without adding system complexity.
3Productivity
If gas is allowed to enter the pump, then the volumetric efficiency of the pump decreases, but preventing gas entry while maintaining liquid flow velocity requires a sophisticated separation mechanism
Solution Approach 1:
The separator employs hydraulic principles by utilizing the density difference between gas and liquid phases to create automatic phase separation. The restricted liquid pathway creates hydrostatic pressure that forces liquid through while gas, being less dense, rises and bypasses through the unrestricted pathway. This pneumatic-hydraulic mechanism achieves effective gas-liquid separation and maintains liquid flow velocity without complex mechanical components.
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 separator effectively increases the efficiency of the pump by preventing free gas from entering the pump, thereby improving the overall pumping capacity and extending the life of the pump assembly.
Implementation Method 1
A horizontal gas and liquid bypass separator is introduced, featuring valves with a plunger mechanism that allows gas to bypass the pump intake while allowing liquid to flow through
Data Source
AI summary
A horizontal gas and liquid bypass separator for use in a hydrocarbon producing well bore is provided for allowing gas to bypass over the top of a pump intake in a horizontal portion of a well bore. The separator includes at least one valve having a body, a conduit extending longitudinally through the body, a channel extending transversely through the body from an outer surface of the body to the conduit, and a plunger positioned within the conduit. The plunger is translatable within the channel to selectively seal the conduit relative to the channel to thereby inhibit gas from entering the conduit when the plunger is translated to a closed position and to allow liquid to flow within the conduit when the plunger is translated to an open position.