Nested Multi-Stage Downhole Gas Separator With Limited-Entry Ports
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Solution Overview
Problem
Existing gas separators for hydrocarbon wells face issues such as gas interference, gas-locking, potential damage to downhole equipment, and limited space occupancy, leading to operational inefficiencies and downtime.
Innovation Solution
A multi-stage gas separator assembly comprising an outer and inner tube with limited entry ports and a variable valve system that allows even fluid distribution across multiple separator stages, along with optional diversion and annular velocity disruption features to manage flow and prevent plugging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gas separator is designed to occupy large amounts of space within the well casing, then separation effectiveness is improved, but insertion and removal become awkward and difficult
Solution Approach 1:
The gas separator assembly employs a nested tubular structure where an inner tube is positioned within an outer tube, creating concentric annular regions. This nesting arrangement maximizes separation functionality within a compact radial footprint, enabling effective gas-liquid separation while maintaining a space-efficient configuration that facilitates insertion and removal from the well casing.
2Manufacturing precision
If limited entry ports are used to control fluid distribution, then flow consistency is improved, but risk of plugging increases
Solution Approach 1:
The gas separator assembly divides the fluid distribution function into multiple discrete limited entry ports positioned at different locations and orientations around the inner tube. This segmentation of the flow control function achieves consistent fluid distribution through controlled restriction while reducing plugging risk by providing multiple alternative flow paths - if one port becomes blocked, fluid can still pass through other ports.
3Reliability
If multiple separator stages are defined in series, then separation efficiency is improved, but device complexity increases
Solution Approach 1:
The gas separator assembly creates multiple separator stages by positioning isolator segments at different elevations within the annular region between the inner and outer tubes. Each isolator segment defines a separate separation stage with its own limited entry ports and flow paths. This nested staging approach achieves enhanced separation efficiency while maintaining a compact, integrated structure that does not significantly increase overall device complexity.
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
Enhances separation efficiency by maintaining consistent flow rates and preventing plugging, reducing the risk of gas-locking and equipment damage, while optimizing space utilization and access for other downhole tools.
Implementation Method 1
A plurality of limited entry ports are defined in the inner tube and provide restricted communication of fluids from the inner annular region into the inner tube
Implementation Method 2
The isolator segments are disposed within the first annular region, each segment separating the first annular region into adjacent separator stages
Implementation Method 3
The pump is in communication with the inner passage
Data Source
AI summary
A gas separator for use in a wellbore. The separator has an annular, staged separator system, whereby a liquid-gas mixture is separated into its liquid and gas components. Gas components are allowed to escape up the annulus around the separator, while liquid components are captured on each stage and removed through an inner tube. The inner tube has limited entry ports. These ports may be sized such that ports at the top of the string have a smaller, more limited entry than those toward the bottom.