Retrievable Downhole Gas Separator Design
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Solution Overview
Problem
Current downhole gas separators increase operational costs as they require removal from the wellbore for maintenance procedures, such as coiled tubing workovers, which disrupts liquid production and efficiency.
Innovation Solution
A retrievable downhole gas separator design that allows servicing without removing the production tubing, featuring an outer casing joined to production tubing with openings for gas separation and a dip tube, and a latching plug for easy retrieval and reinstallation through the tubing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a downhole gas separator is installed to separate gas from liquid hydrocarbons, then operational efficiency of the artificial lift system is improved, but operational costs increase due to required removal for maintenance procedures
Solution Approach 1:
The gas separator is divided into separable components: an outer casing with gas separation functionality and an inner production tubing assembly. This segmentation allows the production tubing to be removed independently for maintenance while the outer casing remains in place, reducing operational costs associated with full system removal.
Solution Approach 2:
The production tubing is extracted as a separate removable component from the outer casing. This extraction enables maintenance procedures to be performed on the production tubing without removing the entire gas separator assembly, thereby reducing operational costs while maintaining the gas separation functionality.
2Ease of repair
If production tubing is removed for well servicing procedures, then well maintenance can be performed, but liquid production and efficiency are disrupted
Solution Approach 1:
The system is segmented into a permanent outer casing that maintains gas separation functionality and a removable inner production tubing. This allows the production tubing to be extracted for maintenance while the outer casing with its gas separation capabilities remains in place, enabling well servicing without disrupting the overall production efficiency.
Solution Approach 2:
The outer casing acts as an intermediary structure that maintains the gas separation function while allowing the production tubing to be removed and reinstalled. This intermediary structure ensures that the gas separation capability is preserved during maintenance operations, minimizing disruption to liquid production efficiency.
3Reliability
If a traditional gas separator design is used, then gas separation is achieved, but the system requires complete removal for any servicing procedures
Solution Approach 1:
The gas separator is designed with segmented components: an outer casing that provides gas separation functionality and an inner production tubing assembly. This segmentation allows the production tubing to be removed for maintenance while the outer casing with gas separation performance remains in place, improving maintenance accessibility without compromising gas separation reliability.
Solution Approach 2:
The outer casing serves multiple functions: it maintains gas separation performance while also serving as a permanent structural component that allows independent access to the production tubing for maintenance. This multi-functionality enables both reliable gas separation and easy maintenance operations.
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
Enables efficient gas-liquid separation while allowing coiled tubing workovers without pulling the production tubing, reducing operational costs and maintaining production efficiency.
Implementation Method 1
a dip tube that extends through an interior of the outer casing, wherein the dip tube is fluidically coupled to the production tubing at one end, and is open to the outer casing at an opposite end
Data Source
AI summary
Systems and a method for efficient downhole separation of gas and liquids while providing well access are provided. An exemplary system provides a downhole gas separator for an artificial lift system. The downhole gas separator includes an outer casing joined to production tubing at one end and comprising a fitting for a plug at an opposite end from the production line. The outer casing comprises openings through the outer casing. A dip tube extends through the interior of the outer casing, wherein the dip tube is fluidically coupled to the production tubing at one end, and is open to the outer casing at an opposite end, wherein the opposite end is proximate to the fitting for the plug. The plug is disposed in the fitting, and comprises a retrieval bar configured to allow the plug to be pulled through the production tubing to the surface.