Reverse Flow Gas Separator for Pump Intake Protection
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Solution Overview
Problem
Pumps in producing wells face performance impediments due to gas entering the pump intake, particularly from gas slugs or high gas concentrations, which can disrupt wellbore operations.
Innovation Solution
A reverse flow gas separator is employed to separate gas from liquid by reversing the fluid flow, utilizing buoyancy and gravity to separate gas and liquid, with a hollow driveshaft as a separate fluid channel for increased separation area and centrifugal force enhancement, allowing the pump to operate even during gas slug presence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional gas separator is used, then gas can be separated from liquid, but the pump still cannot operate continuously when gas slugs are present
Solution Approach 1:
The separator creates a liquid reservoir in advance by continuously separating liquid from gas before pump intake. This pre-established liquid cushion ensures the pump always has liquid to pump, even when gas slugs arrive, enabling continuous operation without shutdowns
Solution Approach 2:
The liquid reservoir acts as an intermediary between the gas slug and the pump. Instead of allowing gas slugs to directly contact the pump, the reservoir provides a buffer of liquid that mediates the interaction, protecting the pump from gas interference
2Reliability
If the separator volume is increased to provide more liquid reservoir, then continuous pump operation is enabled, but the device size and complexity increase
Solution Approach 1:
The separator utilizes changes in flow dynamics and phase distribution parameters within a compact vertical design. By optimizing the separation chamber geometry and utilizing natural buoyancy-driven phase separation, adequate liquid reservoir volume is achieved in a space-efficient manner
Solution Approach 2:
The separator transitions from horizontal to vertical orientation, utilizing the vertical dimension for liquid accumulation. This allows the liquid reservoir to be formed in the vertical direction rather than requiring large horizontal footprint, reducing overall device volume while maintaining reservoir capacity
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
Effectively prevents gas from reaching the pump intake, ensuring continuous operation by separating gas from liquid and providing a reservoir of fluid, thereby maintaining pump functionality during high gas concentrations or gas slug events.
Implementation Method 1
separating the gas portion from the liquid portion of the production fluid by reversing the direction of flow of the production fluid
Implementation Method 2
separating the gas portion from the liquid portion of the production fluid by reversing the direction of flow of the production fluid
Implementation Method 3
the use of a hollow driveshaft as a separate fluid channel increases the area available for fluid flow in the separation space outside the drive shaft
Data Source
AI summary
A reverse flow gas separator having a housing having a housing intake and a first void space within the housing. The reverse flow gas separator further includes a driveshaft disposed adjacent to the first void space. The drive shaft is hollow and comprises a second void space disposed within the interior of the drive shaft. The second void space is continuous from a driveshaft intake to an opening in a terminal end of the driveshaft.