U.S. patent application number 14/481064 was filed with the patent office on 2015-05-28 for downhole gas and solids separator.
The applicant listed for this patent is Troy Botts. Invention is credited to Troy Botts.
Application Number | 20150144328 14/481064 |
Document ID | / |
Family ID | 53181654 |
Filed Date | 2015-05-28 |
United States Patent
Application |
20150144328 |
Kind Code |
A1 |
Botts; Troy |
May 28, 2015 |
Downhole Gas and Solids Separator
Abstract
The disclosed downhole gas and solids separator includes a
suspended helical flighting member for efficient downhole
separation of both gases and solids from a hydrocarbon production
stream. Centrifugal force, provided by the flighting member,
accelerates the coalescence of like materials to enhance separation
of both gases and solids within the separator. Centrifugal force
urges solids to the outer wall of the separator and gases toward
the center, where passageways are designed to allow solids to
efficiently migrate toward and accumulate at the bottom of the
separator while simultaneously allowing gases to efficiently rise
out of the separator device.
Inventors: |
Botts; Troy; (Snyder,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Botts; Troy |
Snyder |
TX |
US |
|
|
Family ID: |
53181654 |
Appl. No.: |
14/481064 |
Filed: |
September 9, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61963213 |
Nov 25, 2013 |
|
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Current U.S.
Class: |
166/231 ;
166/227 |
Current CPC
Class: |
E21B 43/34 20130101;
B01D 19/0052 20130101; E21B 43/38 20130101 |
Class at
Publication: |
166/231 ;
166/227 |
International
Class: |
E21B 43/38 20060101
E21B043/38 |
Claims
1. A separator device for use with a hydrocarbon production well
producing a fluid production stream including gaseous products and
solid products, said separator device comprising: a housing member;
an inner tube member having a first end and a second end, said
inner tube member being at least partially disposed within said
housing member; an annular zone formed between an interior surface
of said housing member and an exterior surface of said inner tube
member; a flighting support member attached to said second end of
said inner tube member; a flighting member having a first end and a
second end, said flighting member being disposed within said
annular zone between said housing member and said inner tube
member, wherein said second end of said flighting member engages
said flighting support member in a manner which suspends said
flighting member around a portion of said inner tube member in a
manner in which said flighting member remains detached from said
inner tube member; an inner annular space defined as the void space
formed between the inside diameter of said flighting member and the
exterior surface of said inner tube member; and an outer annular
space defined as the void space extending from the outside diameter
of the flighting member to the interior surface of the housing
member.
2. The device according to claim 1, wherein said housing member
includes one or more openings therein, said openings in said
housing member being arranged and configured to allow said fluid
production stream to enter said separator device.
3. The device according to claim 2, wherein said one or more
openings in said housing member are configured as elongated narrow
slots configured to hinder said gaseous products from entering said
device.
4. The device according to claim 1, further comprising a gas
discharge member connected to said housing member, wherein said gas
discharge member includes one or more openings arranged and
configured to allow gas to exit said device.
5. The device according to claim 4, wherein said one or more
openings in said gas discharge member are arranged and configured
to allow gas to exit the device following a vertical pathway.
6. The device according to claim 5, wherein said one or more
openings in said gas discharge member are arranged and configured
to allow gas to exit the device following a horizontal pathway.
7. The device according to claim 4, wherein the bottom portion of
said gas discharge member is the widest part of said gas discharge
member and said bottom portion tapers into a narrower top portion
of said gas discharge member.
8. The device according to claim 4, further including a tube
extension member connected to said gas discharge member.
9. The device according to claim 8, wherein said tube extension
member includes one or more openings arranged and configured to
allow gas to exit the device.
10. The device according to claim 1, further comprising an inner
tube coupling member connected to said first end of said inner tube
member.
11. The device according to claim 10, wherein said inner tube
coupling member includes one or more openings arranged and
configured to allow gas to exit the device.
12. The device according to claim 1, wherein said flighting member
defines a helical member suspended around said inner tube
member.
13. The device according to claim 1, further including a solids
accumulation area that defines an empty chamber for receiving said
solid products separated from said production stream.
14. (canceled)
15. (canceled)
16. The device according to claim 1, wherein said flighting member
is arranged and configured to generate centrifugal force to
simultaneously urge said solid products toward said interior
surface of said housing member and said gaseous products toward
said exterior surface of said inner tube member.
17. The device according to claim 1, wherein said device is
arranged and configured to generate centrifugal force to
simultaneously urge said solid products into said outer annular
space and said gaseous products into said inner annular space.
18. A separator device for use with a hydrocarbon production well
producing a fluid production stream including gaseous products and
solid products, said separator device comprising: a housing member;
an inner tube member having a first end and a second end, said
inner tube member being partially disposed within said housing
member; an annular zone formed between an interior surface of said
housing member and an exterior surface of said inner tube member; a
flighting support member attached to said second end of said inner
tube member; a flighting member having a first end and a second
end, said flighting member being disposed within said annular zone
between said housing member and said inner tube member, wherein
said second end of said flighting member engages said flighting
support member in a manner which suspends said flighting member
around a portion of said inner tube member; an inner annular space
defined as the void space formed between the inside diameter of
said flighting member and the exterior surface of said inner tube
member; and an outer annular space defined as the void space
extending from the outside diameter of the flighting member to the
interior surface of the housing member.
19. The device according to claim 18, wherein said second end of
said inner tube member is disposed within said housing member and
said first end of said inner tube member is disposed outside of
said housing member.
20. The device according to claim 1, wherein said flighting support
member is attached to the bottommost portion of said second end of
said inner tube member.
21. A separator device for use with a hydrocarbon production well
producing a fluid production stream including gaseous products and
solid products, said separator device comprising: a housing member;
van inner tube member having a first end and a second end, said
inner tube member being at least partially disposed within said
housing member, wherein said inner tube member is configured to
pass fluids therethrough from said second end to said first end of
said inner tube member; an annular zone formed between an interior
surface of said housing member and an exterior surface of said
inner tube member; a flighting support member attached to said
second end of said inner tube member; a flighting member having a
first end and a second end, said flighting member being disposed
within said annular zone between said housing member and said inner
tube member, wherein said second end of said flighting member
engages said flighting support member in a manner which suspends
said flighting member around a portion of said inner tube member;
an inner annular space defined as the void space formed between the
inside diameter of said flighting member and the exterior surface
of said inner tube member; and an outer annular space defined as
the void space extending from the outside diameter of the flighting
member to the interior surface of the housing member.
22. A separator device for use with a hydrocarbon production well
producing a fluid production stream including gaseous products and
solid products, said separator device comprising: a housing member;
an unperforated inner tube member having a first end and a second
end, said inner tube member having a single opening at said first
end and a single opening at said second end, wherein said inner
tube member is at least partially disposed within said housing
member; an annular zone formed between an interior surface of said
housing member and an exterior surface of said inner tube member; a
flighting support member attached to said second end of said inner
tube member; a flighting member having a first end and a second
end, said flighting member being disposed within said annular zone
between said housing member and said inner tube member, wherein
said second end of said flighting member engages said flighting
support member in a manner which suspends said flighting member
around a portion of said inner tube member; an inner annular space
defined as the void space formed between the inside diameter of
said flighting member and the exterior surface of said inner tube
member; and an outer annular space defined as the void space
extending from the outside diameter of the flighting member to the
interior surface of the housing member.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is related to and claims priority from
earlier filed U.S. Provisional Patent Application No. 61/963,213,
filed Nov. 25, 2013, the disclosure of which is incorporated herein
by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to a downhole gas
and solids separator. More specifically, the present invention
relates to a device which employs centrifugal force for the
downhole separation of gas and solids from a hydrocarbon production
stream.
[0004] 2. Description of Related Art
[0005] Artificial lift systems, such as sucker rod pumping systems
and progressing cavity pumping systems, are an artificial means
employed to increase the flow of fluids (e.g., hydrocarbons) from a
production well. Artificial lift is needed in wells when there is
insufficient pressure in the reservoir to lift the produced fluids
to the surface. Additionally, artificial lift is often used in
naturally flowing wells to increase the flow rate above the natural
flow rate.
[0006] Artificial lift systems often require the attachment of a
gas separator at the pump intake. In many wells that produce
hydrocarbons, the production stream can include both liquid and
gaseous products that are a natural byproduct of the producing
well. As hydrocarbons and water flow through the formation, gases
can travel in the production stream either separate from the liquid
products or entrained within the liquid products. The gas entrained
within the liquid products is carried into the production tubing
and can cause problems with artificial lift systems by reducing the
volumetric efficiency of the pump. The function of a gas separator
is to remove as much of the gas as possible from the liquid
products coming from the reservoir. Avoiding the entrance of gas is
a key factor in maintaining optimum pump efficiency and extending
the life of artificial lift systems.
[0007] Additionally, artificial lift systems often require the use
of a solids or sand separator. In many wells that produce
hydrocarbons, the production stream further includes manmade or
natural solid products. The most common manmade solid found at the
wellhead is proppant or fracture sand, which is increasingly being
used as more and more wells are being fractured to increase the
production of the wells. Additionally, the production stream may
include solids (e.g., sand, silt, etc.) that are a natural
byproduct of the producing well. As hydrocarbons and water flow
through the formation, these solid products are carried in the
production stream and can cause problems with the artificial lift
system, such as reducing the life of the lift system and increasing
maintenance costs.
[0008] Currently, many different separator devices are available
for separating gaseous products or solid products from produced
fluids. Design problems in current devices, however, present
several disadvantages that are overcome by the present
invention.
[0009] Most current devices are either gas separators or solid
separators. Such separators are unable to simultaneously separate
both gases and solids from the production stream. Current devices
that claim to separate both gases and solids from produced fluids
comprise multiple sections or phases--one section or phase for
separating solid products and another section or phase for
separating gaseous products from the produced fluids. Therefore,
such devices inefficiently separate gas and solids in separate
phases, not simultaneously.
[0010] Currently, a need exists for a downhole gas and solids
separator that simultaneously separates gases and solids from a
hydrocarbon production stream. A separator device is needed that
prevents both gaseous products and solid products from entering
pumps and reducing the efficiency of pumps. Further, a device is
needed that reduces the need to repair or replace downhole assembly
parts, thereby reducing costs.
[0011] In view of the foregoing, it is apparent that a need exists
in the art for a gas and solids separator which overcomes,
mitigates or solves the above problems in the art. It is a purpose
of this invention to fulfill this and other needs in the art which
will become more apparent to the skilled artisan once given the
following disclosure.
OBJECTS AND SUMMARY OF THE INVENTION
[0012] It is an object of the present invention to overcome the
above described drawbacks associated with current devices. To
achieve these and other advantages and in accordance with the
purpose of the invention, as embodied and broadly described, the
present disclosure describes a downhole gas and solids separator
which employs centrifugal force for the downhole separation of
gases and solids from a hydrocarbon production stream.
[0013] In all production, gases, sand and other solids enter the
wellbore and create pumping inefficiencies that severely diminish
production and contribute to increased maintenance costs and
unnecessary failures. The disclosed device is a simple, effective
separator that uses centrifugal force and a suspended internal
fighting member for effective downhole separation of both gases and
solids from production fluid. The disclosed device allows clean and
gas-free production fluid to fill the pump intake permitting
greater production and pump efficiency.
[0014] The disclosed separator device generally comprises a housing
member; an inner tube member having a first end and a second end,
the inner tube member being at least partially disposed within the
housing member; an annular zone formed between an interior surface
of the housing member and an exterior surface of the inner tube
member; a flighting support member attached to said second end of
said inner tube member; a flighting member having a first end and a
second end, said flighting member being disposed within said
annular zone between said housing member and said inner tube
member, wherein said second end of said flighting member engages
said flighting support member in a manner which suspends said
flighting member around a portion of said inner tube member; an
inner annular space defined as the void space formed between the
inside diameter of said flighting member and the exterior surface
of said inner tube member; and an outer annular space defined as
the void space extending from the outside diameter of the flighting
member to the interior surface of the housing member. By utilizing
a suspended helical flighting member, the disclosed device is able
to provide for the efficient and effective simultaneous separation
of both gases and solids from production fluid.
[0015] The unique and novel configuration of the disclosed
separator device provides many advantages over current separator
devices. Unlike existing separator devices, the primary advantage
of the disclosed device is that it provides for the simultaneous
separation of both gases and solids from a hydrocarbon production
stream. The disclosed device employs a suspended helical flighting
member for effective downhole separation of both gases and solids
from production fluid. Centrifugal force, provided by the flighting
member, accelerates the coalescence of like materials to enhance
separation of both gases and solids within the separator.
Centrifugal force urges solids to the outer wall of the separator
and gases towards the center where passageways (i.e., void annular
spaces) are designed to allow solids to efficiently migrate towards
and accumulate at the bottom of the separator, while simultaneously
allowing gases to efficiently rise out of the separator device.
[0016] In this manner, the disclosed device effectively cleans
production fluid and prevents gaseous products and solid products
from entering a pump and reducing the efficiency of the pump. By
moving less gaseous products and solid products through the
artificial lift system, oil and gas operators will benefit from
greater pump efficiency and extended run time between failures, and
the operators will thereby increase their profit margin.
[0017] A further advantage provided by the disclosed device is that
in one embodiment of the disclosed invention, the device comprises
components which all have threaded connections to provide for easy
disassembly, inspection, repair or replacement, and reassembly of
each of the components of the device. In comparison, current
separators are typically made of components which are welded
together and thus the entire separator device must be disposed of
when any component of the separator is damaged.
[0018] These, together with other objects of the invention, along
with various features of novelty that characterize the invention,
are pointed out with particularity in the claims annexed hereto and
forming a part of this disclosure. For a better understanding of
the invention, its operating advantages, and the specific objects
attained by its uses, reference should be had to the accompanying
drawings and descriptive matter in which there is described
illustrative embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The accompanying drawings, which are incorporated in and
forma part of the specification, illustrate embodiments of the
present invention, and together with the description, serve to
explain the principles of the invention. It is to be expressly
understood that the drawings are for the purpose of illustration
and description only and are not intended as a definition of the
limits of the invention. In the drawings:
[0020] FIG. 1 is a perspective view of a separator device
constructed in accordance with the teachings of the present
disclosure.
[0021] FIG. 2 is a perspective view showing the internal parts of
the separator device shown in FIG. 1.
[0022] FIG. 3 is a bottom perspective view of a flighting member
suspended around an inner tube member, wherein the flighting member
is engaged with a flighting support member, and wherein said
members are constructed in accordance with the teachings of the
present disclosure.
[0023] FIG. 4 is a sectional view showing the internal structure of
a separator device constructed in accordance with the teachings of
the present disclosure.
[0024] FIG. 5 is a perspective view of a gas discharge member
constructed in accordance with the teachings of the present
disclosure.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0025] The terms "top," "bottom," and "upper" are used in the
specification to describe the embodiments of the invention as
illustrated in the accompanying Figures. It should be appreciated
that in actual use, an embodiment of the invention may be rotated
as needed to accomplish the objectives of the invention. As a
result of such rotation, the various terms used herein of "top,"
"bottom," "upper" and the like may not literally apply to a
particular arrangement. Such terms are relative and are used herein
to describe the Figures for illustration purposes only and are not
intended to limit the embodiments shown to any particular
orientation.
[0026] Referring now to FIGS. 1-5, exemplary embodiments of a gas
and solids separator device 10 in accordance with the present
disclosure are illustrated. The separator device 10 according to
the present disclosure is illustrated and generally includes a
housing member 15; an inner tube member 11 having a first end 33
and a second end 34, the inner tube member 11 being at least
partially disposed within the housing member 15; an annular zone 25
formed between an interior surface 32 of the housing member 15 and
an exterior surface 31 of the inner tube member 11; a flighting
support member 17 attached to said second end 34 of said inner tube
member 11; a flighting member 16 having a first end 35 and a second
end 36, said flighting member 16 being disposed within said annular
zone 25 between said housing member 15 and said inner tube member
11, wherein said second end 36 of said flighting member 16 engages
said flighting support member 17 in a manner which suspends said
flighting member 16 around a portion of said inner tube member 11;
an inner annular space 26 defined as the void space formed between
the inside diameter 29 of said flighting member 16 and the exterior
surface 31 of said inner tube member 11; and an outer annular space
27 defined as the void space extending from the outside diameter 30
of the flighting member 16 to the interior surface 32 of the
housing member 15.
[0027] As depicted in the attached Figures, the housing member 15
may include one or more openings 23 therein. The openings 23 in the
housing member 15 are arranged and configured to allow the fluid
production stream to enter the separator device 10 and flow into
the annular zone 25. The annular zone 25 defines the area extending
between the interior surface 32 of the housing member 15 and the
exterior surface 31 of the inner tube member 11. In the embodiments
illustrated in FIGS. 1 and 4, the openings 23 are configured as
elongated narrow slots. This configuration of the openings 23 is
designed to prevent large gas bubbles from entering the separator.
Nevertheless, one skilled in the art can appreciate that there are
many other possibilities that exist for the shape, configuration,
positioning, and number of the openings 23, all of which are
considered to be within the spirit and scope of the present
invention.
[0028] In the embodiments shown in FIGS. 1, 4 and 5, the housing
member 15 is connected to a gas discharge member 14. The housing
member 15 may be connected to the gas discharge member via a
threaded connection or by any other connection means known to those
skilled in the art. As shown in FIG. 5, the gas discharge member 14
is configured with one or more openings 22, which are arranged and
configured to allow gas to exit the device 10 following a vertical
pathway 37 and/or a horizontal pathway 38. The bottom portion of
the gas discharge member 14 is the widest part of the gas discharge
member 14. The bottom portion of the gas discharge member 14 tapers
into a narrower top portion of said gas discharge member 14. As
depicted in the accompanying Figures, one or more of the openings
22 are arranged such that gas bubbles floating vertically up the
separator device 10 can easily exit the gas discharge member 14 via
a vertical pathway 37. Additionally, the gas bubbles can exit the
gas discharge member 14 via a horizontal pathway 38. In this
embodiment, the gas discharge member 14 is configured to provide
multiple unobstructed pathways for gas bubbles to easily exit the
separator device 10. In comparison, current devices are configured
to only allow gas bubbles to attempt to escape such separators via
horizontal pathways. The disclosed device 10 is better able to get
rid of gas bubbles by also providing one or more vertical pathways
37 for the gas bubbles to exit the device 10.
[0029] As illustrated in FIGS. 1 and 4, the gas discharge member 14
may be connected to a tube extension member 13. The gas discharge
member 14 may be connected to the tube extension member 13 via a
threaded connection or by any other connection means known to those
skilled in the art. The tube extension member 13 may be perforated
and include one or more openings 21 as shown in FIG. 1. Such
openings 21 provide additional outlets for gaseous products to exit
from the separator device 10 before reaching the artificial lift
system.
[0030] The disclosed separator device 10 may further include an
inner tube coupling member 12 connected to the first end 33 of the
inner tube, as depicted in FIGS. 1, 2, and 4. The inner tube
coupling member 12 is also connected to the tube extension member
13. The inner tube coupling member 12 may be coupled to both the
inner tube member 11 and the tube extension member 13 via threaded
connections or any other connection means known to those skilled in
the art. The inner tube coupling member 12 may further include one
or more openings 20 configured to allow gaseous products to exit
the separator device 10 before reaching the artificial lift
system.
[0031] As shown in the accompanying Figures, the disclosed
separator device 10 further includes an inner tube member 11. The
inner tube member 11 includes a first end 33 connected to an inner
tube coupling member 12, and a second end 34 connected to a
flighting support member 17. The inner tube member 11 may be
coupled to both the inner tube coupling member 12 and the flighting
support member 17 via threaded connections or any other connection
means known to those skilled in the art. In operation, the
artificial lift system pulls fluid, after it has been separated
from gases and solids, up through the inner tube member 11.
[0032] The disclosed separator device 10 also includes a flighting
member 16. In the embodiments shown in FIGS. 2-4, the flighting
member 16 is a helical member which is suspended around the inner
tube member 11. The flighting member 16 has a first end 35 and a
second end 36. The second end 36 of the flighting member 16 is
engaged with a flighting support member 17, which flighting support
member 17 is connected to the second end 34 of the inner tube
member 11. As shown in FIG. 3, the flighting member 16 is suspended
around the inner tube member 11 in a manner in which the flighting
member 16 is not directly attached to or engaged with the inner
tube member 11. An inner annular space 26 separates the inside
edges of the flighting member 16 and the exterior surface 31 of the
inner tube member 11. This inner annular space 26 defines the void
space between the inside diameter 29 of the flighting member 16 and
the exterior surface 31 of the inner tube member 11.
[0033] As depicted in FIG. 4, the disclosed separator device 10
further includes an outer annular space 27 which separates the
outermost edges of the flighting member 16 from the interior
surface 32 of the housing member 15. The outer annular space 27
defines the void space extending from the outside diameter 30 of
the flighting member 16 to the interior surface 32 of the housing
member 15.
[0034] The disclosed separator device 10 may further include a
solids accumulation area 18. The solids accumulation area 18 is
located below the inner tube member 11, flighting member 16 and the
flighting support member 17, as shown in FIG. 4. The solids
accumulation area 18 defines an empty chamber for receiving solid
products separated from the production fluid by the disclosed
separator device 10.
[0035] As can be seen in FIGS. 1 and 4, the disclosed separator
device 10 may further include a plug member 19 connected to the
bottom of the device 10. The plug member 19 is easily removable
from the device 10 and can be removed from the device 10 to empty
the accumulated solids from the solids accumulation area 18.
[0036] In operation, the disclosed separator device 10 may work as
follows. The production stream is drawn into the one or more
openings 23 in the housing member 15 by both the artificial lift
system and gravity. Once the production stream enters through the
openings 23 in the housing member 15, the production stream is
drawn down the annular zone 25 between the housing member 15 and
the inner tube member 11. When the production stream is drawn down
the annular zone 25, it is being pulled down the helical path
provided by the flighting member 16 suspended in the annular zone
25. Centrifugal force is generated when the production stream flows
down the helical path provided by the flighting member 16.
Centrifugal force forces the heavier components (i.e., the solids)
in the production stream outwards toward the interior surface 32 of
the housing member 15. The solid products eventually migrate down
the outer annular space 27 until the solids are captured in a
solids accumulation area 18 located below the second end 34 of the
inner tube member 11. At the same time, the centrifugal force
provided by the helical flighting member 16 forces the lighter
components (i.e., the gases) in the production stream inwards
toward the center of the device 10 against the exterior surface 31
of the inner tube member 11. Here, gas bubbles coalesce into larger
gas bubbles and then rise through the void inner annular space 26
provided between the inside diameter 29 of the flighting member 16
and the exterior surface 31 of the inner tube member 11. The gas
will continue to rise through the inner annular space 26 until it
exits through an opening (e.g., an opening in the gas discharge
member) formed in the upper portion of the disclosed separator,
where the gas can easily exit into the well casing annulus and then
continue rising to the surface of the well. Finally, the artificial
lift system draws the production stream, which has been separated
from gases and solids, back up the device 10 through the inner tube
member 11 and into a pump. The pump (not depicted) is located above
the separator device 10. In this manner, the disclosed device 10
effectively cleans production fluid and prevents gaseous products
and solid products from entering the artificial lift system.
[0037] It is important to note that the construction and
arrangement of the elements of the device provided herein are
illustrative only. Although only a few exemplary embodiments of the
present invention have been described in detail in this disclosure,
those skilled in the art who review this disclosure will readily
appreciate that many modifications are possible in these
embodiments (such as variations in orientation of the components of
the system, sizes, structures, shapes and proportions of the
various components, etc.) without materially departing from the
novel teachings and advantages of the invention.
[0038] Many other uses of the present invention will become obvious
to one skilled in the art upon acquiring a thorough understanding
of the present invention. Once given the above disclosures, many
other features, modifications and variations will become apparent
to the skilled artisan in view of the teachings set forth herein.
Such other uses, features, modifications and variations are,
therefore, considered to be a part of this invention, the scope of
which is to be determined by the following claims.
* * * * *