DOWN-HOLE GAS SEPARATION SYSTEM

Abstract

A method and apparatus for gas and solids separation from down-hole fluids is disclosed, including a chamber disposed between a production string or a liquid-gas separator and a production pump. In the chamber, liquids “sink” to the bottom and gas rises to the top. At the top of the chamber, gas exits holes or ports or orifices in the outer walls of the chamber. At the bottom of the chamber, the liquid is drawn up by a pump through a different production tube. These chambers may be coupled serially for a multi-stage gas separating apparatus.

Description

TECHNICAL FIELD

Disclosed herein are improvements to down-hole gas separation method, apparatus, and system.

BACKGROUND ART

In the current state of the art, pumping fluids in low pressure wellbores has the propensity to produce large pockets of gas, over 20 foot columns, and gas-lock a pump, preventing production. In essence, fluid is pumped up from a fluid retrieving section of the bottom hole assembly. As the pumped fluid is “sucked” up the production tube, gas separates from the fluid and bubbles to the top of the fluid column. Eventually, enough gas separates and rises to the top of the fluid column that a pump becomes gas locked and can no longer pump. The pump must stop pumping and wait for the gas to dissipate before it can resume pumping.

There is a strong need to separate gas from production fluids in the wellbore so that only liquids are pumped, thus preventing gas locking of the well and providing more liquid returns from the pump.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a side cross-section view of an example supplemental gas separator unit of the present invention.

FIG. 2 illustrates the supplemental gas separator unit of FIG. 1, with illustration of lines of fluid flow when in operation.

FIG. 3 illustrates a side cross-section view of another example supplemental gas separator unit of the present invention. One or more orifices into the second chamber are added to the tubular housing.

FIG. 4 illustrates the supplemental gas separator unit of FIG. 3, with illustration of lines of fluid flow when in operation.

FIG. 5 illustrates a side cross-section view of another example supplemental gas separator unit of the present invention. One or more orifices into the second chamber are added to the tubular housing. The second plurality of tubes are eliminated.

FIG. 6 illustrates the supplemental gas separator unit of FIG. 5, with illustration of lines of fluid flow when in operation.

FIG. 7 illustrates a side cross-section view showing an example of the placement of a supplemental gas separator unit of the present invention, in relation to a primary gas separator unit and schematic representation of a pump.

DISCLOSURE OF THE INVENTION

In one example, the invention operates by allowing gas to separate from wellbore fluids in a chamber, a Scavenger Chamber, wherein fluids pumped up through production tubing are emptied into the Scavenger Chamber. In the Chamber, liquids “sink” to the bottom and gas rises to the top. At the top of the Chamber, gas exits holes or ports or orifices in the outer walls of the Chamber. At the bottom of the Chamber, the liquid is drawn up by a pump through a different production tube. These chambers may be coupled serially for a multi-stage gas separating apparatus.

By having a staged area where gas separates from liquid as it is pumped, the gas separates and exits the pumped fluid preventing it from reaching, and thus gas locking, the pump. Further, because the fluid contains less gas, the pump is producing more liquid per stroke.

An apparatus and method are disclosed for separating gas from pumped fluids in a wellbore, producing liquid rich fluids and preventing gas locking a pump.

FIG. 1 illustrates a side cross-section view of an example of the supplemental gas separator unit (22) of the present invention. A tubular housing (1) is sized to fit around a production string (2). One or more orifices (3) are positioned in an upper portion of the tubular housing (1) to expel gas.

A first chamber (4) is positioned in the upper portion of the tubular housing. The first chamber (4) is in fluid communication with the outside of the tubular housing (1) through the orifice(s) (3).

A second chamber (5) is positioned and arranged below the first chamber (4).

A gasket (6) separates the first chamber (4) from the second chamber (5), preventing direct fluid communication. Note, also, that the bottom end of production string (2) also terminates into gasket (6), for the function of preventing any direct fluid communication from second chamber (5) into the inside of the production string (2). In this example, the termination of the production string (2) into gasket (6) also prevents fluids from the first chamber (4) from directly entering into the bottom end of production string (2).

A first single or plurality of tubes (7) having first open ends (8) is/are positioned and arranged in the first chamber (4). The first plurality of tubes (7) have second open ends (9) positioned and arranged in the second chamber (5). The first plurality of tubes (7) penetrate or otherwise pass through gasket (6).

A second single or plurality of tubes (10) have first open ends (11) positioned and arranged in the first chamber (4). The second plurality of tubes (10) have second open ends (12) positioned and arranged in the second chamber (5). The second plurality of tubes (10) penetrate or otherwise pass through gasket (6).

Within the first chamber (4), the first set of tubes (7) have their first open ends (8) positioned below the first open ends (11) of the second set of tubes (10).

Within the second chamber (5), the first set of tubes (7) have their second open ends (9) positioned below the second open ends (12) of the second set of tubes (10). In a preferred example, the second open ends (9) of the first set of tubes (7) are located in the lower portion of the second chamber (5), designed to be immersed in liquid.

One or more orifices (13) open into the production string (2) for receiving wellbore fluids, these orifices (13) being positioned and arranged inside the first chamber (4). In a preferred example, orifices (13) are positioned near the bottom of the first chamber (4), designed to be immersed in liquid.

A second production string (14) has an open end (15) terminating inside the second chamber (5). The tubular housing (1) is sized to fit around the second production string (14) with one or more orifices (e.g. 15) to expel wellbore fluids, positioned and arranged inside the second chamber (5). A gasket (16) at the bottom end of the second chamber (5), sealing the second chamber from the rest of the tubular housing (1). The second production string (14) continues downward through the center of the gasket (16), thereby being the source for fluids entering into the second chamber (5).

A gasket (17) likewise is disposed at the top end of the first chamber (4), sealing the first chamber from the rest of the tubular housing (1). The first production string (2) continues upward through the center of gasket (17), thereby being the being the source for fluids, preferably mostly liquids, leaving the first chamber (4) to ultimately be produced into the pump for delivery at the surface of the well.

In one example, the first set of tubes (7) and/or the second set of tubes (10) are composed of polytetrafluoroethylene (PTFE).

In a preferred example, the orifices (3) in the tubular housing (1) of the first chamber (4) are 0.75 inches in diameter. The orifices (3) in the tubular housing (1) of the first chamber (4) are one inch below the top of the first chamber (4). In a further example, there are multiple orifices (3) equally spaced radially around the tubular housing (1) of the first chamber (4).

In a preferred example, there are a quantity of four of the first tubes (7), and a single second tube (10). The tubes (7 and 10) are equally spaced radially around production strings/tubes (2 and 14). The first tube(s) (7) first open ends (8) are positioned above the orifices (13) in the first production string/tube (2).

In a further example, the second tube(s)′ (10) first open ends (11) are positioned in the upper portion of the first chamber (4) and the tube(s)′ (10) second open ends (12) are positioned in the upper portion of the second chamber (5). In a further example, the second tube(s) (10) first open end(s) (11) are positioned in the upper portion of the first chamber (4) and below the orifices (3) in the tubular housing (1). The second tube(s)′ (10) first open end(s) (11) are one inch below the orifices (3) of the tubular housing (1).

In a further example, the second tube(s)′ (10) second open end (12) are positioned above the orifices or open end (15) in the second production tube (14). In a further example, the orifices or open end (15) in the second production tube (14) are positioned in the upper portion of the second chamber (5) and below the second openings (12) of the second set of tubes (10).

FIG. 2 illustrates a side cross-section view of an example of the supplemental gas separator unit (22) of the present invention, with illustration of lines of fluid flow when in operation.

Starting with the fluids in the hydrocarbon reservoir, the fluids will be a mixture of gas and liquid, sometimes with carried solids. The entrained gases can cause a gas lock in an oil field pump. The fluids from the reservoir may go through a primary oil gas separator before entry into the supplemental separator (22) of the current invention (called by the inventor a “scavenger”). These fluids enter the supplemental separator (22) through the open end (15) of second production string or tube (14), dumping the gas-liquid fluid mixture into the second chamber (5). As the fluid mix enters the second chamber (5), there is opportunity for some of the gas (21) from the mix to separate and rise towards the top of the second chamber (5), as shown by flow line (23). The heavier portion of the mix which is now more liquid laden (19), and has opportunity to flow towards the bottom of the second chamber (5), as shown by flow line (24). Since the bottom or second end (9) of the first tube (7) is located in the lower portion of the second chamber (5), it is likely to be immersed in the more liquid laden (19) fluid. The liquid laden fluid (19) will flow up through the first tube(s) (7) and eject through the top or first end (8) of the first tube(s) (7) into the first chamber (4), to exit as liquid mix (18).

The gas (21) in the second chamber (5) has opportunity to enter the bottom or second end (12) of the second tube(s) (10), to be drawn up through tube(s) (10) into the upper portion of the first chamber (4), to exit as gas (20) from the top or first end (11) of second tube(s) (10), as shown in flow line (25). The gas (20) has opportunity to exit the supplemental separator (22) through orifice(s) (3), exiting the tubular housing (1) into the annulus of the well.

Returning to liquid mix (18), further separation occurs or has occurred during its travel in first tube(s) (7), producing additional gas (20). The liquid portion (19) draws downward, with opportunity to flow into orifice (13) of the first production string (2), as shown by flow line (26). From there, the fluid has the minimal amount of remaining gas, is mostly liquid, to be drawn up the production string (2) by the pump. Finally, the additional gases (20) exit the orifice(s) (3), as shown by flow line (27), and as previously described for the gases (20) that follow flow line (25).

FIG. 3 illustrates a side cross-section view of another example of the supplemental gas separator unit (32) of the present invention. One or more orifices (33) into the second chamber (5) are added to the tubular housing (1).

The tubular housing (1) is sized to fit around a production string (2). One or more orifices (3) are positioned in an upper portion of the tubular housing (1) to expel gas.

The first chamber (4) is positioned in the upper portion of the tubular housing. The first chamber (4) is in fluid communication with the outside of the tubular housing (1) through the orifice(s) (3).

The second chamber (5) is positioned and arranged below the first chamber (4). Additionally, one or more orifices (33) are positioned in an upper portion of the second chamber (5) of the tubular housing (1).

Gasket (6) separates the first chamber (4) from the second chamber (5), preventing direct fluid communication. Note, also, that the bottom end of production string (2) also terminates into gasket (6), for the function of preventing any direct fluid communication from second chamber (5) into the inside of the production string (2). In this example, the termination of the production string (2) into gasket (6) also prevents fluids from the first chamber (4) from directly entering the bottom end of production string (2).

The first single or plurality of tubes (7) having first open ends (8) positioned and arranged in the first chamber (4). The first plurality of tubes (7) have second open ends (9) positioned and arranged in the second chamber (5). The first plurality of tubes (7) penetrate or otherwise pass through gasket (6).

The second single or plurality of tubes (10) have first open ends (11) positioned and arranged in the first chamber (4). The second plurality of tubes (10) have second open ends (12) positioned and arranged in the second chamber (5). The second plurality of tubes (10) penetrate or otherwise pass through gasket (6).

Within the first chamber (4), the first set of tubes (7) have their first open ends (8) positioned below the first open ends (11) of the second set of tubes (10).

Within the second chamber (5), the first set of tubes (7) have their second open ends (9) positioned below the second open ends (12) of the second set of tubes (10). In a preferred example, the second open ends (9) of the first set of tubes (7) are located in the lower portion of the second chamber (5), designed to be immersed in liquid.

One or more orifices (13) open into the production string (2) for receiving wellbore fluids, these orifices (13) being positioned and arranged inside the first chamber (4). In a preferred example, orifices (13) are positioned near the bottom of the first chamber (4), designed to be immersed in liquid.

The second production string (14) has an open end (15) terminating inside the second chamber (5). The tubular housing (1) is sized to fit around the second production string (14) and one or more orifices into a second production string to expel wellbore fluids, positioned and arranged inside the second chamber. Gasket (16) at the bottom end of the second chamber (5), sealing the second chamber from the rest of the tubular housing (1). The second production string (14) continues downward through the center of the gasket (16), thereby being the source for fluids entering into the second chamber (5).

The gasket (17) likewise is disposed at the top end of the first chamber (4), sealing the first chamber from the rest of the tubular housing (1). The first production string (2) continues upward through the center of gasket (17), thereby being the being the source for fluids, preferably mostly liquids, leaving the first chamber (4) to ultimately be produced into the pump for delivery at the surface of the well.

In one example, the first set of tubes (7) and/or the second set of tubes (10) are composed of polytetrafluoroethylene (PTFE).

In a preferred example, the orifices (3) in the tubular housing (1) of the first chamber (4) are 0.75 inches in diameter. The orifices (3) in the tubular housing (1) of the first chamber (4) are 1 inch below the top of the first chamber (4). In a further example, there are multiple orifices (3) equally spaced radially around the tubular housing (1) of the first chamber (4).

In a preferred example, there are a quantity of four of the first tubes (7), and a single second tube (10). The tubes (7 and 10) are equally spaced radially around production strings/tubes (2 and 14). The first tube(s)′ (7) first open ends (8) are positioned above the orifices (13) in the first production string/tube (2).

In a further example, the second tube(s)′ (10) first open ends (11) are positioned in the upper portion of the first chamber (4) and the tube(s)′ (10) second open ends (12) are positioned in the upper portion of the second chamber (5). In a further example, the second tube(s) (10) first open end(s) (11) are positioned in the upper portion of the first chamber (4) and below the orifices (3) in the tubular housing (1). The second tube(s)′ (10) first open end(s) (11) are one inch below the orifices (3) of the tubular housing (1).

In a further example, the second tube(s)′ (10) second open end (12) are positioned above the orifices or open end (15) in the second production tube (14). In a further example, the orifices or open end (15) in the second production tube (14) are positioned in the upper portion of the second chamber (5) and below the second openings (12) of the second set of tubes (10).

In a preferred example, the orifices (33) in the tubular housing (1) of the second chamber (5) are 0.5 inches in diameter. In a preferred example, the orifices (33) in the tubular housing (1) of the second chamber (5) are 0.5 inch below the top of the second chamber (5).

In a further example, the second openings (12) of the second tube(s) (10) are below the orifices (33) in tubular housing (1) of the second chamber (5).

FIG. 4 illustrates a side cross-section view of another example of the supplemental gas separator unit (32) of the present invention, with illustration of lines of fluid flow when in operation. In this figure, orifices (33) are added to the tubular housing (1) in the second chamber (5).

Starting with the fluids in the hydrocarbon reservoir, the fluids will be a mixture of gas and liquid, sometimes with carried solids. The entrained gases can cause a gas lock in an oil field pump. The fluids from the reservoir may go through a primary oil gas separator before entry into the supplemental separator (32) of the current invention (called by the inventor a “scavenger”). These fluids enter the supplemental separator (32) through the open end (15) of second production string or tube (14), dumping the gas-liquid fluid mixture into the second chamber (5). As the fluid mix enters the second chamber (5), there is opportunity for some of the gas (21) from the mix to separate and rise towards the top of the second chamber (5), as shown by flow lines (23 and 28). The heavier portion of the mix which is now more liquid laden (19), and has opportunity to flow towards the bottom of the second chamber (5), as shown by flow line (24). Since the bottom or second end (9) of the first tube (7) is located in the lower portion of the second chamber (5), it is likely to be immersed in the more liquid laden (19) fluid. The liquid laden fluid (19) will flow up through the first tube(s) (7) and eject through the top or first end (8) of the first tube(s) (7) into the first chamber (4), to exit as liquid mix (18).

The gas (21) in the second chamber (5) has opportunity to exit the second chamber (5) and exit the supplemental separator (32) through orifice(s) (33), exiting the tubular housing (1) into the annulus of the well, as shown by flow line (28). The gas (21) in the second chamber (5) has opportunity to enter the bottom or second end (12) of the second tube(s) (10) as shown by flow line (23), to be drawn up through tube(s) (10) into the upper portion of the first chamber (4), to exit as gas (20) from the top or first end (11) of second tube(s) (10), as shown in flow line (25). The gas (20) has opportunity to exit the supplemental separator (32) through orifice(s) (3), exiting the tubular housing (1) into the annulus of the well.

Returning to liquid mix (18), further separation occurs or has occurred during its travel in first tube(s) (7), producing additional gas (20). The liquid portion (19) draws downward, with opportunity to flow into orifice (13) of the first production string (2), as shown by flow line (26). From there, the fluid has the minimal amount of remaining gas, is mostly liquid, to be drawn up the production string (2) by the pump. Finally, the additional gases (20) exit the orifice(s) (3), as shown by flow line (27), and as previously described for the gases (20) that follow flow line (25).

FIG. 5 illustrates a side cross-section view of another example of the supplemental gas separator unit (42) of the present invention. One or more orifices (33) into the second chamber (5) are added to the tubular housing (1). The second plurality of tubes (10) are eliminated. In this example, gaseous fluid exits the separator through orifices (33) from the lower chamber (5), reducing the load on orifices (3) in the upper chamber (4). In another example, the second plurality of tubes (10) are not eliminated, but the one or more orifices (33) into the second chamber (5) are still added to the tubular housing (1).

A tubular housing (1) is sized to fit around a production string (2). One or more orifices (3) are positioned in an upper portion of the tubular housing (1) to expel gas.

A first chamber (4) is positioned in the upper portion of the tubular housing. The first chamber (4) is in fluid communication with the outside of the tubular housing (1) through the orifice(s) (3).

A second chamber (5) is positioned and arranged below the first chamber (4). Additionally, one or more orifices (33) are positioned in an upper portion of the second chamber (5) of the tubular housing (1).

A gasket (6) separates the first chamber (4) from the second chamber (5), preventing direct fluid communication. Note, also, that the bottom end of production string (2) also terminates into gasket (6), for the function of preventing any direct fluid communication from second chamber (5) into the inside of the production string (2). In this example, the termination of the production string (2) into gasket (6) also prevents fluids from the first chamber (4) from directly entering the bottom end of production string (2).

A first single or plurality of tubes (7) having first open ends (8) positioned and arranged in the first chamber (4). The first plurality of tubes (7) have second open ends (9) positioned and arranged in the second chamber (5). The first plurality of tubes (7) penetrate or otherwise pass through gasket (6).

In a preferred example, the second open ends (9) of the first set of tubes (7) are located in the lower portion of the second chamber (5), designed to be immersed in liquid.

One or more orifices (13) open into the production string (2) for receiving wellbore fluids, these orifices (13) being positioned and arranged inside the first chamber (4). In a preferred example, orifices (13) are positioned near the bottom of the first chamber (4), designed to be immersed in liquid.

A second production string (14) has an open end (15) terminating inside the second chamber (5). The tubular housing (1) is sized to fit around the second production string (14) and one or more orifices into a second production string to expel wellbore fluids, positioned and arranged inside the second chamber. A gasket (16) at the bottom end of the second chamber (5), sealing the second chamber from the rest of the tubular housing (1). The second production string (14) continues downward through the center of the gasket (16), thereby being the source for fluids entering into the second chamber (5).

A gasket (17) likewise is disposed at the top end of the first chamber (4), sealing the first chamber from the rest of the tubular housing (1). The first production string (2) continues upward through the center of gasket (17), thereby being the being the source for fluids, preferably mostly liquids, leaving the first chamber (4) to ultimately be produced into the pump for delivery at the surface of the well.

In one example, the first set of tubes (7) are composed of polytetrafluoroethylene (PTFE).

In a preferred example, the orifices (3) in the tubular housing (1) of the first chamber (4) are 0.75 inches in diameter. The orifices (3) in the tubular housing (1) of the first chamber (4) are one inch below the top of the first chamber (4). In a further example, there are multiple orifices (3) equally spaced radially around the tubular housing (1) of the first chamber (4).

In a preferred example, there are a quantity of 5 of the first tubes (7). The tubes (7) are equally spaced radially around production strings/tubes (2 and 14). The first tube(s) (7) first open ends (8) are positioned above the orifices (13) in the first production string/tube (2).

In a preferred example, the orifices (33) in the tubular housing (1) of the second chamber (5) are 0.5 inches in diameter. In a preferred example, the orifices (33) in the tubular housing (1) of the second chamber (5) are 0.5 inch below the top of the second chamber (5).

FIG. 6 illustrates a side cross-section view of another example of the supplemental gas separator unit (42) of the present invention, with illustration of lines of fluid flow when in operation. In this figure, the second tube(s) (10) are eliminated.

Starting with the fluids in the hydrocarbon reservoir, the fluids will be a mixture of gas and liquid, sometimes with carried solids. The entrained gases can cause a gas lock in an oil field pump. The fluids from the reservoir may go through a primary oil gas separator before entry into the supplemental separator (42) of the current invention (called by the inventor a “scavenger”). These fluids enter the supplemental separator (42) through the open end (15) of second production string or tube (14), dumping the gas-liquid fluid mixture into the second chamber (5). As the fluid mix enters the second chamber (5), there is opportunity for some of the gas (21) from the mix to separate and rise towards the top of the second chamber (5), as shown by flow lines (28). The heavier portion of the mix which is now more liquid laden (19), and has opportunity to flow towards the bottom of the second chamber (5), as shown by flow line (24). Since the bottom or second end (9) of the first tube (7) is located in the lower portion of the second chamber (5), it is likely to be immersed in the more liquid laden (19) fluid. The liquid laden fluid (19) will flow up through the first tube(s) (7) and eject through the top or first end (8) of the first tube(s) (7) into the first chamber (4), to exit as liquid mix (18).

The gas (21) in the second chamber (5) has opportunity to exit the second chamber (5) and exit the supplemental separator (42) through orifice(s) (33), exiting the tubular housing (1) into the annulus of the well, as shown by flow line (28).

Returning to liquid mix (18), further separation occurs or has occurred during its travel in first tube(s) (7), producing additional gas (20). The liquid portion (19) draws downward, with opportunity to flow into orifice (13) of the first production string (2), as shown by flow line (26). From there, the fluid has the minimal amount of remaining gas, is mostly liquid, to be drawn up the production string (2) by the pump. Finally, the additional gases (20) has opportunity to exit the supplemental separator (42) through orifice(s) (3), exiting the tubular housing (1) into the annulus of the well as shown by flow line (27).

FIG. 7 illustrates a side cross-section view showing an example of the placement of supplemental gas separator unit (100) of the present invention, in relation to a primary gas separator unit (200) and schematic representation of a pump (300). In one example, the supplemental gas separator unit (100) is as illustrated in FIGS. 1-7 (e.g., separators 22, 32, 42). In one example, the top of the primary gas separator unit (200) connects to the bottom of the supplemental gas separator unit (100) such that the separated liquid-fluids of the primary separator exit into the second production string (14) (as illustrated in FIGS. 1, 3, 5) of the supplemental gas separator unit (100). After the separated liquid-fluids from the primary separator (200) are processed by the supplemental separator (100), the liquids exit through the top production string (2) (as illustrated in FIGS. 1, 3, 5) and into the production string that goes to the pump (300).

In another example, the input of the supplemental separator (100) is connected to the output of a primary separator for gas and solids separation that has a configuration as follows. The primary separator has an inner tube having a length in a longitudinal direction and an outer tube disposed about the inner tube; a plurality of chambers, wherein each chamber is defined by an annular region between the outer tube, the inner tube, and a first fluid barrier and a second fluid barrier, each fluid barrier disposed in an annular region between the inner tube and the outer tube; wherein one of the plurality of chambers comprises an intake chamber, in fluid communication with the outside of the outer tube through an orifice; wherein one of the plurality of chambers comprises a first processing chamber (ML) disposed longitudinally adjacent to the intake chamber; wherein one of the plurality of chambers comprises a second processing chamber (H) disposed longitudinally adjacent to the first processing chamber, opposite from the intake chamber; wherein one of the plurality of chambers comprises a third processing chamber (CL) disposed longitudinally adjacent to the second processing chamber (H), opposite from the first processing chamber (ML); wherein one of the plurality of chambers comprises a fourth processing chamber (R1) disposed longitudinally adjacent to the intake chamber, opposite from the first processing chamber (ML); wherein one of the plurality of chambers comprises a fifth processing chamber (R2) disposed longitudinally adjacent to the fourth processing chamber (R1), opposite from the intake chamber; wherein fluid communication between the intake chamber and the first processing chamber (ML) is restricted to fluid flow through a first set of a plurality of tubes; wherein fluid communication between the first processing chamber (ML) and the second processing chamber (H) is restricted to fluid flow through a second set of a plurality of tubes; wherein fluid communication between the second processing chamber (H) and the third processing chamber (CL) is restricted to fluid flow through a third set of a plurality of tubes; wherein a block restricts fluid communication within the inner tube between the fourth processing chamber (R1) and the fifth processing chamber (R2); wherein fluid communication between the third processing chamber (CL) and the fourth processing chamber (R1) is restricted to fluid flow through the inner tube; wherein an orifice in the inner tube is disposed in the fourth processing chamber (R1), proximate to the fifth processing chamber (R2) and on a first side of the block, providing fluid communication between fourth processing chamber (R1) and the inner tube; wherein an orifice in the inner tube is disposed in the fifth processing chamber (R2), proximate to the fourth processing chamber (R1) and on the opposite side of the block, providing fluid communication between fifth processing chamber (R2) and the inner tube; and wherein fluid communication between the fourth processing chamber (R1) and the fifth processing chamber (R2) is restricted to fluid flow through a fourth set of a plurality of tubes.

In a further example, a second orifice is disposed on the outer tube of the first processing chamber, proximate to the intake chamber. In a further example, a second orifice disposed on the outer tube placing the first processing chamber in fluid communication with the exterior surface of the outer tube. In a further example, the first processing chamber (ML) is in fluid communication with the outside of the outer tube through an orifice. In a further example, the second processing chamber (H) is in fluid communication with the outside of the outer tube through an orifice. In a further example, the third processing chamber (CL) is in fluid communication with the outside of the outer tube through an orifice. In a further example, the fourth processing chamber (R1) is in fluid communication with the outside of the outer tube through an orifice. In a further example, the fifth processing chamber (R2) is in fluid communication with the outside of the outer tube through an orifice. In a further example, the tubes of the sets of tubes comprise polytetrafluoroethylene (PTFE).

In another example, the input of the supplemental separator (100) is connected to the output of a primary separator for gas and solids separation that has a configuration as follows. The primary separator has production tube having a length in a longitudinal direction and an outer tube disposed about the production tube. A plurality of chambers are defined by an annular region between the outer tube and the production tube, and a first fluid barrier and a second fluid barrier, each fluid barrier disposed in an annular region between the production tube and the outer tube. One of the plurality of chambers comprises a first processing chamber (“Pressure Loss Chamber”) and one of the plurality of chambers comprises a second processing chamber (“Production Chamber”). Two or more second processing chambers comprise a cascade of second processing chambers (“Production Chamber”), the cascade disposed longitudinally adjacent to the first processing chamber (“Pressure Loss Chamber”). A terminating chamber (TC) is defined by a region between the outer tube and the production tube, and a fluid barrier disposed between the terminating chamber (TC) and the second processing chamber or cascade of second processing chambers (“Production Chamber”). The terminating chamber is disposed longitudinally adjacent to the second processing chamber or cascade of second processing chambers (“Production Chamber”), and opposite from the first processing chamber (“Pressure Loss Chamber”). The production tube comprises one or more orifices (“Thief Jet Port”) opening into one or more of the second processing chamber or cascade of second processing chambers (“Production Chamber”). The first processing chamber (“Pressure Loss Chamber”) is in fluid communication with the outside of the outer tube through one or more orifices (“Gas Exit from the Pressure Loss Chamber”) in the outer tube, the one or more orifices disposed in the first processing chamber (“Pressure Loss Chamber”). The second processing chamber (“Production Chamber”) is in fluid communication with the outside of the outer tube through a first set of one or more orifices (“Gas Exit from the Production Chamber”) in the outer tube, the one or more orifices disposed in an upper portion of the second processing chamber (“Production Chamber”). The second processing chamber (“Production Chamber”) is in fluid communication with the outside of the outer tube through a second set of one or more orifices (“Fluid Intake into the Production Chamber”) in the outer tube, the one or more orifices disposed in an upper portion of the second processing chamber (“Production Chamber”) and below the first set of one or more orifices (“Gas Exit from the Production Chamber”). One or more third tubes (“Gas Highway Tube”) are each disposed in the second processing chamber or cascade of second processing chambers (“Production Chamber”) having an open end disposed in the first processing chamber (“Pressure Loss Chamber”). The third tube (“Gas Highway Tube”) comprises one or more orifices opening into one or more of the second processing chamber or cascade of second processing chambers (“Production Chamber”). One or more second processing chambers (“Production Chamber”) comprise a fourth tube (“Solids Management Tube”) have a first open end disposed in a lower portion of the second processing chamber (“Production Chamber”) and a second open end disposed external to said second processing chamber (“Production Chamber”).

In one further example, the production tube of the primary separator comprises one or more orifices (“Thief Jet Port”) opening into the terminating chamber (TC).

In one further example of the primary separator, the terminating chamber (TC) is in fluid communication with the outside of the outer tube through a first set of one or more orifices (“Gas Exit from the Terminating Chamber) in the outer tube, the one or more orifices disposed in an upper portion of the terminating chamber (TC).

In one further example of the primary separator, the terminating chamber (TC) is in fluid communication with the outside of the outer tube through a second set of one or more orifices (“Fluid Intake into the Terminating Chamber”) in the outer tube, the one or more orifices disposed in an upper portion of the terminating chamber (TC) and below the first set of one or more orifices (“Gas Exit from the Terminating Chamber”).

In one further example of the primary separator, the one or more third tubes (“Gas Highway Tube”) have a second open end disposed in the terminating chamber (TC).

In one further example of the primary separator, the one or more orifices disposed in the outer tube of the pressure loss chamber (“Pressure Loss Chamber”) are disposed in a lower portion of the pressure loss chamber (“Pressure Loss Chamber”) and the open end of the one or more third tubes (“Gas Highway Tube”) that is disposed in the first processing chamber (“Pressure Loss Chamber”) is disposed in the upper portion of the first processing chamber (“Pressure Loss Chamber”).

In another example, the input of the supplemental separator (100) is connected to the output of a primary separator for gas and solids separation that has a configuration as follows. The primary separator has:

• • a) one or more production cylinders having an intake port below an exhaust port,
  • b) one or more pressure loss cylinders having a gas exhaust port which allows gas to exit the apparatus into the well bore,
  • c) one or more pressure loss gas relief tube having pressure loss gas relief ports which are in fluid communication with the pressure loss cylinder and the production cylinder, and
  • d) one or more dip tube having production cylinder thief jet ports which are in fluid communication with the production cylinder and a desired exit point for gasless liquid.

Operation

In another set of examples, a method is disclosed for gas separation from wellbore fluids, the method or process comprising: entrance of a fluid into a first chamber which allows the gas to separate and rise to the upper portion of the chamber while the remaining liquid fluid sinks towards the lower portion; the gas enters into a tube or other conduit in the upper portion of the first chamber and rises to the upper portion of a second chamber positioned above the first chamber; the gas exits the chamber via orifices in the upper portion of the second chamber; liquid is drawn up a tube or other conduit from the lower portion of the first chamber and exits the conduit in the middle portion of the second chamber; liquid sinks to the lower portion of the second chamber while gas, if any, separates and rises to the top of the second chamber and exits via orifices in the upper portion of the second chamber; the liquid in the lower portion of the second chamber is drawn up a production tube or other conduit from the lower portion of the second chamber.

In another set of examples, an apparatus is disclosed for gas separation from wellbore fluids, the apparatus comprising: a tubular housing sized to fit around a production string; one or more orifices positioned in an upper portion of the tubular housing to expel gas, a first chamber positioned in the upper portion of the tubular housing, in fluid communication with the outside of the tubular housing through the orifice; a second chamber positioned and arranged below the first chamber; one or more orifices positioned in the tubular housing at the upper portion of the second chamber to expel gas, a first single or plurality of tubes having first open ends positioned and arranged in the first chamber; the first plurality of tubes having second open ends positioned and arranged in the second chamber; a second single or plurality of tubes having first open ends positioned and arranged in the first chamber, below the first open ends of the first plurality of tubes; a second plurality of tubes having second open ends positioned and arranged in the second chamber, below the second open ends of the first plurality of tubes; one or more orifices into a first production string for receiving wellbore fluids, positioned and arranged inside the first chamber; and one or more orifices into a second production string to expel wellbore fluids, positioned and arranged inside the second chamber.

INDUSTRIAL APPLICABILITY

The method(s), apparatus, and system(s) disclosed herein have direct industrial applicability in the oil & gas extraction industry.

In summary, herein disclosed are particular structural means for forcing the de-gassing of the gaseous liquid, including means for changing the velocity of the gaseous liquid (speed changes on each exit from the tubes owing to the volume difference between the tubes and the chamber), means for changing the direction of the gaseous liquid (owing to the flow changing direction from exiting one set of tubes to travel to the opening to enter the next set of tubes), and means for changing the pressure of the gaseous liquid (owing perhaps in part to evolution of gas upon entering increased volume).

These and other objectives, features, and advantages of the present invention will become apparent from the following detailed drawings and associated description that accompanying the drawings.

Although the present invention is described herein with reference to a specific preferred embodiment(s), many modifications and variations therein will readily occur to those with ordinary skill in the art. Accordingly, all such variations and modifications are included within the intended scope of the present invention as defined by the reference numerals used.

From the description contained herein, the features of any of the examples, especially as set forth in the claims, can be combined with each other in any meaningful manner to form further examples and/or embodiments.

The foregoing description is presented for purposes of illustration and description, and is not intended to limit the invention to the forms disclosed herein. Consequently, variations and modifications commensurate with the above teachings and the teaching of the relevant art are within the spirit of the invention. Such variations will readily suggest themselves to those skilled in the relevant structural or mechanical art. Further, the embodiments described are also intended to enable others skilled in the art to utilize the invention and such or other embodiments and with various modifications required by the particular applications or uses of the invention.

Claims

1. A method for gas separation from wellbore fluids, the method or process comprising: entering a wellbore fluid into a first chamber;separating, in the first chamber, a portion of the gas from the wellbore fluid;rising the separated gas in the first chamber into an upper portion of a second chamber, the second chamber disposed above the first chamber;sinking the remaining wellbore fluid towards the lower portion of the first chamber;rising the sunk remaining wellbore fluid in the first chamber into a lower portion of the second chamber;separating, in the second chamber, a portion of the gas from the risen sunk remaining wellbore fluid;disposing the remaining risen sunk remaining wellbore fluid into a production string;exhausting a portion of the risen gas in the first chamber into a wellbore annulus;exhausting the risen gas in the second chamber into the wellbore annulus; andextracting the remaining risen sunk remaining wellbore fluid from the production string.

2. An apparatus for gas separation from wellbore fluids, the apparatus comprising: a tubular housing sized to fit around a first production string;one or more first orifices positioned in an upper portion of the tubular housing to expel gas,a first chamber positioned in the upper portion of the tubular housing, in fluid communication with the outside of the tubular housing through the orifice;a second chamber positioned and arranged below the first chamber;a first single or plurality of tubes having first open ends positioned and arranged in an upper portion of the first chamber, the first plurality of tubes having second open ends positioned and arranged in an upper portion of the second chamber;a second single or plurality of tubes having first open ends positioned and arranged in a lower portion of the first chamber, the second single or plurality of tubes having second open ends positioned and arranged in a lower portion of the second chamber;one or more orifices opening into the first production string for receiving wellbore fluids, positioned and arranged inside the first chamber; andone or more orifices opening into a second production string to dispose wellbore fluids into the second chamber, positioned and arranged inside the second chamber.

3. The apparatus of claim 2 further compromising a downhole oil-gas separator wherein an output of the oil-gas separator is connected to the second production string for intake into the second chamber, whereby processed fluids from the downhole oil-gas separator are received for further processing.

4. The apparatus of claim 2 for gas separation from wellbore fluids further comprising a primary apparatus for gas and solids separation from down-hole fluids connected to a second opening of the second production string, the primary separation apparatus comprising: an inner tube having a length in a longitudinal direction;an outer tube disposed about the inner tube;a plurality of chambers, wherein each chamber is defined by an annular region between the outer tube, the inner tube, and a first fluid barrier and a second fluid barrier, each fluid barrier disposed in an annular region between the inner tube and the outer tube;wherein one of the plurality of chambers comprises an intake chamber, in fluid communication with the outside of the outer tube through an orifice;wherein one of the plurality of chambers comprises a first processing chamber (ML) disposed longitudinally adjacent to the intake chamber;wherein one of the plurality of chambers comprises a second processing chamber (H) disposed longitudinally adjacent to the first processing chamber, opposite from the intake chamber;wherein one of the plurality of chambers comprises a third processing chamber (CL) disposed longitudinally adjacent to the second processing chamber (H), opposite from the first processing chamber (ML);wherein one of the plurality of chambers comprises a fourth processing chamber (R1) disposed longitudinally adjacent to the intake chamber, opposite from the first processing chamber (ML);wherein one of the plurality of chambers comprises a fifth processing chamber (R2) disposed longitudinally adjacent to the fourth processing chamber (R1), opposite from the intake chamber;wherein fluid communication between the intake chamber and the first processing chamber (ML) is restricted to fluid flow through a first set of a plurality of tubes;wherein fluid communication between the first processing chamber (ML) and the second processing chamber (H) is restricted to fluid flow through a second set of a plurality of tubes;wherein fluid communication between the second processing chamber (H) and the third processing chamber (CL) is restricted to fluid flow through a third set of a plurality of tubes;wherein a block restricts fluid communication within the inner tube between the fourth processing chamber (R1) and the fifth processing chamber (R2);wherein fluid communication between the third processing chamber (CL) and the fourth processing chamber (R1) is restricted to fluid flow through the inner tube;wherein an orifice in the inner tube is disposed in the fourth processing chamber (R1), proximate to the fifth processing chamber (R2) and on a first side of the block, providing fluid communication between fourth processing chamber (R1) and the inner tube;wherein an orifice in the inner tube is disposed in the fifth processing chamber (R2), proximate to the fourth processing chamber (R1) and on the opposite side of the block, providing fluid communication between fifth processing chamber (R2) and the inner tube; andwherein fluid communication between the fourth processing chamber (R1) and the fifth processing chamber (R2) is restricted to fluid flow through a fourth set of a plurality of tubes.

5. The apparatus of claim 2 further comprising one or more second orifices positioned in the tubular housing at the upper portion of the second chamber to expel gas.

6. The apparatus of claim 5 further compromising a downhole oil-gas separator wherein an output of the oil-gas separator is connected to the second production string for intake into the second chamber, whereby processed fluids from the downhole oil-gas separator are received for further processing.

7. The apparatus of claim 5 for gas separation from wellbore fluids further comprising a primary apparatus for gas and solids separation from down-hole fluids connected to a second opening of the second production string, the primary separation apparatus comprising: an inner tube having a length in a longitudinal direction;an outer tube disposed about the inner tube;a plurality of chambers, wherein each chamber is defined by an annular region between the outer tube, the inner tube, and a first fluid barrier and a second fluid barrier, each fluid barrier disposed in an annular region between the inner tube and the outer tube;wherein one of the plurality of chambers comprises an intake chamber, in fluid communication with the outside of the outer tube through an orifice;wherein one of the plurality of chambers comprises a first processing chamber (ML) disposed longitudinally adjacent to the intake chamber;wherein one of the plurality of chambers comprises a second processing chamber (H) disposed longitudinally adjacent to the first processing chamber, opposite from the intake chamber;wherein one of the plurality of chambers comprises a third processing chamber (CL) disposed longitudinally adjacent to the second processing chamber (H), opposite from the first processing chamber (ML);wherein one of the plurality of chambers comprises a fourth processing chamber (R1) disposed longitudinally adjacent to the intake chamber, opposite from the first processing chamber (ML);wherein one of the plurality of chambers comprises a fifth processing chamber (R2) disposed longitudinally adjacent to the fourth processing chamber (R1), opposite from the intake chamber;wherein fluid communication between the intake chamber and the first processing chamber (ML) is restricted to fluid flow through a first set of a plurality of tubes;wherein fluid communication between the first processing chamber (ML) and the second processing chamber (H) is restricted to fluid flow through a second set of a plurality of tubes;wherein fluid communication between the second processing chamber (H) and the third processing chamber (CL) is restricted to fluid flow through a third set of a plurality of tubes;wherein a block restricts fluid communication within the inner tube between the fourth processing chamber (R1) and the fifth processing chamber (R2);wherein fluid communication between the third processing chamber (CL) and the fourth processing chamber (R1) is restricted to fluid flow through the inner tube;wherein an orifice in the inner tube is disposed in the fourth processing chamber (R1), proximate to the fifth processing chamber (R2) and on a first side of the block, providing fluid communication between fourth processing chamber (R1) and the inner tube;wherein an orifice in the inner tube is disposed in the fifth processing chamber (R2), proximate to the fourth processing chamber (R1) and on the opposite side of the block, providing fluid communication between fifth processing chamber (R2) and the inner tube; andwherein fluid communication between the fourth processing chamber (R1) and the fifth processing chamber (R2) is restricted to fluid flow through a fourth set of a plurality of tubes.