TREA

DOWNHOLE SEPARATOR

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Information

  • Patent Application
  • 20230366306
  • Publication Number
    20230366306
  • Date Filed
    May 16, 2023
    a year ago
  • Date Published
    November 16, 2023
    12 months ago
Information
Abstract
There is provided a downhole apparatus configured for integration within a gas-depleted fluid production assembly of a reservoir fluid production assembly disposed within a wellbore string passage of a wellbore string that is emplaced within a wellbore, for modifying the gas-depleted fluid production assembly such that improved gas separation characteristics are obtained.
Description
FIELD

The present disclosure relates to mitigating gas interference with downhole pump operation during hydrocarbon production.


BACKGROUND

Reservoir fluids often contain entrained gases and solids. In producing reservoir fluids containing a relatively substantial fraction of gaseous material, the presence of such gaseous material hinders production by contributing to sluggish flow, and interfering with pump operation. As well, the presence of solids interferes with pump operation, including contributing to erosion of mechanical components.


Separators are provided help remedy or mitigate downhole pump gas interference during hydrocarbon production. However, separators often occupy relatively significant amounts of space within a wellbore, rendering efficient separation of gaseous material that is entrained within the reservoir fluid difficult. Some separators are complex structures and are associated with increased material and manufacturing costs. Accordingly, efficient and cost effective separation of gaseous material that is entrained within the reservoir fluid is desirable.


SUMMARY

In one aspect, there is provided a downhole apparatus configured for integration within a gas-depleted fluid production assembly of a reservoir fluid production assembly disposed within a wellbore string passage of a wellbore string that is emplaced within a wellbore, the integration is with effect that a apparatus-defined flow conductor configuration is established;


wherein:

    • the gas-depleted fluid production assembly co-operates with the wellbore string 108 to define a flow diverter;
    • the flow diverter defines a reservoir fluid conductor configuration, a separation zone, a downwardly-conducting flow conductor configuration, and an upwardly-conducting flow conductor configuration;
    • the reservoir fluid conductor configuration, the separation zone, the downwardly-conducting flow conductor configuration, and the upwardly-conducting flow conductor configuration are co-operatively configured such that:
      • while reservoir fluid flow is being received within a reservoir fluid-receiving zone, of the wellbore string passage, from the subterranean formation, the reservoir fluid flow is conducted upwardly to the gas separation zone via the reservoir fluid conductor configuration, with effect that the reservoir fluid flow becomes emplaced within the separation zone;
      • while the reservoir fluid flow is disposed within the separation zone, in response to buoyancy forces, gaseous material is separated from the reservoir fluid flow, with effect that an upwardly-flowing gas-enriched reservoir fluid flow and a downwardly-flowing gas-depleted reservoir fluid flow are obtained, and such that the downwardly-flowing gas-depleted reservoir fluid flow is received and conducted by the downwardly-conducting flow conductor configuration; and
      • while the gas-depleted reservoir fluid flow is being conducted in a downwardly direction by the downwardly-conducting flow conductor configuration, the gas-depleted reservoir fluid flow is diverted such that an upwardly gas-depleted reservoir fluid flow is being conducted through the upwardly-conducting flow conductor configuration for suppling a pumping assembly of the reservoir fluid production assembly;
    • the separation zone extends through a separation zone-defining wellbore section that extends from a lower wellbore cross section to an upper wellbore cross section;
    • the apparatus-defined flow conductor configuration defines at least a portion of the upwardly-conducting flow conductor configuration;
    • at least a portion of the apparatus-defined flow conductor configuration includes a flow interference-mitigating conductor configuration that extends through the separation zone-defining wellbore section; and
    • the flow interference-mitigating conductor configuration defines an eccentrically-disposed conductor configuration, wherein the eccentrically-disposed conductor configuration is disposed eccentrically relative to the central longitudinal axis of the wellbore string passage.


In another aspect, there is provided a kit comprising the apparatus, as described above, and an elongated member for connection to a portion of the apparatus-defined flow conductor configuration and also for connection to a separator of the gas-depleted fluid production assembly, such that, while the apparatus is integrated within the gas-depleted fluid production assembly of a reservoir fluid production assembly, the separator is supported by the apparatus-defined flow conductor configuration.


In another aspect, there is provided a method for producing hydrocarbon material, from an oil reservoir within a subterranean formation, via a system includes a production string, including a reservoir fluid production assembly, disposed within a wellbore string passage of the wellbore string, wherein the reservoir fluid production assembly includes:

    • a gas-depleted fluid production assembly; and
    • a pumping assembly;


      wherein:
    • the gas-depleted fluid production assembly co-operates with the wellbore string to define a flow diverter;
    • the flow diverter defines a reservoir fluid conductor configuration, a separation zone, a downwardly-conducting flow conductor configuration, and an upwardly-conducting flow conductor configuration;
    • the reservoir fluid conductor configuration, the separation zone, the downwardly-conducting flow conductor configuration, and the upwardly-conducting flow conductor configuration are co-operatively configured such that:
      • while reservoir fluid flow is being received within a reservoir fluid-receiving zone, of the wellbore string passage, from the subterranean formation, the reservoir fluid flow is conducted upwardly to the gas separation zone via the reservoir fluid conductor configuration, with effect that the reservoir fluid flow becomes emplaced within the separation zone;
      • while the reservoir fluid flow is disposed within the separation zone, in response to buoyancy forces, gaseous material is separated from the reservoir fluid flow, with effect that an upwardly-flowing gas-enriched reservoir fluid flow and a downwardly-flowing gas-depleted reservoir fluid flow are obtained, and such that the downwardly-flowing gas-depleted reservoir fluid flow is received and conducted by the downwardly-conducting flow conductor configuration; and
      • while the gas-depleted reservoir fluid flow is being conducted in a downwardly direction by the downwardly-conducting flow conductor configuration, the gas-depleted reservoir fluid flow is diverted such that an upwardly gas-depleted reservoir fluid flow is being conducted through the upwardly-conducting flow conductor configuration for suppling the pumping assembly;
    • the separation zone extends through a separation zone-defining wellbore section that extends from a lower wellbore cross section to an upper wellbore cross section;
    • the gas-depleted fluid production assembly includes a separator;
    • the separator defines a separator-defined flow conductor configuration the separator-defined flow conductor configuration includes a separator-defined upwardly-conducting flow conductor configuration (“separator-defined UCFCC”), and the separator-defined UCFCC defines a portion of the upwardly-conducting flow conductor configuration; and


      wherein the method comprises:
    • producing hydrocarbon material via the system;
    • suspending the producing; and
    • while the producing is suspended, integrating a separator-co-operating apparatus within the gas-depleted fluid production assembly such that a modified system is obtained;
    • wherein:
      • the separator-co-operating apparatus defines an apparatus-defined flow conductor configuration;
      • at least a portion of the apparatus-defined flow conductor configuration includes a flow interference-mitigating conductor configuration;
      • the flow interference-mitigating conductor configuration defines an eccentrically-disposed conductor configuration;
      • the integration of the separating co-operating apparatus within the gas-depleted fluid production assembly includes emplacement between the pumping assembly and the separator, and is with effect that:
        • the apparatus-defined flow conductor configuration is disposed in flow communication with the separator-defined UCFCC, such that the apparatus-defined flow conductor configuration is disposed for receiving the gas-depleted reservoir fluid flow being conducted by the separator-defined UCFCC;
        • the apparatus-defined flow conductor configuration is disposed for supplying the gas-depleted reservoir fluid flow to the pumping assembly;
        • the flow interference-mitigating conductor configuration extends through the separation zone-defining wellbore section; and
        • the eccentrically-disposed conductor configuration is disposed eccentrically relative to the central longitudinal axis of the wellbore string passage.





BRIEF DESCRIPTION OF THE DRAWINGS

Reference will now be made, by way of example, to the accompanying drawings which show example embodiments of the present application, and in which:



FIG. 1 is a schematic illustration of an embodiment of a reservoir fluid production system, including a first embodiment of a gas-depleted fluid production assembly, disposed within a wellbore;



FIG. 2 is a schematic illustration of an embodiment of a reservoir production system, including a second embodiment of a gas-depleted fluid production assembly, disposed within a wellbore;



FIG. 3 is a schematic illustration of an embodiment of a reservoir production system, including a third embodiment of a gas-depleted fluid production assembly, disposed within a wellbore;



FIG. 4 is a schematic illustration of an embodiment of a reservoir fluid production system, including a fourth embodiment of a gas-depleted fluid production assembly, disposed within a wellbore;



FIG. 5 is a schematic illustration of an embodiment of a separator co-operating apparatus that is integrated within the embodiments of the gas-depleted fluid production assembly illustrated in FIGS. 1, 2, and 3;



FIG. 6 is a schematic illustration of an elongated member (e.g. rigid bar) supporting a separator of the embodiments of the gas-depleted fluid production assembly illustrated in FIGS. 1, 2, and 3;



FIG. 7 is a schematic illustration of an embodiment of a separator co-operating apparatus that is integrated within the embodiment illustrated in FIG. 4;



FIG. 8 is an enlarged view of Detail “A” in FIG. 4; and



FIG. 9 is a top plan view of the production system, taken along the cross-section “XC” in FIG. 8.





Similar reference numerals may have been used in different figures to denote similar components.


DESCRIPTION OF EXAMPLE EMBODIMENTS

Referring to FIGS. 1 to 7, there are provided systems 10 for producing hydrocarbon material from an oil reservoir within a subterranean formation 100.


A wellbore 102 of a subterranean formation can be straight, curved or branched. The wellbore can have various wellbore sections. A wellbore section is an axial length of a wellbore 102. A wellbore section can be characterized as “vertical” or “horizontal” even though the actual axial orientation can vary from true vertical or true horizontal, and even though the axial path can tend to “corkscrew” or otherwise vary. In some embodiments, for example, the central longitudinal axis of the passage of a horizontal section is disposed along an axis that is between about 70 and about 110 degrees relative to the vertical, while the central longitudinal axis of the passage of a vertical section is disposed along an axis that is less than about 20 degrees from the vertical “V”, and a transition section is disposed between the horizontal and vertical sections.


“Reservoir fluid” is fluid that is contained within an oil reservoir. Reservoir fluid can be liquid material, gaseous material, or a mixture of liquid material and gaseous material. The reservoir fluid includes hydrocarbon material, such as oil, natural gas condensates, or any combination thereof. The reservoir fluid can also contain water. The reservoir fluid can also include fluids injected into the reservoir for effecting stimulation of resident fluids within the reservoir.


The term “fluid conductor configuration” refers to a configuration which conducts fluid. The configuration can be: (a) a single conductor, (b) a plurality of parallel conductors, (c) a network of interconnected conductors, or any combination of (a), (b), and (c).


A wellbore string 108 is emplaced within the wellbore 102 for stabilizing the subterranean formation 100. In some embodiments, for example, the wellbore string 108 also contributes to effecting fluidic isolation of one zone within the subterranean formation 100 from another zone within the subterranean formation 100.


The fluid productive portion of the wellbore 102 may be completed either as a cased-hole completion or an open-hole completion.


With respect to a cased-hole completion, in some embodiments, for example, a wellbore string 108, in the form of a wellbore casing that includes one or more casing strings, each of which is positioned within the wellbore 102, having one end extending from the wellhead 106, is provided. In some embodiments, for example, each casing string is defined by jointed segments of pipe. The jointed segments of pipe typically have threaded connections.


Typically, a wellbore 102 contains multiple intervals of concentric casing strings, successively deployed within the previously run casing. With the exception of a liner string, casing strings typically run back up to the surface 104. Typically, casing string sizes are intentionally minimized to minimize costs during well construction. Generally, smaller casing sizes make production and artificial lifting more challenging.


For wells that are used for producing reservoir fluid, few of these actually produce through the wellbore casing. This is because producing fluids can corrode steel or form undesirable deposits (for example, scales, asphaltenes or paraffin waxes) and the larger diameter can make flow unstable. In this respect, a production string is usually installed inside the last casing string. The production string is provided to conduct reservoir fluid, received within the wellbore, to the wellhead 106. In some embodiments, for example, the annular region between the last casing string and the production string may be sealed at the bottom by a packer.


The wellbore 102 is disposed in flow communication (such as through perforations provided within the installed casing or liner, or by virtue of the open hole configuration of the completion), or is selectively disposable into flow communication (such as by perforating the installed casing, or by actuating a valve to effect opening of a port), with the subterranean formation 100. When disposed in flow communication with the subterranean formation 100, the wellbore 102 is disposed for receiving reservoir fluid flow from the subterranean formation 100, with effect that the system 10 receives the reservoir fluid.


In some embodiments, for example, the wellbore casing is set short of total depth. Hanging off from the bottom of the wellbore casing, with a liner hanger or packer, is a liner string. The liner string can be made from the same material as the casing string, but, unlike the casing string, the liner string does not extend back to the wellhead 106. Cement may be provided within the annular region between the liner string and the oil reservoir for effecting zonal isolation (see below), but is not in all cases. In some embodiments, for example, this liner is perforated to effect flow communication between the reservoir and the wellbore. In some embodiments, for example, the production tubing string may be engaged or stung into the liner string, thereby providing a fluid passage for conducting the produced reservoir fluid to the wellhead 106.


An open-hole completion is established by drilling down to the producing formation, and then lining the wellbore (such as, for example, with a wellbore string 108). The wellbore is then drilled through the producing formation, and the bottom of the wellbore is left open (i.e. uncased), to effect flow communication between the reservoir and the wellbore.


The system 10 receives, via the wellbore 102, the reservoir fluid flow from the subterranean formation 100. As discussed above, the wellbore 102 is disposed in flow communication (such as through perforations provided within the installed casing or liner, or by virtue of the open hole configuration of the completion), or is selectively manipulated into flow communication (such as by perforating the installed casing, or by actuating a valve to effect opening of a port), with the subterranean formation 100. When disposed in flow communication with the subterranean formation 100, the wellbore 102 is disposed for receiving reservoir fluid flow from the subterranean formation 100, with effect that the system 10 receives the reservoir fluid.


In some embodiments, for example, the system 10 includes a production string, including a reservoir fluid production assembly 200, disposed within a wellbore string passage 110 of the wellbore string 108. The reservoir production assembly 200 includes a gas-depleted fluid production assembly 400 and a pumping assembly 300.


The pumping assembly 300 includes a pump 301 and a pressurized gas-depleted reservoir flow conductor 500. The pump 301 includes a suction 301A (or “intake”) and a discharge 301B. The gas-depleted fluid production assembly 400 is fluidly coupled to the pump suction 301A. The pressurized gas-depleted reservoir flow conductor 500 is fluidly coupled to the pump discharge 301B.


In some embodiments, for example, the pump 301 is a rod pump 301. The rod pump 301 includes a conveyor, such as a rod or a rod string, extending through the pressurized gas-depleted reservoir fluid conductor 500, and connected to surface equipment which causes reciprocating movement of the conveyor. In some embodiments, for example, the surface equipment includes a prime mover (e.g. an internal combustion engine or a motor), a crank arm, and a beam. The prime mover rotates the crank arm, and the rotational movement of the crank arm is converted to reciprocal longitudinal movement through the beam. In some embodiments, for example, the prime mover is a pumpjack. The beam is attached to a polished rod by cables hung from a horsehead at the end of the beam. The polished rod passes through a stuffing box and is attached to the conveyor. Accordingly, the surface equipment effects reciprocating longitudinal movement of the conveyor, and further defines the upper and lower displacement limits of the conveyor. Reservoir fluid is produced to the surface in response to reciprocating longitudinal movement of the rod by the pumpjack.


A reservoir fluid-receiving zone 602 is disposed within the wellbore string passage 110 for receiving reservoir fluid flow 702 that is conducted from the subterranean formation 100 and into the wellbore 102. In this respect, reservoir fluid flow 702, from the subterranean formation 100, is received by the reservoir fluid-receiving zone 602. In some embodiments, for example, the reservoir fluid-receiving zone 602 is disposed within a horizontal section of the wellbore 102.


The gas-depleted fluid production assembly 400 co-operates with the wellbore string 108 to define a flow diverter 402. The flow diverter 402 defines a reservoir fluid conductor configuration 403, a separation zone 405, a downwardly-conducting flow conductor configuration 404, and an upwardly-conducting flow conductor configuration 406.


The reservoir fluid conductor configuration 403, the separation zone 405, the downwardly-conducting flow conductor configuration 404, and the upwardly-conducting flow conductor configuration 406 are co-operatively configured such that:

    • while reservoir fluid flow 702 is being received within a reservoir fluid-receiving zone 602, of the wellbore string passage 110, from the subterranean formation 100, the reservoir fluid flow 702 is conducted upwardly to the gas separation zone 405 via the reservoir fluid conductor configuration 403, with effect that the reservoir fluid flow becomes emplaced within the separation zone 405;
    • while the reservoir fluid flow is disposed within the separation zone 405, in response to buoyancy forces, gaseous material is separated from the reservoir fluid flow 702, with effect that an upwardly-flowing gas-enriched reservoir fluid flow 706 and a downwardly-flowing gas-depleted reservoir fluid flow 708A are obtained, and such that the downwardly-flowing gas-depleted reservoir fluid flow 708A is received and conducted by the downwardly-conducting flow conductor configuration 404; and
    • while the gas-depleted reservoir fluid flow 708A is being conducted in a downwardly direction by the downwardly-conducting flow conductor configuration 404, the gas-depleted reservoir fluid flow is diverted such that an upwardly gas-depleted reservoir fluid flow 708 is being conducted through the upwardly-conducting flow conductor configuration 406 for suppling the suction 301A of the pump 301.


The gas separation zone 405 has a sufficiently large cross-sectional flow area, relative to that of the reservoir fluid conductor configuration 403 through which the reservoir fluid-derived flow is conducted from the receiving zone 602, with effect that the flowrate of the reservoir fluid flow 702 is sufficiently reduced so as to permit the separation.


In some embodiments, for example, the separation zone 405 extends through a separation zone-defining wellbore section 4055. The wellbore section 4055 extends from a lower wellbore cross section 4052 to an upper wellbore cross section 4053.


In some embodiments, for example, the gas separation zone 405 is disposed within a passage of the wellbore 102 whose central longitudinal is disposed along an axis that is disposed at an acute angle of less than about 45 degrees from the vertical “V”, such as, for example, less than about 35 degrees from the vertical “V”.


The pump suction 301A defines a flow receiving communicator 301AA (e.g. inlet port) for receiving the gas-depleted reservoir fluid flow 708 being supplied by the upwardly-conducting flow conductor configuration 406. The pump 301 is effective for pressurizing the upwardly-flowing gas-depleted reservoir fluid flow 708B that is supplied to the suction 301A of the pump 301, with effect that the pressurized gas-depleted reservoir fluid flow 710 is discharged via the pump discharge 301B and received by the pressurized gas-depleted reservoir flow conductor 500, for flow to the surface via the pressurized gas-depleted reservoir flow conductor 500. In this respect, the pump discharge 301B defines a flow discharging communicator 301BB (e.g. outlet port) for effectuating the discharging of the pressurized gas-depleted reservoir fluid flow 710.


In this respect, the gas-depleted fluid production assembly 400 is effective for separating the gas-depleted reservoir fluid flow 708 from the reservoir fluid-derived fluid flow 704, and supplying the gas-depleted reservoir fluid flow 708 to the pump 301, for pressurizing the gas-depleted reservoir fluid flow 708 by the pump 301 for flow to the surface via the flow conductor 500.


In parallel, the gas-enriched reservoir fluid flow 706 is conducted upwardly to the surface 104 via a gas-enriched reservoir fluid-conducting passage 112 defined within the wellbore 102. In this respect, the gas-enriched reservoir fluid-conducting passage 112 is disposed uphole relative to, and in flow communication with, the separation zone 405.


The reservoir fluid produced from the subterranean formation 100, via the wellbore 102, including the gas-depleted reservoir fluid, the gas-enriched reservoir fluid, or both, may be discharged through the wellhead 106 to a collection facility, such as a storage tank within a battery.


In this respect, a fluid passage 900 is defined within the wellbore 102, extending from the reservoir fluid-receiving zone 402 to the pump 301, for supplying the gas-depleted reservoir fluid flow 708, derived from the reservoir fluid flow 702 received by the receiving zone 402, to the pump 301, for pressurization by the pump 301 for flow to the surface 104 as the flow 710 via the pressurized gas-depleted reservoir flow conductor 500. The fluid passage 900 is defined by a fluid conductor configuration which includes the reservoir fluid conductor configuration 403, the separation zone 405, the downwardly-conducting flow conductor configuration 404, and the upwardly-conducting flow conductor configuration 406.


In some embodiments, for example, a separator co-operating apparatus 401 is integrated within the gas-depleted fluid production assembly 400. In this respect, in some embodiments, for example, the apparatus 401 is integratable within the gas-depleted fluid production assembly 400 such that there is established a apparatus-defined flow conductor configuration 4011A, and the apparatus-defined flow conductor configuration 4011A defines at least a portion of the upwardly-conducting flow conductor configuration 406. In some embodiments, for example, the integration of the apparatus 401 within the gas-depleted fluid production assembly 400 is effectuated by a downhole connection configuration 600 and an uphole connection configuration 602. In some embodiments, for example, each one of the downhole connection configuration 600 and the uphole connection configuration 602, independently, is a threaded connection configuration. In this respect, the apparatus 401 is threaded at each end.


At least a portion of the apparatus-defined flow conductor configuration 4011A includes a flow interference-mitigating conductor configuration 4011B. In some embodiments, for example, the flow interference-mitigating conductor configuration 4011B extends through the separation zone-defining wellbore section 4055.


In some embodiments, for example, the flow interference-mitigating conductor configuration 4011B defines an eccentrically-disposed conductor configuration 4011C. The eccentrically-disposed conductor configuration 4011C is disposed eccentrically relative to the central longitudinal axis 110X of the wellbore string passage 110.


Referring to FIG. 8, in some embodiments, for example, the eccentrically-disposed conductor configuration 4011C has a total length “L1” of at least three (3) feet, as measured along the central longitudinal axis 4011CX of the eccentrically-disposed conductor configuration 4011C. In some embodiments, for example, the eccentrically-disposed conductor configuration 4011C has a total length “L1” of at least six (6) feet. In some embodiments, for example, the eccentrically-disposed conductor configuration 4011C has a total length “L1” of at least 15 feet. In some embodiments, for example, the eccentrically-disposed conductor configuration 4011C has a total length “L1” of at least 20 feet. In some embodiments, for example, the eccentrically-disposed conductor configuration 4011C has a total length “L1” of at least 30 feet.


Referring again to FIG. 8, in some embodiments, for example, for every cross-section of the wellbore string passage 110 throughout the entire separation zone-defining wellbore section 4055, there is an absence of a ratio, of: (i) the minimum distance “D1” between the central longitudinal axis 110X of the wellbore string passage 110, within the cross-section of the wellbore string passage 110, and the eccentrically-disposed conductor configuration 4011C to (ii) the minimum distance “D2” between the central longitudinal axis 110X of the wellbore string passage 110, within the cross-section of the wellbore string passage 110, and the wellbore string 108, that is less than 1:1.2. In some of these embodiments, for example, the minimum distance “D1” is the perpendicular distance between the central longitudinal axis 110X, of the wellbore string passage 110 within the cross-section of the wellbore string passage 110, and the eccentrically-disposed conductor configuration 4011C, and the minimum distance “D2” is the perpendicular distance between the central longitudinal axis 110X, of the wellbore string passage 110 within the cross-section of the wellbore string passage 110, and the wellbore string 108.


In some embodiments, for example, throughout the entirety of the eccentrically-disposed conductor configuration 4011C that is extending through the separation zone-defining wellbore section 4055, the eccentrically-disposed conductor configuration 4011C is spaced-apart from the wellbore string 108 by a maximum distance “D3” of less than 0.75 inches, such as, for example, less than 0.5 inches, such as, for example, less than 0.25 inches.


Referring to FIG. 9, in some embodiments, for example, throughout the entirety of the eccentrically-disposed conductor configuration 4011C that is extending through the separation zone-defining wellbore section 4055, the eccentrically-disposed conductor configuration 4011C has a cross-sectional profile that is non-circular (e.g. oval-shaped). Configuring the eccentrically-disposed conductor configuration 4011C, such that its cross-sectional profile is non-circular, further mitigates interference with the separation, within the space 4055, of the reservoir fluid into the gas-depleted reservoir fluid and the gas-enriched reservoir fluid, by the eccentrically-disposed conductor configuration 4011C, and this is more pronounced where the cross-sectional profile of the eccentrically-disposed conductor configuration 4011C is oval-shaped and the cross-sectional profile of the wellbore string cross-section XC, traversed by the eccentrically-disposed conductor configuration 4011C, is circular.


In some embodiments, for example, the flow interference-mitigating conductor configuration 4011B co-operates with the wellbore string 108 to define a cylindrical unoccupied space 4051. The unoccupied space 4051 is space that is unoccupied by the upwardly-conducting flow conductor configuration 406. The unoccupied space 4051 occupies at least 70% (such as, for example, at least 80%) of the total cross-sectional area of a cross-section 110XC of the wellbore string passage 110 which traverses the unoccupied space 4051. In some embodiments, for example, the central longitudinal axis 110X of wellbore string passage 110 extends through the cylindrical unoccupied space 4051. In some embodiments, for example, the unoccupied space 4051 defines a portion of the separation zone 405. Referring to FIG. 8, in some embodiments, for example, the cylindrical unoccupied space 4051 has a diameter “DD1” of at least one (1) inch (such as, for example, at least 1.5 inches, such as, for example, at least two (2) inches) and a height “H1” of at least one (1) foot (such as, for example, at least two (2) feet, such as, for example, at least three (3) feet, such as, for example, at least four (4) feet, such as, for example, at least five (5) feet, such as, for example, at least six (6) feet). In some embodiments, for example, the space 4051 is disposed adjacent to the eccentrically-disposed conductor configuration 4011C.


Referring to FIGS. 4 and 7, in some embodiments, for example, the apparatus 401 includes a flow receiving communicator 4012 (defined by one or more inlet ports), for receiving the upwardly-flowing gas-depleted reservoir fluid flow 708B, and a flow discharging communicator 4013 (defined by one or more outlet ports), for discharging the upwardly-flowing gas-depleted reservoir fluid flow 708B for flow to the suction 300A of the pump 301. Intermediate the flow receiving communicator 4012 and the flow discharging communicator 4013, the apparatus 401 includes fluid conductor branches 4014A, 4014B. In this respect, the flow receiving communicator 4012 is disposed in flow communication with the flow discharging communicator 4013 via the fluid conductor branches 4014A, 4014B. Each one of the fluid conductor branches 4014A, 4014B, independently, includes a respective one of branch portions 4015A, 4015B. The branch portions 4015A, 4015B co-operate to define the flow interference-mitigating conductor configuration 4011B. In this respect, the branch portion 4015A is spaced apart relative to the branch portion 4015B. In some embodiments, for example, the flow receiving communicator 4012 is defined by a single inlet port, and the flow discharging communicator 4013 is defined by a single outlet port, and the integration of the apparatus 401 within the gas-depleted fluid production assembly 400 is effectuated via a downhole connection and an uphole connection, and, in some of these embodiments, each one of the downhole connection and the uphole connection, independently, is a threaded connection.


By integrating the apparatus 401 within the gas-depleted fluid production assembly 400, as described above, fluid communication is established between the gas-depleted fluid production assembly 400 and the pumping assembly 300 for effectuating conducting of the gas-depleted reservoir fluid from the gas-depleted fluid production assembly 400 to the pumping assembly 300, while, in parallel, establishing a configuration of a separation zone 405 for encouraging the separation of the reservoir fluid flow 702 into the upwardly-flowing gas-enriched reservoir fluid flow 706 and the downwardly-flowing gas-depleted reservoir fluid flow 708A.


Referring to FIGS. 1 to 4, in some embodiments, for example, the gas-depleted fluid production assembly 400 includes a separator 400A. The separator 400A includes a housing 408 and defines a separator-defined flow conductor configuration 411. The separator-defined flow conductor configuration 411 is defined within the housing 408. In some of these embodiments, for example, the housing 408 includes a shroud 412 with a closed bottom 414, such that a space 416 is defined within the housing 408, and the separator-defined flow conductor configuration 411 is defined within the space 416.


The separator-defined flow conductor configuration 411 includes a separator-defined upwardly-conducting flow conductor configuration (“separator-defined UCFCC”) 406A, and the separator-defined UCFCC 406A defines a portion of the upwardly-conducting flow conductor configuration 406. In some embodiments, for example, the separator-defined UCFCC 406A is a dip tube. The housing 408 defines a gas-depleted reservoir fluid discharging flow communicator 409 (such as, for example, one or more outlet ports). In such embodiments, for example, the integration of the apparatus 401 within the gas-depleted fluid production assembly 400 is established by: (i) a connection of the apparatus 401 to the gas-depleted reservoir fluid discharging flow communicator 409, wherein the connection of the apparatus 401 to the gas-depleted reservoir fluid discharging flow communicator 409 is with effect that the apparatus-defined flow conductor configuration 4011A is disposed in flow communication with the separator-defined UCFCC 406A, such that the apparatus-defined flow conductor configuration 4011A is disposed for receiving the gas-depleted reservoir fluid flow being conducted by the separator-defined UCFCC 406A, and (ii) a connection of the apparatus 401 to the pump suction 301A, wherein the connection of the apparatus 401 to the pump suction 301A is with effect that the apparatus-defined flow conductor configuration 406A is disposed for supplying the gas-depleted reservoir fluid flow to the pumping assembly 300. In this respect, a portion of the upwardly-conducting flow conductor configuration 406 is defined by the separator 400A and another portion of the upwardly-conducting flow conductor configuration 406 is defined by the apparatus 401.


In some of these embodiments, for example, each one of the gas-depleted reservoir fluid discharging flow communicator 409 of the housing 408 and the flow receiving communicator 301AA of the pump suction 301A, independently, is centrally-disposed within the wellbore string 108. In some embodiments, for example, the gas-depleted reservoir fluid discharging flow communicator 409 is either one of: (i) co-located with the central longitudinal axis 110X of the wellbore string passage 110, or (ii) spaced apart, from the central longitudinal axis 110X of the wellbore string passage 110, by a minimum distance of less than 0.125 inches from the central longitudinal axis 110X of the wellbore string passage 110 (see FIG. 4), and, in some of these embodiments, for example, the minimum distance “D4” is the perpendicular distance between the gas-depleted reservoir fluid discharging flow communicator 409 and the central longitudinal axis 110X. In some embodiments, for example, the flow receiving communicator 301AA is either one of: (i) co-located with the central longitudinal axis 110X of the wellbore string passage 110, or (ii) spaced apart, from the central longitudinal axis 110X of the wellbore string passage 110, by a minimum distance of less than 0.125 inches from the central longitudinal axis 110X of the wellbore string passage 110, and, in some of these embodiments, for example, the minimum distance is the perpendicular distance between the flow receiving communicator 301AA and the central longitudinal axis 110X.


Referring to FIGS. 1 and 4, in some embodiments, for example, the reservoir fluid conductor configuration 403 is defined between the housing 408 of the separator 400A and the wellbore string 108 (such as, for example, an annular space disposed between the housing 408 and the wellbore string 108), and the separator-defined flow conductor configuration 411 further includes the downwardly-conducting flow conductor configuration 404. Referring specifically to FIG. 1, in some embodiments, for example, the housing 408 defines a separator body 400B, and a flow receiving communicator 418 (e.g. one or more inlet ports) is defined through an outermost surface 410 of an upper portion of the separator body 400B, and is effecting flow communication between the reservoir fluid conductor configuration 403 and the downwardly-conducting flow conductor configuration 404. In some of these embodiments, for example, the flow receiving communicator 418 is disposed on a side surface of the separator body 400B. In some embodiments, for example, the separation zone 405 is disposed externally of the housing 408, and above the flow receiving communicator 418, such that the flow receiving communicator 418 is disposed for receiving a downwardly-flowing gas-depleted reservoir fluid flow 708A. In some embodiments, for example, a portion of the separation zone 405 is disposed externally of the separator 400A and above the flow receiving communicator 418, and another portion of the separation zone 405 is disposed within the space 416 within the housing 408, such that a fraction of the separation is effectuated externally of the separator 400A and another fraction of the separation is effectuated within the separator body 400B, and, in some of these embodiments, for example, the separator body 400A includes a flow-discharging communicator for effectuating removal of the separated gaseous material from the space 216. In either case, the separator 400A and the wellbore string 108 are co-operatively configured such that the downwardly-flowing gas-depleted reservoir fluid 708A becomes emplaced within the space 416 and is conducted downwardly by the downwardly-conducting flow conductor configuration 404. The separator-defined UCFCC 406A is disposed in flow communication with the downwardly-conducting flow conductor configuration 404, and includes a flow receiving communicator 407 for receiving the gas-depleted reservoir fluid flow 708 conducted by the downwardly-conducting flow conductor configuration 404. Co-operatively, and as described above, while the gas-depleted reservoir fluid flow 708 is being conducted in a downwardly direction by the downwardly-conducting flow conductor configuration 404, the gas-depleted reservoir fluid flow is diverted such that an upwardly gas-depleted reservoir fluid flow 708 is flowed through the separator-defined UCFCC 406A, discharged via the gas-depleted reservoir fluid discharging flow communicator 409, and conducted by the apparatus-defined flow conductor configuration 4011A to the pump 300. In some of these embodiments, for example, the separator 400A is a “poor boy separator”.


Referring to FIGS. 2, in some embodiments, for example, the separator 400A further includes a sealed interface effector 420 (e.g. a packer mounted to the housing 408), and the sealed interface effector is disposed in sealing engagement with the wellbore string 108 such that a sealed interface 422 is defined. Each one of the reservoir fluid conductor configuration 403 and the separator-defined UCFCC 406A, independently, is defined by the separator 400A, and the downwardly-conducting flow passage 404 is disposed between the housing 408 and the wellbore string 108 (such as, for example, an annular space disposed between the separator 400A and the wellbore string 108). The downwardly-conducting flow conductor configuration 404, the sealed interface effector 420, and the upwardly-conducting flow conductor configuration 406 are co-operatively configured such that, while a gas-depleted reservoir fluid flow 708 is flowing downwardly within the downwardly-conducting flow conductor configuration 404, the downwardly-flowing gas-depleted reservoir fluid flow 708A is diverted by the sealed interface effector 420 with effect that flow of the downwardly-flowing gas-depleted reservoir fluid flow 708A is diverted such that the upwardly-flowing gas-depleted reservoir fluid flow 708B is obtained and is conducted via the separator-defined UCFCC 406A, discharged via the gas-depleted reservoir fluid discharging flow communicator 409, and conducted by the apparatus-defined flow conductor configuration 4011A to the pump 301. In some of these embodiments, for example, the separator 400A is a “packer-type gas separator”. In some of these embodiments, for example, the separator 400A includes a body 424 and a velocity string 426. The body 424 defines a portion of the separator-defined UCFCC 406A, and also defines a portion of the reservoir fluid conductor configuration 403. The velocity string 426 defines another portion of the reservoir fluid conductor configuration 403. In this respect, a portion of the reservoir fluid conductor configuration 403 is defined by the body 424, and another portion of the reservoir fluid configuration 403 is defined by the velocity string 426. The portion of reservoir fluid conductor configuration 403, which is defined by the body 424, is a body-defined conductor configuration 430, and the portion of reservoir fluid conductor configuration 403, which is defined by the velocity string 426, is the flow passage 428 defined by the velocity string 426. The velocity string 426 includes a flow-receiving communicator 431 (e.g. an inlet port) for receiving reservoir flow from the subterranean formation 100, and is disposed in flow communication with the body-defined conductor configuration 430 via a flow receiving communicator 427 (defined by one or more inlet ports) defined within the body 424. The body-defined conductor configuration 430 defines a flow-discharging communicator 434 (defined by one or more outlet ports) for discharging reservoir fluid, being conducted via the body-defined conductor configuration, into the separation zone 405. The velocity string 426 and the body 424 are co-operatively configured such that, while reservoir fluid is being received by the flow-receiving communicator 431, the reservoir fluid is conducted upwardly via, in succession, the velocity string passage 428 and the body-defined conductor configuration 430, and discharged into the separation zone 405.


Referring specifically to FIG. 3, in some embodiments, for example, the gas-depleted fluid production assembly 400 within which the apparatus is integratable is the gas-depleted fluid production assembly 400 disclosed in International Publication No. 2021/258211 (publication of International Application No. PCT/CA2021/050870). In some of these embodiments, for example, the uphole connection configuration 602 is a connection to the pump suction 301A.


Referring to FIG. 6, in some embodiments, for example, the separator 400A is supported by an elongated member 800 connected to a portion of the apparatus-defined flow conductor configuration 4011A. In some of these embodiments, for example, the connection of the elongated member 800 to the apparatus-defined flow conductor configuration 4011A is to a portion of the apparatus-defined flow conductor configuration 4011A disposed above the flow interference-mitigating conductor configuration 4011B, such that the elongated member 800 extends past the flow interference-mitigating conductor configuration 4011B in a spaced apart relationship relative to the flow interference-mitigating conductor configuration 4011B. In some embodiments, for example, the elongated member 800 is connected to the flow interference-mitigating conductor configuration 4011B with a plurality of gusset braces 802. In this respect, for each one of the gusset braces 802, independently, the gusset brace 702 connects a respective portion of the elongated member 800 to a counterpart portion of the flow interference-mitigating conductor configuration 4011B. In some embodiments, for example, the elongated member is in the form of a rigid bar. In some embodiments, for example, the rigid bar has a maximum cross-sectional area of less than 0.5 square inches. In some embodiments, for example, the member 800 is provided to increase structural strength. In some embodiments, for example, the member 800 is provided to oppose a bending moment.


Referring to FIG. 7, in those embodiments where the apparatus 401 includes a flow receiving communicator 4012 (defined by one or more ports), for receiving the upwardly-flowing gas-depleted reservoir fluid flow 708B, and a flow discharging communicator 4013 (defined by one or more ports), for discharging the upwardly-flowing gas-depleted reservoir fluid flow 708B for flow to the suction 300A of the pump 301, and, intermediate the flow receiving communicator 4012 and the flow discharging communicator 4013, the apparatus 401 includes fluid conductor branches 4014A, 4014B, in some of these embodiments, for example, the branch portion 4104A is connected to the branch 4014B with a plurality of gusset braces 804 In this respect, for each one of the gusset braces 804, independently, the gusset brace 804 connects a respective portion of the branch portion 4014A to a counterpart portion of the branch portion 4014B.


In some embodiments, for example, the apparatus 401 is provided for the integration within the gas-depleted fluid production assembly 400. In some embodiments, for example, the apparatus 401 is part of a kit, and the kit further includes the elongated member 800 for connection at the work site to effectuate the supporting of the separator 400A.


In some embodiments, for example, a method is provided and includes producing hydrocarbon material with the system 10. The method further includes suspending the producing. While the producing is suspended, the method further includes integration of the apparatus 401 within the gas-depleted fluid production assembly 400 such that a modified system 10A is obtained (see FIGS. 5 to 7). In some embodiments, for example, after the modifying, hydrocarbon material is produced from the subterranean formation via the modified system 10A.


In some embodiments, for example, prior to the integration, the production string is removed from the wellbore 102, and the integration is effectuated at surface. Once the integration is completed such that a modified production string is obtained, the modified production string is deployed within the wellbore 102, and hydrocarbon material is then further produced from the subterranean formation.


In some embodiments, for example, the modification is with effect that a flow-interfering flow conductor configuration 406A, of the upwardly-conducting flow conductor configuration, is replaced by at least a portion of the flow interference-mitigating conductor configuration 4011B of the apparatus 401. The flow-interfering flow conductor configuration 406A defines at least a portion of the upwardly-conducting flow conductor configuration 406. In some embodiments, for example, the flow-interfering flow conductor configuration 406A is centrally-disposed within the wellbore string 108. In some embodiments, for example, the flow-interfering flow conductor configuration 406A is either one of: (i) co-located with the central longitudinal axis 110X of the wellbore string passage 110, or (ii) spaced apart, from the central longitudinal axis 110X of the wellbore string passage 110, by a minimum distance of less than 0.125 inches from the central longitudinal axis 110X of the wellbore string passage 110, and, in some of these embodiments, for example, the minimum distance is the perpendicular distance between the flow-interfering flow conductor configuration 406A and the central longitudinal axis 110X.


In some embodiments, for example, the modification is with effect that improved gas separation characteristics are obtained.


In the above description, for purposes of explanation, numerous details are set forth in order to provide a thorough understanding of the present disclosure. Although certain dimensions and materials are described for implementing the disclosed example embodiments, other suitable dimensions and/or materials may be used within the scope of this disclosure. All such modifications and variations, including all suitable current and future changes in technology, are believed to be within the sphere and scope of the present disclosure. Therefore, it will be understood that certain adaptations and modifications of the described embodiments can be made and that the above discussed embodiments are considered to be illustrative and not restrictive. All references mentioned are hereby incorporated by reference in their entirety.

Claims
  • 1-29. (canceled)
  • 30. A downhole apparatus configured for integration within a gas-depleted fluid production assembly of a reservoir fluid production assembly disposed within a wellbore string passage of a wellbore string that is emplaced within a wellbore, the integration is with effect that a apparatus-defined flow conductor configuration is established;
  • 31. The apparatus as claimed in claim 30;
  • 32. The apparatus as claimed in claim 31;
  • 33. The apparatus as claimed in claim 30;
  • 34. The apparatus as claimed in claim 33;
  • 35. The apparatus as claimed in claim 34;
  • 36. The apparatus as claimed in claim 30, further comprising: a flow receiving communicator, for receiving the upwardly-flowing gas-depleted reservoir fluid flow;a flow discharging communicator, for discharging the upwardly-flowing gas-depleted reservoir fluid flow for flow to the pumping assembly;fluid conductor branches, disposed between the flow receiving communicator and the flow discharging communicator, such that the flow receiving communicator is disposed in flow communication with the flow discharging communicator via the fluid conductor branches;wherein: each one of the fluid conductor branches, independently, includes a respective one of branch portions; andthe branch portions co-operate to define the flow interference-mitigating conductor configuration.
  • 37. The apparatus as claimed in claim 30;
  • 38. The apparatus as claimed in claim 30;
  • 39. The apparatus as claimed in claim 30;
  • 40. A kit comprising the apparatus as claimed in claim 30, and an elongated member for connection to a portion of the apparatus-defined flow conductor configuration and also for connection to a separator of the gas-depleted fluid production assembly, such that, while the apparatus is integrated within the gas-depleted fluid production assembly of a reservoir fluid production assembly, the separator is supported by the apparatus-defined flow conductor configuration.
  • 41. A method for producing hydrocarbon material, from an oil reservoir within a subterranean formation, via a system includes a production string, including a reservoir fluid production assembly, disposed within a wellbore string passage of the wellbore string, wherein the reservoir fluid production assembly includes: a gas-depleted fluid production assembly; anda pumping assembly;
  • 42. The method as claimed in claim 41;
  • 43. The method as claimed in claim 41;
  • 44. The method as claimed in claim 41;
  • 45. The method as claimed in claim 41;
  • 46. The method as claimed in claim 41;
  • 47. The method claimed in claim 41;
  • 48. The apparatus as claimed in claim 47;
  • 49. The apparatus as claimed in claim 48;
CROSS-REFERENCE TO RELATED APPLICATION

This application is claims the benefits of priority to U.S. Provisional Patent Application No. 63/342,412, filed May 16, 2022, titled DOWNHOLE SEPARATOR, the contents of which are hereby expressly incorporated into the present application by reference in their entirety.

Provisional Applications (1)
Number Date Country
63342412 May 2022 US