Note: Descriptions are shown in the official language in which they were submitted.
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SYSTEMS AND APPARATUSES FOR SEPARATING WELLBORE FLUIDS AND
SOLIDS DURING PRODUCTION
FIELD
[0001] The present disclosure relates to artificial lift systems, and
related apparatuses, for use
in producing hydrocarbon-bearing reservoirs.
BACKGROUND
[0002] Gas interference is a problem encountered while producing wells,
especially wells
with horizontal portions. Gas interference results in downhole pumps becoming
gas locked
and/or low pump efficiencies. Downhole packer-type gas anchors or separators
are provided to
remedy gas lock. However, packer-type gas anchors are generally not design to
effectively
separate and manage debris. They are also relatively expensive. Further, the
packers on packer-
type gas anchors are susceptible to having debris accumulate thereon and, as a
result, becoming
stuck within the wellbore tubular against which it forms a seal and/or
reducing their ability to
separate gas or blocking flow passages within the packer-type gas anchor. A
stuck packer makes
it difficult to remove production tubing from the wellbore or to access the
wellbore below it,
such as during a workover. Such attempt at removal may also damage the packer
or wellbore
casing, thereby rendering the packer-type gas anchor unusable for future
production or even loss
of the wellbore.
SUMMARY
10003] In one aspect, there is provided a system for processing at least
reservoir fluids within
a wellbore that is disposed within an oil reservoir, the system comprising a
wellbore fluid
conductor disposed within the wellbore, the wellbore fluid conductor
comprising: a separator co-
operating fluid conductor; a liner, the liner being coupled to and disposed in
sealing, or
substantially sealing, engagement with the separator co-operating fluid
conductor, and including
a liner fluid passage for receiving reservoir fluids from the reservoir and
for conducting at least
reservoir fluids; and a separator including: a first inlet port disposed in
fluid communication
with the liner fluid passage for receiving at least reservoir fluids from the
liner fluid passage; a
first outlet port; a reservoir fluid-conducting passage extending between the
first inlet port and
the first outlet port; a second inlet port disposed downhole relative to the
first outlet port; a
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second outlet port; a gas-depleted fluid conducting passage extending between
the second inlet
port and the second outlet port; a co-operating surface portion co-operating
with the separator co-
operating fluid conductor to define an intermediate fluid passage therebetween
for effecting fluid
communication between the first outlet port and the second inlet port; and a
sealing surface
disposed in sealing, or substantially sealing, engagement with the liner.
[0004] In another aspect, there is provided a system for processing at
least reservoir fluids
within a wellbore that is disposed within an oil reservoir, the system
comprising: a wellbore fluid
conductor disposed within the wellbore; and a liner coupled to and sealingly,
or substantially
sealingly, engaged with the wellbore fluid conductor for conducting reservoir
fluid, the wellbore
fluid conductor including a wellbore fluid conductor passage and the liner
defining a liner fluid
passage downhole from, and in fluid communication with, the wellbore fluid
conductor passage;
and a separator disposed in the wellbore fluid conductor passage, the
separator including an inlet
port for receiving at least reservoir fluid and an outlet port for delivering
gas-depleted reservoir
fluid, the inlet port being disposed in fluid communication with the liner
fluid passage and in
substantial sealing engagement with the liner to prevent, or substantially
prevent, the reservoir
fluid from bypassing the inlet port.
[0005] In another aspect, there is provided a system for processing at
least reservoir fluids
within a wellbore that is disposed within an oil reservoir, the system
comprising a wellbore fluid
conductor disposed within the wellbore, the wellbore fluid conductor
comprising: a separator co-
operating fluid conductor including: a downhole wellbore fluid passage for
receiving reservoir
fluids from the reservoir and for conducting at least reservoir fluids; and a
constricted portion;
a separator including: a first inlet port disposed in fluid communication with
the downhole
wellbore fluid passage for receiving at least reservoir fluids from the
downhole wellbore fluid
passage; a first outlet port; a reservoir fluid-conducting passage extending
between the first inlet
port and the first outlet port; a second inlet port disposed downhole relative
to the first outlet
port; a second outlet port; a gas-depleted fluid conducting passage extending
between the second
inlet port and the second outlet port; a co-operating surface portion co-
operating with the
separator co-operating fluid conductor to define an intermediate fluid passage
therebetween for
effecting fluid communication between the first outlet port and the second
inlet port; and a
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separator sealing surface disposed in the sealing, or substantially sealing,
engagement with the
constricted portion.
[0006] In another aspect, there is provided a system for processing at
least reservoir fluids
within a wellbore that is disposed within an oil reservoir, the system
comprising a wellbore fluid
conductor disposed within the wellbore, the wellbore fluid conductor
comprising: a separator co-
operating fluid conductor including a downhole wellbore fluid passage for
receiving reservoir
fluids from the reservoir and for conducting at least reservoir fluids; a
separator including a first
inlet port disposed in fluid communication with the liner fluid passage for
receiving at least
reservoir fluids from the liner fluid passage; a first outlet port; a
reservoir fluid-conducting
passage extending between the first inlet port and the first outlet port; a
second inlet port
disposed downhole relative to the first outlet port; a second outlet port; a
gas-depleted fluid
conducting passage extending between the second inlet port and the second
outlet port; and a co-
operating surface portion co-operating with the separator co-operating fluid
conductor to define
an intermediate fluid passage therebetween for effecting fluid communication
between the first
outlet port and the second inlet port; and a sealing member; wherein the
sealing member is
disposed between a sealing member engaging surface portion of the separator co-
operating fluid
conductor and a sealing member engaging surface portion of the separator to
define a sealed
interface, and such that fluid flow, across the sealed interface, is
prevented, or substantially
prevented, wherein the sealing member is disposed downhole relative to the
second inlet port;
and wherein the sealing member, including an exposed surface portion, that is
disposed in fluid
communication with the intermediate fluid passage, is extending across a gap,
between the
separator and the separator co-operating fluid conductor, having a minimum
distance of less than
2.5 millimitres.
[0007] In another aspect, there is provided a system for processing at
least reservoir fluids
within a wellbore that is disposed within an oil reservoir, the system
comprising: a separator co-
operating fluid conductor disposed within the wellbore, and including a
downhole wellbore fluid
passage for receiving reservoir fluids from the reservoir and for conducting
at least reservoir
fluids; a separator including: a first inlet port disposed in fluid
communication with the
downhole wellbore fluid passage for receiving at least reservoir fluids from
the downhole
wellbore fluid passage; a first outlet port; a reservoir fluid-conducting
passage extending
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between the first inlet port and the first outlet port; a second inlet port
disposed downhole
relative to the first outlet port; a second outlet port; a gas-depleted fluid
conducting passage
extending between the second inlet port and the second outlet port; and a co-
operating surface
portion co-operating with the separator co-operating fluid conductor to define
an intermediate
fluid passage therebetween for effecting fluid communication between the first
outlet port and
the second inlet port; wherein the separator is sealingly, or substantially
sealingly, disposed
relative to the separator co-operating fluid conductor to defined a sealed
interface, and the
sealing disposition is effected downhole relative to the second inlet port,
with effect that fluid
flow, across the sealed interface, is prevented, or substantially prevented;
and wherein the space,
between: (a) the second inlet port of the separator, and (b) the sealed
interface, defines a sump
for collection of solid particulate that is entrained within fluid being
discharged from the first
outlet port of the separator, and the space has a volume of at least 0.1 m3.
[0008] In another aspect, there is provided a system for processing at
least reservoir fluids
within a wellbore that is disposed within an oil reservoir, the wellbore
including a wellbore fluid
conductor having a fluid passage, the wellbore fluid conductor comprising: a
separator co-
operating fluid conductor disposed within the wellbore, and including a
downhole wellbore fluid
passage for receiving reservoir fluids from the reservoir and for conducting
at least reservoir
fluids; a separator including: a first inlet port disposed in fluid
communication with the downhole
wellbore fluid passage for receiving at least reservoir fluids from the
downhole wellbore fluid
passage; a first outlet port; a reservoir fluid-conducting passage extending
between the first inlet
port and the first outlet port; a second inlet port disposed downhole relative
to the first outlet
port; a second outlet port; a gas-depleted fluid conducting passage extending
between the second
inlet port and the second outlet port; and a co-operating surface portion co-
operating with the
separator co-operating fluid conductor to define an intermediate fluid passage
therebetween for
effecting fluid communication between the first outlet port and the second
inlet port; wherein the
separator is sealingly, or substantially sealingly, disposed relative to the
separator co-operating
fluid conductor to defined a sealed interface, and the sealing disposition is
effected downhole
relative to the second inlet port, with effect that fluid flow, across the
sealed interface, is
prevented, or substantially prevented; and wherein the space, between: (a) the
second inlet port
of the separator, and (b) the sealed interface, defines a sump for collection
of solid particulate
that is entrained within fluid being discharged from the first outlet port of
the separator, and the
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minimum separation distance between: (a) the second inlet port of the
separator, and (b) the
sealed interface, measured along a line parallel to the axis of the fluid
passage of the wellbore
fluid conductor, is at least 30 feet.
[0009] In another aspect, there is provided a separator for effecting
separation of materials
from reservoir fluid within a wellbore fluid conductor disposed within a
wellbore, the wellbore
fluid conductor including a separator co-operating fluid conductor, the
separator co-operating
fluid conductor including a downhole wellbore fluid passage for receiving
reservoir fluids from
the reservoir and for conducting at least reservoir fluids, wherein the
separator comprises: a first
inlet port for receiving at least reservoir fluids from the downhole wellbore
fluid passage; a first
outlet port; a reservoir fluid-conducting passage extending between the first
inlet port and the
first outlet port; a second inlet port, positioned relative to the first
outlet port such that, when the
separator is disposed within the wellbore and oriented for receiving at least
reservoir fluids via
the first inlet port, the second inlet portion is disposed downhole relative
to the first outlet port; a
second outlet port; a gas-depleted fluid conducting passage extending between
the second inlet
port and the second outlet port; a co-operating surface portion configured for
co-operating with
the separator co-operating fluid conductor, when the separator is disposed
within the wellbore
and oriented for receiving at least reservoir fluids via the first inlet port,
to define an intermediate
fluid passage therebetween for effecting fluid communication between the first
outlet port and
the second inlet port; a seal support portion having an outer surface; and a
sealing member
supported by the seal support portion, the sealing member being configured for
sealingly, or
substantially sealingly, engaging the separator co-operating fluid conductor,
and positioned
relative to the second inlet port such that, when the separator is disposed
within the wellbore and
oriented for receiving at least reservoir fluids via the first inlet port, the
sealing member is
disposed downhole relative to the second inlet port and in sealing, or
substantially sealing,
engagement with the separator co-operating fluid conductor; wherein the
sealing member
projects outwardly from the outer surface by a distance of less than 2.5
millimetres.
[0010] In another aspect, there is provided a separator for separating
material from at least
reservoir fluid received from a fluid conductor of a wellbore in an oil
reservoir, the separator
comprising: an inlet port for receiving reservoir fluid from the fluid
conductor and an outlet port
for delivering gas-depleted reservoir fluid; a seal support member having an
outer surface; and a
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sealing member supported by the seal support member, the sealing member being
configured to
sealingly, or substantially sealingly, engage the inlet port with the fluid
conductor and prevent, or
substantially prevent, the reservoir fluid from bypassing the inlet port, the
sealing member
projecting outwardly, from the outer surface by a distance of less than 2.5
mm.
[0011] In another aspect, there is provided a separator for effecting
separation of materials
from reservoir fluid within a wellbore fluid conductor disposed within a
wellbore, the wellbore
fluid conductor including a separator co-operating fluid conductor, the
separator co-operating
fluid conductor including a downhole wellbore fluid passage for receiving
reservoir fluids from
the reservoir and for conducting at least reservoir fluids, wherein the
separator comprises: a first
inlet port for receiving at least reservoir fluids from the downhole wellbore
fluid passage; a first
outlet port; a reservoir fluid-conducting passage extending between the first
inlet port and the
first outlet port; a second inlet port, positioned relative to the first
outlet port such that, when the
separator is disposed within the wellbore and oriented for receiving at least
reservoir fluids via
the first inlet port, the second inlet portion is disposed downhole relative
to the first outlet port; a
second outlet port; a gas-depleted fluid conducting passage extending between
the second inlet
port and the second outlet port; a co-operating surface portion configured for
co-operating with
the separator co-operating fluid conductor, while the separator is disposed
within the wellbore
and oriented for receiving at least reservoir fluids via the first inlet port,
to define an intermediate
fluid passage therebetween for effecting fluid communication between the first
outlet port and
the second inlet port; a seal support portion; a sealing member supported by
the seal support
portion, the sealing member being configured for sealingly, or substantially
sealingly, engaging
the separator co-operating fluid conductor, and positioned relative to the
second inlet port such
that, when the separator is disposed within the wellbore and oriented for
receiving at least
reservoir fluids via the first inlet port, the sealing member is disposed
downhole relative to the
second inlet port and in sealing, or substantially sealing, engagement with
the separator co-
operating fluid conductor; wherein, the sealing member is further configured
such that, when the
separator is disposed within the wellbore and oriented for receiving at least
reservoir fluids via
the first inlet port, and the sealing member is sealingly, or substantially
sealingly, engaged to the
separator co-operating fluid conductor, the sealing member, including an
exposed surface
portion, that is disposed in fluid communication with the intermediate fluid
passage, is extending
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across a gap, between the separator and the separator co-operating fluid
conductor, having a
minimum distance of less than 2.5 millimetres.
[0012] In another aspect, there is provided a separator for effecting
separation of materials
from reservoir fluid within a wellbore fluid conductor disposed within a
wellbore, the wellbore
fluid conductor including a separator co-operating fluid conductor and a
liner, the separator co-
operating fluid conductor including a downhole wellbore fluid passage for
receiving reservoir
fluids from the reservoir and for conducting at least reservoir fluids, the
liner being coupled to
and disposed in sealing, or substantially sealing, engagement with the
separator co-operating
fluid conductor, and including a liner fluid passage, such that the downhole
wellbore fluid
passage includes the liner fluid passage, wherein the separator comprises: a
first inlet port for
receiving at least reservoir fluids from the downhole wellbore fluid passage;
a first outlet port; a
reservoir fluid-conducting passage extending between the first inlet port and
the first outlet port;
a second inlet port, positioned relative to the first outlet port such that,
when the separator is
disposed within the wellbore and oriented for receiving at least reservoir
fluids via the first inlet
port, the second inlet portion is disposed downhole relative to the first
outlet port; a second outlet
port; a gas-depleted fluid conducting passage extending between the second
inlet port and the
second outlet port; a co-operating surface portion configured for co-operating
with the separator
co-operating fluid conductor, while the separator is disposed within the
wellbore and oriented for
receiving at least reservoir fluids via the first inlet port, to define an
intermediate fluid passage
therebetween for effecting fluid communication between the first outlet port
and the second inlet
port; a sealing member configured for sealingly, or substantially sealingly,
engaging the liner,
and positioned relative to the second inlet port such that, when the separator
is disposed within
the wellbore and oriented for receiving at least reservoir fluids via the
first inlet port, the sealing
member is disposed downhole relative to the second inlet port and in sealing,
or substantially
sealing, engagement with the liner; and a latch seal assembly, carrying the
sealing member, and
co-operatively configured for releasable connection to the liner.
BRIEF DESCRIPTION OF DRAWINGS
[0013] The process of the preferred embodiments of the invention will now
be described
with the following accompanying drawing:
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[0014] Figure 1 is a schematic illustration of an embodiment of a system of
the present
disclosure using a downhole pump;
[0015] Figure 2 is an enlarged view of the sealing engagement of the
separator to the liner,
illustrated in Figure 1;
[0016] Figure 3 is an enlarged view of Detail "A" in Figure 1, illustrating
an embodiment of
a flow diverter;
[0017] Figure 4 is a top plan view of an embodiment of a flow diverter;
[0018] Figure 5 is a bottom plan view of the flow diverter illustrated in
Figure 4;
[0019] Figure 6 is a sectional elevation view, taken along lines B-B in
Figure 4, of the flow
diverter illustrated in Figure 4;
[0020] Figure 7 is a sectional elevation view, taken along lines C-C in
Figure 6, of the flow
diverter illustrated in Figure 4;
[0021] Figure 8 is a schematic illustration of another embodiment of a
system of the present
disclosure using a downhole pump;
[0022] Figure 9 is an enlarged view of the sealing engagement of the
separator to a
constricted portion of the wellbore wellbore casing, illustrated in Figure 1;
[0023] Figure 10 is a schematic illustration of an embodiment of an
artificial lift system of
the present disclosure using a downhole pump and gas lift;
[0024] Figure 11 is an enlarged view of Detail "B" in Figure 10,
illustrating the flow
diverter;
[0025] Figure 12 is a schematic illustration of a flow diverter of the
embodiment illustrated
in Figure 10;
[0026] Figure 13 is a top plan view of the flow diverter illustrated in
Figure 12;
[0027] Figure 14 is a bottom plan view of the flow diverter illustrated in
Figure 12; and
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[0028] Figure 15 is a schematic illustration of another embodiment of a
system of the present
disclosure using a downhole pump.
DETAILED DESCRIPTION
[0029] As used herein, the terms "up", "upward", "upper", or "uphole",
mean,
relativistically, in closer proximity to the surface and further away from the
bottom of the
wellbore, when measured along the longitudinal axis of the wellbore. The terms
"down",
"downward", "lower", or "downhole" mean, relativistically, further away from
the surface and in
closer proximity to the bottom of the wellbore, when measured along the
longitudinal axis of the
wellbore.
[0030] There is provided systems, with associated apparatuses, for
producing hydrocarbons
from an oil reservoir, such as an oil reservoir, when reservoir pressure
within the oil reservoir is
insufficient to conduct hydrocarbons to the surface through a wellbore.
[0031] The wellbore can be straight, curved, or branched. The wellbore can
have various
wellbore portions. A wellbore portion is an axial length of a wellbore. A
wellbore portion 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. The term "horizontal", when used to describe a wellbore
portion, refers to a
horizontal or highly deviated wellbore portion as understood in the art, such
as, for example, a
wellbore portion having a longitudinal axis that is between 70 and 110 degrees
from vertical.
[0032] The wellbore may be completed either as a cased-hole completion or
an open-hole
completion.
[0033] Well completion is the process of preparing the well for injection
of fluids into the oil
reservoir, or for production of reservoir fluid from the oil reservoir. This
may involve the
provision of a variety of components and systems to facilitate the injection
and/or production of
fluids, including components or systems to segregate oil reservoir zones along
sections of the
wellbore.
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[0034] "Reservoir fluid" is fluid that is contained within an oil
reservoir. Reservoir fluid
may be liquid material, gaseous material, or a mixture of liquid material and
gaseous material.
In some embodiments, for example, the reservoir fluid includes water and
hydrocarbons, such as
oil, natural gas, or combinations thereof.
[0035] Fluids may be injected into the oil reservoir through the wellbore
to effect stimulation
of the reservoir fluid. For example, such fluid injection is effected during
hydraulic fracturing,
water flooding, water disposal, gas floods, gas disposal (including carbon
dioxide sequestration),
steam-assisted gravity drainage ("SAGD") or cyclic steam stimulation ("CSS").
In some
embodiments, for example, the same wellbore is utilized for both stimulation
and production
operations, such as for hydraulically fractured formations or for formations
subjected to CSS. In
some embodiments, for example, different wellbores are used, such as for
formations subjected
to SAGD, or formations subjected to waterflooding.
[0036] A cased-hole completion involves running wellbore casing down into
the wellbore
through the production zone. The wellbore casing at least contributes to the
stabilization of the
oil reservoir after the wellbore has been completed, by at least contributing
to the prevention of
the collapse of the oil reservoir within which the wellbore is defined.
[0037] The annular region between the deployed wellbore casing and the oil
reservoir may
be filled with cement for effecting zonal isolation (see below). The cement is
disposed between
the wellbore casing and the oil reservoir for the purpose of effecting
isolation, or substantial
isolation, of one or more zones of the oil reservoir from fluids disposed in
another zone of the oil
reservoir. Such fluids include reservoir fluid being produced from another
zone of the oil
reservoir (in some embodiments, for example, such reservoir fluid being flowed
through a
production tubing string disposed within and extending through the wellbore
casing to the
surface), or injected fluids such as water, gas (including carbon dioxide), or
stimulations fluids
such as fracturing fluid or acid. In this respect, in some embodiments, for
example, the cement is
provided for effecting sealing, or substantial sealing, of fluid communication
between one or
more zones of the oil reservoir and one or more others zones of the oil
reservoir (for example,
such as a zone that is being produced). By effecting the sealing, or
substantial sealing, of such
fluid communication, isolation, or substantial isolation, of one or more zones
of the oil reservoir,
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from another subterranean zone (such as a producing formation), is achieved.
Such isolation or
substantial isolation is desirable, for example, for mitigating contamination
of a water table
within the oil reservoir by the reservoir fluid (e.g. oil, gas, salt water, or
combinations thereof)
being produced, or the above-described injected fluids.
[0038] In some embodiments, for example, the cement is disposed as a sheath
within an
annular region between the wellbore casing and the oil reservoir. In some
embodiments, for
example, the cement is bonded to both of the production casing and the oil
reservoir.
[0039] In some embodiments, for example, the cement also provides one or
more of the
following functions: (a) strengthens and reinforces the structural integrity
of the wellbore, (b)
prevents, or substantially prevents, produced reservoir fluid of one zone from
being diluted by
water from other zones. (c) mitigates corrosion of the wellbore casing, and
(d) at least
contributes to the support of the wellbore casing.
[0040] The cement is introduced to an annular region between the wellbore
casing and the oil
reservoir after the subject wellbore casing has been run into the wellbore.
This operation is
known as "cementing".
[0041] In some embodiments, for example, the wellbore casing includes one
or more casing
strings, each of which is positioned within the well bore, having one end
extending from the well
head. In some embodiments, for example, each casing string is defined by
jointed segments of
pipe. The jointed segments of pipe typically have threaded connections.
[0042] Typically, a wellbore 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.
[0043] For wells that are used for producing reservoir fluid, few of these
actually produce
through 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 tubing string is usually
installed inside the last casing
string. The production tubing string is provided to conduct reservoir fluid,
received within the
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wellbore, to the wellhead. In some embodiments, for example. the annular
region between the
last casing string and the production tubing string may be sealed at the
bottom by a packer.
[0044] To facilitate fluid communication between the reservoir and the
wellbore, the
wellbore casing may be perforated, or otherwise include per-existing ports, to
provide a fluid
passage for enabling flow of reservoir fluid from the reservoir to the
wellbore.
[0045] 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. 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 fluid communication between the reservoir and the
wellbore. In this respect,
in some embodiments, for example, the liner string can also be a screen or is
slotted. In some
embodiments, for example, the production tubing string may be stung into the
liner string,
thereby providing a fluid passage for conducting the produced reservoir fluid
to the wellhead. In
some embodiments, for example, no cemented liner is installed, and this is
called an open hole
completion.
[0046] An open-hole completion is effected by drilling down to the top of
the producing
formation, and then casing the wellbore. The wellbore is then drilled through
the producing
formation, and the bottom of the wellbore is left open (i.e. uncased), to
effect fluid
communication between the reservoir and the wellbore. Open-hole completion
techniques
include bare foot completions, pre-drilled and pre-slotted liners, and open-
hole sand control
techniques such as stand-alone screens, open hole gravel packs and open hole
expandable
screens. Packers can segment the open hole into separate intervals.
[0047] Referring to Figures 1, 3, 8 and 10, the system 10 includes an
artificial lift system 12
a wellbore fluid conductor 100. The artificial lift system 12 is provided to
contribute to the
production of reservoir fluids from the reservoir 22. Suitable exemplary
artificial lift systems
include a pump, gas-lift systems, and jet lift systems. A pump 12 is described
herein, but it is
understood that other artificial lift systems could be used.
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[0048]
The pump 12 is provided to, through mechanical action, energize and effect
movement of the reservoir fluid from the reservoir 22, through the wellbore
14, and to the
surface 24, and thereby effect production of the reservoir fluid. The wellbore
fluid conductor
100 includes a fluid passage 101, and is provided for conducting, through the
wellbore 14, fluids
being energized and moved by at least the pump 12. It is understood that the
reservoir fluid may
be energized by other means, including by gas-lift, as will be further
discussed below with
respect to some embodiments. In this respect, in some implementations using
gas-lift to effect
production of the reservoir fluid, in addition to the reservoir fluid, the
fluid being conducted by
through the fluid passage 101 of the wellbore fluid conductor 100, and also
being energized and
moved by the pump 12, includes gaseous material supplied from the surface and
into the
wellbore 14, for effecting gas-lift of the reservoir fluid.
[0049]
The wellbore fluid conductor 100 includes an upstream fluid conductor 102. The
upstream fluid 102 conductor receives at least reservoir fluid from the
wellbore 14, and conducts
the received fluid within the wellbore 14. The upstream fluid conductor 102 is
disposed in fluid
communication with the pump suction 16 such that at least a fraction of the
received fluid being
conducted by the upstream fluid conductor 102 is supplied the pump suction. In
some
embodiments, for example, the wellbore fluid conductor 100 includes wellbore
casing 130.
[0050]
The wellbore fluid conductor 100 also includes a downstream fluid conductor
104,
for conducting fluid, that is being discharged by the pump 12 through the pump
discharge 18, to
the surface, or gaseous material that has been separated by a separator 108
(see below). In some
embodiments, for example, the downstream fluid conductor 104 includes a piping
or tubing
string that extends from the pump discharge 18 to the wellhead 20.
[0051]
The upstream fluid conductor 102 includes a separator co-operating fluid
conductor
106, disposed within the wellbore 14, and a separator 108. The separator co-
operating fluid
conductor 106 co-operates with the separator 108 to effect separation of at
least a fraction of
gaseous material from reservoir fluid being conducted through the upstream
fluid conductor 102,
prior to its introduction to the pump suction 16, as described below. In some
embodiments, for
example, the wellbore fluid conductor 100 includes wellbore casing 130, and
the wellbore casing
130 includes the separator co-operating fluid conductor 106.
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[0052] The separator co-operating fluid conductor 106 includes an inlet
port 110 for
receiving reservoir fluids from the reservoir 20, and a downhole wellbore
fluid passage 112 for
effecting conducting (e.g. flowing) of the received fluid, including reservoir
fluid, to the
separator 108. In co-operation with the separator co-operating fluid conductor
106, the separator
108 functions to effect depletion of gaseous material from the fluid being
supplied by the
downhole wellbore fluid passage 112, such that a fluid, depleted in gaseous
material, is supplied
to the pump suction.
[0053] Reservoir fluid may contain gaseous material. As well, in some
embodiments, the
system 10 may include a gas lift component, in which case suitable
infrastructure is provided so
as to supply gaseous material for admixing with reservoir fluid received
within the wellbore 14
so as to effect a density reduction in the fluid disposed within the wellbore
14 for conduction
(such as by flowing) to the pump suction 16 (such density reduction effects a
reduction in
pressure of the fluid within the wellbore 14, increases drawdown, and thereby
facilitates an
increased rate of production of reservoir fluid from the reservoir 22).
[0054] In either case, it is preferable to at least partially remove
gaseous material from the
fluid being conducted within the upstream fluid conductor 102, prior to the
pump suction 16, in
order to mitigate gas interference or gas lock conditions during pump
operation. The separator
108, in co-operation with the separator co-operating fluid conductor 106, is
provided to, amongst
other things, perform this function.
[0055] The separator 108 includes a first inlet port 114 and a first outlet
port 116. The first
inlet port 114 is disposed in fluid communication with the downhole wellbore
fluid passage 112
for receiving at least reservoir fluids (see directional arrow 502) from the
downhole wellbore
fluid passage 112. A reservoir fluid-conducting passage 118 extends between
the first inlet port
114 and the first outlet port 116.
[0056] The separator 108 also includes a second inlet port 120 and a second
outlet port 122.
The second inlet port 120 is disposed downhole relative to the first outlet
port 116. A gas-
depleted fluid conducting passage 124 extends between the second inlet port
120 and the second
outlet port 122.
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[0057] In some embodiments, for example, the first inlet port 114 of the
separator 108 is
disposed downhole relative to the second outlet port 122 of the separator 108.
[0058] The separator 108 further includes a co-operating surface portion
125. The co-
operating surface portion 125 co-operates with the separator co-operating
fluid conductor 106 to
define an intermediate fluid passage 126 (such as an annular fluid passage)
therebetween for
effecting fluid communication between the first outlet port 116 and the second
inlet port 120.
While at least reservoir fluid is flowing within the intermediate fluid
passage 126 (see directional
arrow 504), at least a fraction of gaseous material, within the downwardly
flowing fluid within
the intermediate fluid passage 126, is separated from the downwardly flowing
fluid in response
to buoyancy forces, to produce a gaseous material-depleted fluid. The
separated gaseous
material is conducted uphole to the wellhead 20 through a conductor 131 that
is disposed in fluid
communication with the intermediate fluid passage 126. In some embodiments,
for example, the
conductor 131 defines a gas conducting passage 131a disposed between the
wellbore fluid
conductor 100 (such as a wellbore casing) and a pressurized fluid conductor
128 that is
extending uphole from a pump discharge 18 (see below). The gaseous material-
depleted fluid is
conducted (see directional arrow 506) to the pump suction 16 via the gas-
depleted fluid
conducting passage 124.
[00591 The separator 108 is sealingly, or substantially sealingly, disposed
relative to the
separator co-operating fluid conductor 106. The sealing, or substantially
sealing, disposition is
effected downhole relative to the second inlet port 120. The sealing
disposition is such that a
sealing interface 300 is defined, and such that fluid flow, across the sealed
interface 300, is
prevented, or substantially prevented. In some embodiments, for example, the
sealing, or
substantially sealing, disposition of the separator 108 relative to the
separator co-operating fluid
conductor 106 is with effect that fluid flow, across the sealed interface 300,
in at least a
downhole direction, is prevented, or substantially prevented. In some
embodiments, for
example, the sealing, or substantially sealing, disposition of the separator
108 relative to the
separator co-operating fluid conductor 106 is with effect that fluid, that is
being conducted in a
downhole direction within the intermediate fluid passage 126, is directed to
the second inlet port
120. In this respect, the gaseous material-depleted fluid, produced after the
separation of
gaseous material within the intermediate fluid passage 126, is directed to the
second inlet port
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122 (see directional arrow 508), and conducted to the pump suction 16 (see
directional arrow
506) via the gas-depleted fluid conducting passage 124.
[0060] Referring to Figure 1, in some embodiments, for example, the
wellbore fluid
conductor 100 may also include a liner 132 that is connected or coupled to
(for example, hung
from), and sealed, or substantially sealed, relative to, the separator co-
operating fluid conductor
106. The liner 132 includes a liner fluid passage 134, such that the downhole
wellbore fluid
passage 112 includes the liner fluid passage 132. In some embodiments, for
example, the sealed,
or substantially sealed, disposition of the liner 132 relative to the
separator co-operating fluid
conductor 108 is effected by a packer 136 disposed between the liner 132 and
the wellbore
casing 130. In some embodiments, for example, the coupling and sealing, or
substantially
sealing, engagement between the liner 132 and the separator co-operating fluid
conductor,
includes coupling and sealing, or substantially sealing, engagement between
the liner 132 and the
wellbore casing 130.
[0061] Referring to Figure 8, in some embodiments, for example, the
separator co-operating
fluid conductor 106 includes a constricted portion 138 of wellbore casing 130.
[0062] In some embodiments, for example, the separator 108 includes, or
carries, a sealing
member 202 for effecting the sealing, or substantially sealing, disposition of
the separator 108
relative to the separator co-operating fluid conductor 106. In some
embodiments, for example,
the sealing member 202 is a compressible sealing member. In some embodiments,
for example,
the sealing member 202 includes one or more o-rings.
[0063] In some embodiments, for example, the wellbore casing 130 includes a
casing fluid
passage 1311, and the liner fluid passage 132 is disposed downhole from the
casing fluid passage
1311. In some embodiments, for example, the separator 108 is disposed within
the casing fluid
passage 1311.
[0064] In some embodiments, for example, the separator 108 includes a
downhole fluid
conductor 150 and a flow diverter 160.
[0065] The downhole fluid conductor 150 includes the first inlet port 114,
a first intermediate
outlet port 152, and a downhole reservoir fluid-conducting passage 154. The
downhole reservoir
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fluid-conducting passage 154 extends between the first inlet port 114 and the
intermediate outlet
port 152. In some embodiments, for example, the downhole fluid conductor 150
also includes a
separator sealing surface 156, such as a separator sealing surface defined by
the sealing member
140. In some embodiments, for example, the downhole fluid conductor 150
includes a piping or
tubing string. In some embodiments, for example, the downhole fluid conductor
150 includes, or
carries, the sealing member 202. In some embodiments, for example, the
downhole fluid
conductor 150 is configured such that received fluid (including reservoir
fluids) is conducted
through the downhole fluid conductor 150, and the conducting of the received
fluid is such that
the superficial gas velocity of gaseous material, of the received fluid, being
conducted through
the downhole fluid conductor 150, is greater than five (5) feet per second.
[0066] The flow diverter 160 includes a first intermediate inlet port 162,
the first outlet port
116, and an uphole reservoir fluid-conducting passage 164. The uphole
reservoir fluid-
conducting passage 164 extends between the intermediate inlet port and the
first outlet port 116.
[0067] The flow diverter 160 also includes the second inlet port 120, the
second outlet port
122, and the gas-depleted fluid conducting passage 124. The gas-depleted fluid
conducting
passage 124 extends between the second inlet port 120 and the second outlet
port 122.
[0068] The flow diverter 160 also includes the co-operating surface portion
125.
[0069] An embodiment of a flow diverter 160 is illustrated in Figures 3 to
7. Referring to
Figures 3 to 7, in some embodiments, for example, the flow diverter 160
includes a plurality of
first outlet ports 116a, 116b, 116c, 116d and the uphole reservoir fluid-
conducting passage 164
includes a plurality of branched fluid passage portions 164a, 164b, 164c, 164d
(two are shown)
that extend into corresponding first outlet ports 116a, 116b, 116c, 116d, for
effecting fluid
coupling with the first intermediate inlet port 162. The flow diverter 160
further includes a
plurality of second inlet ports 120a, 120b, 120c, 120d, and the gas-depleted
fluid conducting
passage 124 includes a plurality of branched fluid passage portions 124a,
124b, 124c, 124d (two
are shown) extending from the second inlet ports 120a, 120b, 120c, 120d for
effecting fluid
coupling with the second outlet port 122. In some embodiments, for example,
the fluid diverter
160 includes a shroud (or "skirt") 161 extending downwardly below the second
inlet ports 120a,
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120b, 120c, 120d. This provides increased residence time for separation of
gaseous material
within the intermediate fluid passage 126.
[0070] The combination of the downhole fluid conductor 150 and the flow
diverter 160 is
such that the reservoir fluid-conducting passage 118 includes the downhole
reservoir fluid-
conducting passage 154 and the uphole reservoir fluid-conducting passage 164.
[0071] The downhole fluid conductor 150 is connected to the flow diverter
100 such that the
intermediate outlet port 152 of the downhole fluid conductor 150 is disposed
in fluid
communication with the intermediate inlet port 162 of the flow diverter 160 ,
thereby effecting
supplying of fluid from the intermediate outlet port 152 to the intermediate
inlet port 162. In
some embodiments, for example, the downhole reservoir fluid conductor 150 is
threadably
connected to the flow diverter 160.
[0072] In some embodiments, for example, the axis of the second outlet port
122 of the flow
diverter 160 is disposed in alignment, or substantial alignment, with the axis
of the downhole
reservoir fluid-conducting passage 154 of the downhole fluid conductor 150.
[0073] The separator 108 is connected to the pump 12 such that the second
outlet port 122 is
fluidly coupled to the pump suction 16 for supplying gaseous material-depleted
fluid to the pump
suction 16. In some embodiments, for example, the connection is a threaded
connection.
[0074] The pump 12 functions to effect transport of at least reservoir
fluid from the reservoir
22 to the surface 24. In some embodiments, for example, the pump 12 is a
sucker rod pump.
Other suitable pumps include screw pumps, electrical submersible pumps, and
jet pumps.
[0075] The pressurized fluid conductor 128 is connected to the pump
discharge 18 such that
an inlet port 129 of the pressurized fluid conductor 128 is fluidly coupled to
the pump discharge
18 for receiving pressurized gaseous material-depleted fluid being discharged
by the pump 12.
The pressurized fluid conductor 128 extends to the surface 24 via the wellhead
20 , to thereby
effect transport of the gaseous material-depleted fluid to the surface 24 (see
directional arrow
512). The pressurized fluid conductor 128 is hung from the wellhead.
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[0076] The reservoir fluid produced through the pressurized fluid conductor
128 may be
discharged through the wellhead 20 to a collection facility, such as a storage
tank within a
battery.
[0077] Referring to Figure 10, in some embodiments, and as alluded to
above, the wellbore
fluid conductor 100, for example, is further configured to assist with
production of reservoir
fluids from the reservoir 22 by providing infrastructure to enable gas lift of
the reservoir fluid
received within the wellbore 14 from the reservoir. In this respect, in some
embodiments, for
example, the wellbore fluid conductor 100, includes a gaseous fluid conductor
170 for
conducting gaseous material (see directional arrow 514) being supplied from a
gaseous material
source. The gaseous fluid conductor 170 extends from the surface 124 and into
the wellbore 14.
In some embodiments, for example, the gaseous fluid conductor 170 includes a
piping or tubing
string. In some of these embodiments, the piping or tubing string extends from
the wellhead 20
and into the wellbore 14.
[0078] The gaseous fluid conductor 170 includes an outlet port 172 disposed
in fluid
communication with the inlet port 114 of the separator 108, for effecting
admixing of gaseous
material with reservoir fluid to produce a density-reduced fluid that includes
the reservoir fluid.
The admixing is effected upstream of the inlet port 114, such that the inlet
port 114 is disposed
for receiving the density-reduced fluid. In this respect, the "at least
reservoir fluid" includes the
gaseous material that has been supplied from the surface.
[0079] Referring to Figure 11, in some embodiments, for example, where the
separator 108
includes a flow diverter 1160 (see Figures 12, 13, and 14), in some of these
embodiments, for
example, the gaseous fluid conductor 170 includes an uphole gaseous fluid
conductor 174,
including an uphole gas conducting passage 175, and a downhole gaseous fluid
conductor 176.
[0080] The uphole gaseous fluid conductor 174 extends between the surface
24 and the flow
diverter 1160. In this respect, in some embodiments, for example, the uphole
gaseous fluid
conductor 174 is connected to the wellhead 20 and extends from the wellhead
20, and is disposed
in fluid communication with a gaseous material supply source, disposed at the
surface 24, via the
wellhead 20 and through an inlet port 178 of the uphole gaseous fluid
conductor 174, for
receiving gaseous material from the gaseous material supply source and
conducting the received
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gaseous material to the flow diverter 1160. In some embodiments, for example,
the uphole
gaseous fluid conductor 174 is connected to the flow diverter 1160 such that
an outlet port 180 of
the uphole gaseous fluid conductor 174 is fluidly coupled to an inlet port
1602 of the flow
diverter 160 for supplying the conducted gaseous material to the inlet port
1602 of the flow
diverter 1160.
[0081] The downhole gaseous fluid conductor 176 extends downhole from the
flow diverter
1160 to a position whereby the outlet port 172 of the downhole gaseous fluid
conductor 176 is
disposed for supplying the conducted gaseous material for admixing with
reservoir fluid to
produce a density-reduced fluid, upstream of the inlet port 114 of the
downhole reservoir fluid
conductor 150, such that the density-received fluid is disposed in fluid
communication with the
inlet port 114 of the downhole fluid conductor 150 for receiving by the inlet
port 114 of the
downhole fluid conductor 1160. In this respect, the downhole gaseous fluid
conductor 176 is
connected to the flow diverter 160 such that fluid communication between an
outlet port 1604 of
the flow diverter 1160 and an inlet port 184 of the downhole gaseous fluid
conductor 176 is
effected. Between the inlet 1602 and outlet ports 1604 of the flow diverter
160 extends a gas-
conducting passage 1606 which fluidly couples the inlet and outlet ports 1602,
1604, such that
the fluid coupling of the outlet port 1604 of the flow diverter 1160 and the
inlet port 184 of the
downhole gaseous fluid conductor 176 effects supplying of the gaseous
material, being
conducted through the uphole gaseous fluid conductor 174, to the downhole
gaseous fluid
conductor 176. In this respect, the flow diverter 1160 effects fluid coupling
between the uphole
and downhole gaseous fluid conductors 174,176.
[0082] In some embodiments, for example, the downhole gas conducting
passage 177 is
disposed within the downhole fluid conductor 150, along with the downhole
reservoir fluid-
conducting passage 154. In this respect, the downhole fluid conductor 150
includes the
downhole gas conducting passage 177 and the downhole reservoir fluid-
conducting passage 154.
In some of these embodiments, for example, the downhole fluid conductor 150
includes the
downhole gaseous fluid conductor 176, including the downhole gas conducting
passage 177, and
a downhole reservoir fluid conductor 190, including the downhole reservoir
fluid-conducting
passage 154, and the downhole reservoir fluid conductor 190 is nested within
the downhole
gaseous fluid conductor 176, such that the downhole gas conducting passage 177
is defined by
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an intermediate passage (such as an annulus) between the downhole gaseous
fluid conductor 176
and the downhole reservoir fluid conductor 190.
[0083] Referring to Figure 1, in one aspect, the liner 132 is connected or
coupled to (for
example, hung from), and is disposed in sealing, or substantially sealing,
engagement with the
separator co-operating fluid conductor 106, and the separator 108 is disposed
in sealing, or
substantially sealing, engagement with the liner 132. In this configuration,
the first inlet port 114
is disposed for receiving at least reservoir fluid via the liner fluid passage
134.
[0084] In some embodiments, for example, the separator 108 further includes
a latch seal
assembly 200 releasably coupled to the liner 132, wherein the sealing, or
substantially sealing,
engagement between the liner 132 and the separator 108 is effected by the
latch seal assembly
130. A suitable latch seal assembly 130 is a Weatherfordi'm Thread-Latch
Anchor Seal
Assembly.
[0085] In some embodiments, for example, the sealing, or substantially
sealing, engagement
includes sealing, or substantially sealing, engagement of the liner 132 to a
separator sealing
surface 156 of the separator 108, and the separator sealing surface 156
includes one or more o-
rings.
[0086] In some embodiments, for example, the sealing, or substantially
sealing, engagement
includes sealing, or substantially sealing, engagement of the separator 108 to
a polished bore
receptacle 131 of the liner 132.
[0087] In some embodiments, for example, the separator 108 is disposed in
an interference
fit with the liner 132.
[0088] In some embodiments, for example, the separator 108 is landed or
"stung" within the
liner 132.
[0089] In some embodiments, for example, the combination of at least: (a)
the sealing, or
substantially sealing, engagement of the liner 132 with the wellbore casing
130, and (b) the
sealing, or substantially sealing, engagement of the separator 108 with the
liner 132, effects the
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sealing, or substantially sealing, disposition of the separator 108 (and, more
specifically, the
separator sealing surface 156) relative to the separator co-operating fluid
conductor 106.
[0090] In some embodiments, for example, the combination of at least: (i)
the sealing, or
substantially sealing, engagement between the liner 132 and the separator co-
operating fluid
conductor 106, and (ii) the sealing, or substantially sealing, engagement
between the separator
sealing surface 156 and the liner 132, is such that the separator sealing
surface 156 is sealed, or
substantially sealed, relative to the separator co-operating fluid conductor
106 and thereby
defines the sealed interface 301, such that fluid flow, across the sealed
interface 301, is prevented
or substantially prevented.
[0091] In some embodiments, for example, the combination of at least: (i)
the sealing, or
substantially sealing, engagement between the liner 132 and the separator co-
operating fluid
conductor 106, and (ii) the sealing, or substantially sealing, engagement
between the separator
sealing surface 156 and the liner 132, is with effect that fluid flow, across
the sealed interface
301, in at least a downhole direction, is prevented or substantially
prevented.
[0092] In some embodiments, for example, the combination of at least: (i)
the sealing, or
substantially sealing, engagement between the liner 132 and the separator co-
operating fluid
conductor 106 , and (ii) the sealing, or substantially sealing, engagement
between the separator
sealing surface 156 and the liner 132, is with effect that fluid, that is
being conducted in a
downhole direction within the intermediate fluid passage 126, is directed to
the second inlet port
120.
[0093] Referring to Figure 2, in related aspects, the separator 108
includes (or carries) a
sealing member 202, and the sealing member 202 is disposed between a sealing
member
engaging surface portion 157a of the separator 108 and the sealing member
engaging surface
portion 157b of the liner 132 for effecting sealing, or substantial sealing,
of the sealing member
engaging portion 157a of the separator 108 relative to the sealing member
engaging portion 157b
of the liner 132. The combination of at least: (i) the sealing, or
substantially sealing, engagement
between the liner 132 and the wellbore casing 130, and (ii) the sealing, or
substantial sealing, of
the sealing member-engaging surface portion 157a of the separator 108 relative
to the sealing
member-engaging surface portion 157b of the liner 132, effects the sealing, or
substantially
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sealing, disposition of the separator 108 (and, more specifically, the sealing
member-engaging
surface portion 157a of the separator 108) relative to the separator co-
operating fluid conductor
106 and thereby defines a sealed interface 302. The sealing, or substantially
sealing, disposition
of the separator sealing member engaging surface portion 157a of the separator
108 relative to
the separator co-operating fluid conductor 106 is effected downhole relative
to the second inlet
port 120. Further, this sealing, or substantially sealing, disposition is such
that fluid flow, across
the sealed interface 302, is prevented or substantially prevented.
[0094] In a related aspect, the sealing member 202, having an exposed
surface portion 202a,
that is disposed in fluid communication with the intermediate fluid passage
126, is extending
across a gap 204a, between the separator 108 and the liner 132, having a
minimum distance of
less than 2.5 millimitres. In some embodiments, for example, the gap 204a has
a minimum
distance of less than one (1.0) millimetre.
[0095] In another related aspect, the inlet port 114 is disposed in fluid
communication with
the liner fluid passage 134 and in sealing, or substantially sealing,
engagement with the liner 132
to prevent, or substantially prevent, the at least reservoir fluid from
bypassing the inlet port 114.
[0096] Referring to Figure 8, in another aspect, a separator sealing
surface 156 is disposed in
sealing, or substantially sealing, engagement with a constricted portion 138
of wellbore casing
130, such that the sealing, or substantially sealing, disposition of the
separator sealing surface
156 relative to the separator co-operating fluid conductor 106 is effected by
the sealing, or
substantially sealing, engagement of the separator sealing surface 156 with
the constricted
portion 138 and defines a sealed interface 304. The sealing, or substantially
sealing, engagement
of the separator sealing surface 156 with the constricted portion 138 is
effected downhole
relative to the second inlet port 120 and is with effect that fluid flow,
across the sealed interface
304, is prevented, or substantially prevented. In some embodiments, for
example, the separator
108 is disposed in an interference fit with the constricted portion 138. In
some embodiments, the
constricted portion 138 of wellbore casing 130 includes an inwardly extending
projection.
[0097] In some embodiments, for example, the sealing, or substantially
sealing, engagement
between the separator sealing surface 156 and the constricted portion 138 is
with effect that fluid
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flow, across the sealed interface 304, in at least a downhole direction, is
prevented, or
substantially prevented.
[0098] In some embodiments, for example, the sealing, or substantially
sealing, engagement
between the separator sealing surface 156 and the constricted portion 138 is
with effect that
fluid, that is being conducted in a downhole direction within the intermediate
fluid passage 126,
is directed to the second inlet port 120.
[0099] Referring to Figure 9, in a related aspect, the separator 108
includes (or carries) a
sealing member 202, and the sealing, or substantially sealing, engagement
between the separator
sealing surface 156 and the constricted portion 138 is effected by the sealing
member 202. In
this respect, the sealing member 202 is disposed between a sealing member
engaging surface
portion 157a of the separator 108 and a sealing member engaging portion 157c
of the constricted
portion 138 such that a sealed interface 306 is thereby defined, and such that
fluid flow, across
the sealed interface 306, is prevented, or substantially prevented. The
sealing member 202,
having an exposed surface portion 202a, that is disposed in fluid
communication with the
intermediate fluid passage 126, is extending across a gap 204b, between the
separator 208 and
the constricted portion 138, having a minimum distance of less than 2.5
millimetres. In some
embodiments, for example, the gap 204b has a minimum distance of less than one
(1) millimetre.
[00100] The above-described configurations for sealing, or substantially
sealing, disposition
of the separator 108 relative to the separator co-operating fluid conductor
106 provide for
conditions which minimize solid debris accumulation in the joint between the
separator 108 and
the separator co-operating fluid conductor 106. By providing for conditions
which minimize
solid debris accumulation within the joint, interference to movement of the
separator 108 relative
to the separator co-operating fluid conductor 106, which could be effected by
accumulated solid
debris, is mitigated.
[00101] In another aspect, the space, between: (a) the second inlet port 120
of the separator
108, and (b) the sealed interface (such as of sealed interface 300, 302, 304,
or 306), defines a
sump 206 for collection of solid particulate that is entrained within fluid
being discharged from
the first outlet port 116 of the separator 108, and the sump 206 has a volume
of at least 0.1 m3.
In some embodiments, for example, the volume is at least 0.5 m3. In some
embodiments, for
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example, the volume is at least 1.0 m3. In some embodiments, for example, the
volume is at
least 3.0 m3.
[00102] In a related aspect, the space, between: (a) the second inlet port 120
of the separator
108, and (b) the sealed interface (such as sealed interface 300, 302, 304, or
306), defines a sump
206 for collection of solid particulate that is entrained within fluid being
discharged from the
first outlet port 116 of the separator 108, and the minimum separation
distance between: (a) the
second inlet port 120 of the separator 108 , and (b) the sealed interface
(such as sealed interface
300, 302, 304. or 306), measured along a line parallel to the axis of the
fluid passage of the
wellbore fluid conductor 100, is at least 30 feet, is at least 30 feet. In
some embodiments, for
example, the minimum separation distance is at least 45 feet. In some
embodiments, for
example, the minimum separation distance is at least 60 feet.
[00103] Referring to Figure 15, in some of these embodiments, for example, the
wellbore
fluid conductor 100 includes the wellbore casing 130, and the wellbore casing
130 includes the
separator co-operating fluid conductor 106, and the sealing, or substantially
sealing, disposition
of the separator 108 relative to the separator co-operating fluid conductor
106 is effected by at
least a packer 208 disposed between the separator 108 and the wellbore casing
130. In some of
these embodiments, for example, the packer 208 is carried by the separator
108. In some of
these embodiments, for example, the packer 208 is disposed downhole relative
to the second
inlet port 120. In some of these embodiments, for example, the wellbore fluid
conductor further
includes a liner 132, the liner 132 being connected or coupled to (such as,
for example, by being
hung from the wellbore casing 130), and being disposed in sealing, or
substantially sealing,
engagement with the wellbore casing 130 such that the above-described sealed
interface is
defined (as sealed interface 308). The liner 132 includes a liner fluid
passage 134, such that the
downhole wellbore fluid conductor fluid passage 112 includes the liner fluid
passage 112, and
such that the first inlet port 114 is disposed for receiving at least
reservoir fluids via the liner
fluid passage 134. In some of these embodiments, for example, the sealing, or
substantially
sealing, engagement between the liner and the wellbore casing is with effect
that fluid flow,
across the sealed interface 308, at least in a downhole direction, is
prevented or substantially
prevented at the sealing engagement. In some of these embodiments, for
example, the sealing, or
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substantially sealing, engagement between the liner 132 and the wellbore
casing 130 is effected
by a packer 136 disposed between the liner 132 and the wellbore casing 130.
[00104] Referring to Figure 1, in some of these embodiments, for example, the
separator co-
the liner 132 is connected or coupled to (such as, for example, being hung
from) the separator
co-operating fluid conductor 106 and disposed in sealing, or substantially
sealing, engagement
with the separator co-operating fluid conductor 106, and including a liner
fluid passage 134, such
that the downhole wellbore fluid passage 112 includes the liner fluid passage
134. The separator
108 is disposed in sealing, or substantially sealing engagement with the liner
132. As discussed
above, the sealing, or substantially sealing, disposition of the separator 108
relative to the
separator co-operating fluid conductor 106 is effected by at least: (a) the
sealing, or substantially
sealing, engagement of the liner 132 with the separator co-operating fluid
conductor 106, and (b)
the sealing, or substantially sealing, engagement of the separator 108 with
the liner 132. The
first inlet port 114 is disposed for receiving at least reservoir fluid via
the liner fluid passage 134.
In some embodiments, for example, the separator 108 further includes a latch
seal assembly 200
releasably coupled to the liner 132, wherein the sealing, or substantially
sealing, engagement
between the liner 132 and the separator 108 is effected by the latch seal
assembly 200. In some
embodiments, for example, the sealing, or substantially sealing, engagement
between the liner
132 and the separator co-operating fluid conductor 106 is effected by a packer
136 disposed
between the liner 132 and the separator co-operating fluid conductor 106.
[00105] Referring to Figure 8, in some of these embodiments, for example, and
as discussed
above, the separator co-operating fluid conductor 106 includes a constricted
portion 138, and the
separator 108 is disposed in sealing, or substantially sealing, engagement
with the constricted
portion 138, such that the sealing, or substantially sealing, disposition of
the separator 108
relative to the separator co-operating fluid conductor 106 is effected by at
least the sealing, or
substantially sealing, engagement of the separator 108 with the constricted
portion 138. In some
embodiments, for example, the sealing, or substantially sealing, engagement
between the
separator 108 and the constricted portion 136 is effected by at least a
sealing member 202 that is
carried by the separator 108. In some embodiments, for example, the separator
108 is disposed
in an interference fit relationship with the constricted portion 138.
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[00106] By providing for a sump 206 having the above-described volumetric
space
characteristic, and/or the above-described minimum separation distance
characteristic, a suitable
space is provided for collecting relative large volumes of solid debris, such
that interference by
the accumulated solid debris with the production of oil through the system is
mitigated. This
increases the run-time of the system before any maintenance is required. As
well, because the
solid debris is deposited over a larger area, the propensity for the collected
solid debris to
interfere with movement of the separator 108 relative to the separator co-
operating fluid
conductor 106, such as during maintenance (for example, a workover) is
reduced.
[00107] In further related aspects, a separator 108 is provided for effecting
separation of
materials from reservoir fluid within a wellbore fluid conductor 100 disposed
within a wellbore
The wellbore fluid conductor 100 including a separator co-operating fluid
conductor 106, the
separator co-operating fluid conductor 106 including a downhole wellbore fluid
passage for
receiving reservoir fluids from the reservoir and for conducting at least
reservoir fluids. The
separator 108 includes:
(a) a first inlet port 114 for receiving at least reservoir fluids from the
downhole wellbore
fluid passage 112;
(b) a first outlet port 116;
(c) a reservoir fluid-conducting passage 118 extending between the first
inlet port 114 and
the first outlet port 116;
(d) a second inlet port 120, positioned relative to the first outlet port
116 such that, when the
separator 108 is disposed within the wellbore 14 and oriented for receiving at
least reservoir
fluids via the first inlet port 114, the second inlet port 120 is disposed
downhole relative to the
first outlet port 116;
(e) a second outlet port 112;
(f) a gas-depleted fluid conducting passage 124 extending between the
second inlet port 120
and the second outlet port 122;
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(g) a co-operating surface portion 125 configured for co-operating with the
separator co-
operating fluid conductor 106, when the separator 108 is disposed within the
wellbore and
oriented for receiving at least reservoir fluids via the first inlet port 114,
to define an intermediate
fluid passage 126 therebetween for effecting fluid communication between the
first outlet port
116 and the second inlet port 120;
(h) a seal support portion 1081 having an outer surface 1083; and
(i) a sealing member 202.
[00108] Referring to Figures 2 and 9, the sealing member 202 is supported by
the seal support
portion 1081. The sealing member 202 is configured for sealingly, or
substantially sealingly,
engaging the separator co-operating fluid conductor 106. The sealing member
202 is positioned
relative to the second inlet port 120 such that, when the separator 108 is
disposed within the
wellbore 114 and oriented for receiving at least reservoir fluids via the
first inlet port 114, the
sealing member 202 is disposed downhole relative to the second inlet port 120
and in sealing, or
substantially sealing, engagement with the separator co-operating fluid
conductor 106.
[00109] In a first related aspect, the sealing member 202 is further
configured such that, when
the separator 108 is disposed within the wellbore 14 and oriented for
receiving at least reservoir
fluids via the first inlet port 114, and the sealing member 202 is sealingly,
or substantially
sealingly, engaged to the separator co-operating fluid conductor 106, the
sealing member 202,
having an exposed surface portion 202, that is disposed in fluid communication
with the
intermediate fluid passage 126, is extending across a gap, between the
separator 108 and the
separate co-operating fluid conductor 106, having a minimum distance of less
than 2.5
millimetres. In some embodiments, for example, the gap has a minimum distance
of less than
one (1.0) millimetre.
[00110] In a second related aspect, the sealing member 202 projects outwardly
from the outer
surface 103 by a distance of less than 2.5 millimetres, such as less than one
(1.0) millimetre. In
some embodiments, for example, the sealing member 202 is retractable, such
that, in the
retracted state, the sealing member 202 projects outwardly from the outer
surface 103, by a
distance of less than 2.5 millimetres, such as less than one (1.0) millimetre
(it is understood that,
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in an extended state, such sealing member may project outwardly more than 2.5
millimitres when
there is no resistance to deployment of the sealing member).
[00111] In a third related aspect, the separator 108 further includes a latch
seal assembly 200,
carrying the sealing member 202, and co-operatively configured for releasable
connection to the
separate co-operating fluid conductor 106.
[00112] The above-described configurations for the sealing member 202 of the
separator 108,
provide for conditions which minimize solid debris accumulation in the joint
between the
separator 108 and a separator co-operating fluid conductor 106, when the
separator 108 is
installed downhole and coupled to the separator co-operating fluid conductor
106. By providing
for conditions which minimize solid debris accumulation within the joint,
interference to
movement of the separator 108 relative to the separator co-operating fluid
conductor 106, which
could be effected by accumulated solid debris, is mitigated.
[00113] In the above description, for purposes of explanation, numerous
details are set forth in
order to provide a thorough understanding of the present disclosure. However,
it will be
apparent to one skilled in the art that these specific details are not
required in order to practice
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. All references mentioned are hereby
incorporated by reference
in their entirety.
29
