Note: Descriptions are shown in the official language in which they were submitted.
DOWNHOLE SEPARATOR
FIELD
[0001] The present disclosure relates to mitigating gas interference with
downhole pump operation during hydrocarbon production.
BACKGROUND
[0002] 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.
[0003] 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
[0004] In one aspect, there is provided a downhole sub 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 sub-
defined
flow conductor configuration is established;
wherein:
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Date Recue/Date Received 2022-05-16
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;
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Date Recue/Date Received 2022-05-16
the sub-defined flow conductor configuration defines at least a portion of the
upwardly-conducting flow conductor configuration;
at least a portion of the sub-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.
[0005] In another aspect, there is provided a kit comprising the sub, as
described above, and an elongated member for connection to a portion of the
sub-
defined flow conductor configuration and also for connection to a separator of
the
gas-depleted fluid production assembly, such that, while the sub is integrated
within the gas-depleted fluid production assembly of a reservoir fluid
production
assembly, the separator is supported by the sub-defined flow conductor
configuration.
[0006] In another aspect, there is provided a reservoir fluid production
assembly, disposed within a wellbore string passage of a wellbore string that
is
emplaced within a wellbore, comprising:
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;
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Date Recue/Date Received 2022-05-16
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 and a
separator-co-operating sub
the separator includes a housing and defines a separator-defined flow
conductor configuration
the separator-defined flow conductor configuration includes a separator-
defined upwardly-conducting flow conductor configuration ("separator-defined
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Date Recue/Date Received 2022-05-16
UCFCC"), and the separator-defined UCFCC defines a portion of the upwardly-
conducting flow conductor configuration;
the housing defines a gas-depleted reservoir fluid discharging flow
communicator;
the separator-co-operating sub defines a sub-defined flow conductor
configuration;
the sub-defined flow conductor configuration defines at least a portion of the
upwardly-conducting flow conductor configuration, and is disposed for
receiving the
gas-depleted reservoir fluid flow being conducted by the separator-defined
UCFCC;
at least a portion of the sub-defined flow conductor configuration includes a
flow interference-mitigating conductor configuration that extends through the
separation zone-defining wellbore section;
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; and
integration of the sub within the gas-depleted fluid production assembly is
established by: (i) a connection of the sub to the gas-depleted reservoir
fluid
discharging flow communicator, wherein the connection of the sub to the gas-
depleted reservoir fluid discharging flow communicator is with effect that the
sub-
defined flow conductor configuration is disposed in flow communication with
the
separator-defined UCFCC, such that the sub-defined flow conductor
configuration is
disposed for receiving the gas-depleted reservoir fluid flow being conducted
by the
separator-defined UCFCC, and (ii) a connection of the sub to the pump suction,
wherein the connection of the sub to the pump suction is with effect that the
sub-
defined flow conductor configuration is disposed for supplying the gas-
depleted
reservoir fluid flow to the pumping assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
Date Recue/Date Received 2022-05-16
[0007] Reference will now be made, by way of example, to the accompanying
drawings which show example embodiments of the present application, and in
which:
[0008] Figure 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;
[0009] Figure 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;
[0010] Figure 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;
[0011] Figure 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;
[0012] Figure 5 is a schematic illustration of an embodiment of a separator
co-
operating sub that is integrated within the embodiments of the gas-depleted
fluid
production assembly illustrated in Figures 1, 2, and 3;
[0013] Figure 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 Figures 1, 2, and 3;
[0014] Figure 7 is a schematic illustration of an embodiment of a separator
co-
operating sub that is integrated within the embodiment illustrated in Figure
4;
[0015] Figure 8 is an enlarged view of Detail "A" in Figure 4; and
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Date Recue/Date Received 2022-05-16
[0016] Figure 9 is a top plan view of the production system, taken along
the
cross-section "XC" in Figure 8.
[0017] Similar reference numerals may have been used in different figures
to
denote similar components.
DESCRIPTION OF EXAMPLE EMBODIMENTS
[0018] Referring to Figures 1 to 7, there are provided systems 10 for
producing
hydrocarbon material from an oil reservoir within a subterranean formation
100.
[0019] 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.
[0020] "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.
[0021] The term "fluid conductor configuration" refers to a configuration
which
conducts fluid. The configuration can be: (a) a single conductor, (b) a
plurality of
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Date Recue/Date Received 2022-05-16
parallel conductors, (c) a network of interconnected conductors, or any
combination
of (a), (b), and (c).
[0022] 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.
[0023] The fluid productive portion of the wellbore 102 may be completed
either as a cased-hole completion or an open-hole completion.
[0024] 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.
[0025] 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.
[0026] 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
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Date Recue/Date Received 2022-05-16
last casing string and the production string may be sealed at the bottom by a
packer.
[0027] 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.
[0028] 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.
[0029] 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.
[0030] 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
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Date Recue/Date Received 2022-05-16
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.
[0031] 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.
[0032] 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.
[0033] 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 punnpjack. 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
Date Recue/Date Received 2022-05-16
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 punnpjack.
[0034] 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.
[0035] 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.
[0036] 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
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Date Recue/Date Received 2022-05-16
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.
[0037] 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.
[0038] 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.
[0039] 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".
[0040] 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
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Date Recue/Date Received 2022-05-16
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.
[0041] 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.
[0042] 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.
[0043] 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.
[0044] 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.
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Date Recue/Date Received 2022-05-16
[0045] In some embodiments, for example, a separator co-operating sub 401
is integrated within the gas-depleted fluid production assembly 400. In this
respect, in some embodiments, for example, the sub 401 is integratable within
the
gas-depleted fluid production assembly 400 such that there is established a
sub-
defined flow conductor configuration 4011A, and the sub-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 sub 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 sub 401 is threaded at
each
end.
[0046] At least a portion of the sub-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.
[0047] 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.
[0048] Referring to Figure 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
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Date Recue/Date Received 2022-05-16
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.
[0049] Referring again to Figure 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.
[0050] 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.
[0051] Referring to Figure 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
Date Recue/Date Received 2022-05-16
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.
[0052] In some embodiments, for example, the flow interference-mitigating
conductor configuration 4011B co-operates with the wellbore string 108 to
define a
cylindrical uninterrupted space 4051 which 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 uninterrupted space 4051.
In
some embodiments, for example, the central longitudinal axis 110X of wellbore
string passage 110 extends through the cylindrical uninterrupted space 4051.
In
some embodiments, for example, the uninterrupted space 4051 defines a portion
of
the separation zone 405. Referring to Figure 8, in some embodiments, for
example, the cylindrical uninterrupted 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.
[0053] Referring to Figures 4 and 7, in some embodiments, for example, the
sub 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,
16
Date Recue/Date Received 2022-05-16
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 sub 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 sub
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.
[0054] By integrating the sub 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.
[0055] Referring to Figures 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
17
Date Recue/Date Received 2022-05-16
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.
[0056] 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 sub 401 within the gas-depleted fluid production assembly
400 is
established by: (i) a connection of the sub 401 to the gas-depleted reservoir
fluid
discharging flow communicator 409, wherein the connection of the sub 401 to
the
gas-depleted reservoir fluid discharging flow communicator 409 is with effect
that
the sub-defined flow conductor configuration 4011A is disposed in flow
communication with the separator-defined UCFCC 406A, such that the sub-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 sub 401 to the pump suction 301A, wherein the connection
of
the sub 401 to the pump suction 301A is with effect that the sub-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 sub 401.
[0057] 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,
18
Date Recue/Date Received 2022-05-16
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
Figure 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.
[0058] Referring to Figures 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
Figure 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
19
Date Recue/Date Received 2022-05-16
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 sub-defined flow
conductor configuration 4011A to the pump 300. In some of these embodiments,
for example, the separator 400A is a "poor boy separator".
[0059] Referring to Figures 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
Date Recue/Date Received 2022-05-16
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 sub-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
21
Date Recue/Date Received 2022-05-16
(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.
[0060] Referring specifically to Figure 3, in some embodiments, for
example,
the gas-depleted fluid production assembly 400 within which the sub 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.
[0061] Referring to Figure 6, in some embodiments, for example, the
separator
400A is supported by an elongated member 800 connected to a portion of the sub-
defined flow conductor configuration 4011A. In some of these embodiments, for
example, the connection of the elongated member 800 to the sub-defined flow
conductor configuration 4011A is to a portion of the sub-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
22
Date Recue/Date Received 2022-05-16
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.
[0062] Referring to Figure 7, in those embodiments where the sub 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 sub 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.
[0063] In some embodiments, for example, the sub 401 is provided for the
integration within the gas-depleted fluid production assembly 400. In some
embodiments, for example, the sub 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.
[0064] 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 separator co-operating sub 401 within the gas-
depleted
fluid production assembly 400 such that a modified system 10A is obtained (see
Figures 5 to 7). In some embodiments, for example, after the modifying,
hydrocarbon material is produced from the subterranean formation via the
modified
system 10A.
23
Date Recue/Date Received 2022-05-16
[0065] 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.
[0066] 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 sub 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.
[0067] 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
24
Date Recue/Date Received 2022-05-16
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.
Date Recue/Date Received 2022-05-16
