Downhole flow diverter with arcuate-shaped flow conductor

There is provided a flow diverter for coupling to a reservoir fluid conductor, a gas-depleted reservoir fluid conductor, and a sealed interface effector for establishing a production assembly configured for disposition in a production effective orientation within a wellbore string of a wellbore, extending into a subterranean formation, for effecting production from the subterranean formation. The flow diverter includes a body and a body co-operator. The body co-operator is joined to the body at a joint with effect that at least a portion of the intermediate passage-defining outermost surface of the flow diverter is defined by the outermost surface of the body co-operator.

Skip to: Description  ·  Claims  · Patent History  ·  Patent History
Description
CROSS-REFERENCE TO RELATED APPLICATION

The present application claims priority to and the benefit of U.S. provisional application Ser. No. 63/176,733, filed on Apr. 19, 2021, the contents of which are hereby incorporated in their entirety.

FIELD

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

BACKGROUND

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

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

SUMMARY

In one aspect, there is provided a flow diverter for coupling to a reservoir fluid conductor, a gas-depleted reservoir fluid conductor, and a sealed interface effector for establishing a production assembly configured for disposition in a production effective orientation within a wellbore string of a wellbore, extending into a subterranean formation, for effecting production from the subterranean formation, wherein the flow diverter defines:

    • a reservoir fluid receiver;
    • a reservoir fluid discharging communicator;
    • a reservoir fluid conducting passage effecting flow communication between the reservoir fluid receiver and the fluid discharging communicator;
    • a gas-depleted reservoir fluid receiver;
    • a gas-depleted reservoir fluid discharging communicator; and
    • a gas-depleted reservoir fluid conducting passage effecting flow communication between the gas-depleted reservoir fluid receiver and the gas-depleted reservoir fluid discharging communicator;

wherein:

    • the reservoir fluid conductor defines a reservoir fluid conductor receiver and a reservoir fluid conductor fluid passage for conducting reservoir fluid received by the reservoir fluid conductor fluid receiver, and the coupling of the reservoir fluid conductor to the flow diverter is with effect that reservoir fluid, receivable by the reservoir fluid conductor receiver is conductible to the reservoir fluid receiver of the flow diverter;
    • the gas-depleted reservoir fluid conductor defines a fluid passage, and the coupling of the gas-depleted reservoir fluid conductor to the flow diverter is with effect that gas-depleted reservoir fluid, dischargeable from the gas-depleting reservoir fluid discharging communicator of the flow diverter, is conductible to the surface by the fluid passage of the gas-depleted reservoir fluid conductor;
    • the production assembly is configured such that, while disposed within the wellbore string in a production effective orientation:
      • the reservoir fluid receiver of the flow diverter is disposed downhole relative to the reservoir fluid discharging communicator of the flow diverter;
      • the gas-depleted reservoir fluid receiver of the flow diverter is disposed downhole relative to the gas-depleted reservoir fluid discharging communicator of the flow diverter;
      • the reservoir fluid discharging communicator of the flow diverter is disposed uphole relative to the gas-depleted reservoir fluid receiver of the flow diverter; and
      • intermediate fluid passage-defining outermost surface of the flow diverter co-operates with the wellbore string for establishing an intermediate fluid passage between the intermediate fluid passage-defining outermost surface of the flow diverter and the wellbore string;
    • the intermediate fluid passage is disposed for effecting flow communication between the reservoir fluid discharging communicator and the gas-depleted reservoir fluid receiver;
    • the reservoir fluid conductor receiver, the reservoir fluid conductor fluid passage, the reservoir fluid receiver of the flow diverter, the reservoir fluid conducting passage of the flow diverter, and the reservoir fluid discharging communicator of the flow diverter are co-operatively configured such that, while the production assembly is disposed within the wellbore string in the separation-effective orientation, the sealed interface effector is disposed in sealing disposition with the wellbore string such that a sealed interface is defined, and reservoir fluid flow is being received by the reservoir fluid conductor receiver, the received reservoir fluid flow is conducted to the reservoir fluid discharging communicator, via the reservoir fluid conductor fluid passage, the reservoir fluid receiver of the flow conductor, and the reservoir fluid conducting passage of the flow diverter, for discharging from the flow diverter via the reservoir fluid discharging communicator;
    • the gas-depleted reservoir fluid conducting passage of the flow diverter, the gas-depleted reservoir fluid receiver of the flow diverter, the gas-depleted reservoir fluid discharging communicator of the flow diverter, and the fluid passage of the gas-depleted reservoir fluid conductor are co-operatively configured such that, while the production assembly is disposed within the wellbore string in the production-effective orientation, the sealed interface effector is disposed in sealing disposition with the wellbore string such that a sealed interface is defined, and gas-depleted reservoir fluid flow is being received by the gas-depleted reservoir fluid communicator of the flow diverter, the received gas-depleted reservoir fluid flow is conducted, via the gas-depleted reservoir fluid conducting passage of the flow diverter, the gas-depleted reservoir fluid discharging communicator of the flow diverter, and the fluid passage of the gas-depleted reservoir fluid conductor, such that the gas-depleted reservoir fluid becomes disposed uphole relative to the gas-depleted reservoir fluid receiver;
    • the reservoir fluid discharging communicator of the flow diverter, the sealed interface effector, and the gas-depleted reservoir fluid receiver of the flow diverter are co-operatively configured such that, while the production assembly is disposed within the wellbore string in the production-effective orientation, the sealed interface effector is disposed in sealing disposition with the wellbore string such that a sealed interface is defined, and reservoir fluid flow is being discharged from the reservoir fluid discharging communicator:
      • the reservoir fluid becomes disposed externally of the separator within a wellbore space within the wellbore string;
      • a gas-depleted reservoir fluid is separated from the discharged reservoir fluid, within the wellbore space, in response to at least buoyancy forces; and
      • bypassing of the gas-depleted reservoir fluid receiver, by the gas-depleted reservoir fluid, that is being conducted downhole via the intermediate wellbore passage, is prevented by the sealed interface effector, such that the gas-depleted reservoir fluid is received by the gas-depleted reservoir fluid receiver;
    • the flow diverter includes a body and a body co-operator;
    • the body defines:
      • the reservoir fluid receiving communicator;
      • the gas-depleted reservoir fluid receiving communicator;
      • the gas-depleted reservoir fluid-conducting passage; and
      • the gas-depleted reservoir fluid discharging communicator;
    • the body co-operator includes an outermost surface;
    • the body co-operator is joined to the body at a joint with effect that at least a portion of the intermediate passage-defining outermost surface of the flow diverter is defined by the outermost surface of the body co-operator;
    • the body and the body co-operator co-operate to define an externally-disposed reservoir fluid conducting passage;

at least a portion of the reservoir fluid conducting fluid passage is defined by the externally-disposed reservoir fluid conducting passage.

BRIEF DESCRIPTION OF THE DRAWINGS

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

FIG. 1 is a schematic illustration of an embodiment of a system of the present disclosure;

FIG. 2 is a perspective view of a flow diverter according to an example embodiment of the present disclosure;

FIG. 3 top view of the flow diverter of FIG. 2;

FIG. 4 is a side cross-sectional view of the flow diverter of FIG. 3, taken along section line A-A of FIG. 3;

FIG. 5 is a perspective view of a section of the body of the flow diverter of FIG. 3;

FIG. 6 is a view of one side of the section illustrated in FIG. 6;

FIG. 7 is a cross-sectional view of another side of the section of FIG. 6 taken along section line A-A of FIG. 6;

FIG. 8 is a view of another side of the section illustrated in FIG. 6, with the view having being rotated 180 degrees relative to the view illustrated in FIG. 6;

FIG. 9 is a perspective view of an arcuate shell section of the body co-operator of the flow diverter of FIG. 2;

FIG. 10 is a side view of the body co-operator of FIG. 9;

FIG. 11 is an end view of the body co-operator of FIG. 9;

FIG. 12 is a cross-sectional view of the body co-operator of FIG. 10, taken along section line A-A of FIG. 11; and

FIGS. 13, 14, and 15 are identical to FIGS. 2, 3, and 4, respectively, and schematically illustrate the flows through the flow diverter during production.

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

 DESCRIPTION OF EXAMPLE EMBODIMENTS

Referring to FIGS. 1-15 there is provided a system for producing hydrocarbons from an oil reservoir within a subterranean formation 100.

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

“Reservoir fluid” is fluid that is contained within an oil reservoir. Reservoir fluid 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 condensates, or any combination thereof. Reservoir fluid may also include fluids injected into the reservoir for effecting stimulation of resident fluids within the reservoir.

A wellbore string 200 is emplaced within the wellbore 102 for stabilizing the subterranean formation 100. In some embodiments, for example, the wellbore string 200 also contributes to effecting fluidic isolation of one zone within the subterranean formation 100 from another zone within the subterranean formation 100.

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

With respect to a cased-hole completion, in some embodiments, for example, a wellbore string 200, in the form of a wellbore casing that includes one or more casing strings, each of which is positioned within the wellbore 102, having one end extending from the wellhead 106, is provided. In some embodiments, for example, each casing string is defined by jointed segments of pipe. The jointed segments of pipe typically have threaded connections.

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

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

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

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

An open-hole completion is effected by drilling down to the producing formation, and then lining the wellbore (such as, for example, with a wellbore string 200). The wellbore is then drilled through the producing formation, and the bottom of the wellbore is left open (i.e. uncased), to effect flow communication between the reservoir and the wellbore.

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

In some embodiments, for example, the system 10 includes a production assembly 300 disposed within the wellbore 102. The production assembly 300 is suspended within the wellbore 102 from the wellhead 106.

The production assembly 300 includes a reservoir fluid conductor 400, a flow diverter 500, a sealed interface effector 600, and a gas-depleted reservoir fluid conductor 700. The gas-depleted reservoir fluid conductor 700 includes a pump 800 for pressurizing the gas-depleted reservoir fluid being conducted through the gas-depleted reservoir fluid conductor 700.

The production assembly 300 is configured for producing reservoir fluid while, amongst other things, mitigating gas lock within the pump 800.

In this respect, the reservoir fluid conductor 400 includes a reservoir fluid receiver 402 for receiving reservoir fluid which has become emplaced within a downhole-disposed space 110 of the wellbore 102 after having been conducted from the subterranean formation 100. The reservoir fluid conductor 400 defines a reservoir fluid-conducting passage 404 for conducting the received reservoir fluid to the flow diverter 500. In this respect, the reservoir fluid conductor 400 is coupled to the flow diverter 500. The flow diverter 500 includes a reservoir fluid receiver 502, and the coupling of the reservoir fluid conductor 400 is with effect that the reservoir fluid-conducting passage 404 is disposed in flow communication with the reservoir fluid receiver 502 for supplying the reservoir fluid as flow 902.

The flow diverter 500 further includes a reservoir fluid discharge communicator 504 for discharging reservoir fluid into an uphole wellbore space 108 of the wellbore 102. While the assembly 300 is disposed in the production effective orientation, the reservoir fluid discharge communicator 504 is disposed vertically above the reservoir fluid receiver 502. In some embodiments, for example, the central axis of the reservoir fluid discharge communicator 504 is disposed at an angle of less than 20 degrees relative to the central longitudinal axis of the wellbore 102.

The uphole wellbore space 108 is disposed vertically above the downhole wellbore space 110. In some embodiments, for example, the uphole wellbore space 108 is disposed within a vertical portion of the wellbore 102. In some embodiments, for example, the uphole-disposed space 108 spans a continuous space extending from the assembly 300 to the wellbore string 200, and the continuous space extends outwardly relative to the central longitudinal axis of the assembly 300. In some embodiments, for example, the uphole-disposed space 108 spans a continuous space extending from the assembly 300 to the wellbore string 200, and the continuous space extends outwardly relative to the central longitudinal axis of the wellbore 102. In some embodiments, for example, the reservoir fluid discharging communicator 504 is disposed immediately below the uphole-disposed space 108.

In some embodiments, for example, the discharging is with effect that the discharged reservoir fluid becomes disposed vertically above the reservoir fluid discharge communicator 504. While the reservoir fluid is disposed within the uphole-disposed space 108, a gas-depleted reservoir fluid is separated from the reservoir fluid in response to at least buoyancy forces.

The flow diverter 500 further defines a reservoir fluid-conducting passage 506. The reservoir fluid-conducting passage 506 effects flow communication between the reservoir fluid receiver 502 and the reservoir fluid discharge communicator 504, for conducting the received reservoir fluid from the reservoir fluid receiver 502 to the reservoir fluid discharge communicator 504.

In some embodiments, for example, while the assembly 300 is disposed within the wellbore 102 in the production effective orientation, the reservoir fluid-conducting passage 404, the reservoir fluid-conducting passage 506, and the uphole-disposed space 108 are co-operatively configured such that, in operation, while the reservoir fluid is being supplied to the uphole-disposed space 108 via the reservoir fluid discharging communicator 504, the velocity of the gaseous portion of the reservoir fluid, being conducted via the reservoir fluid-conducting passage 404, and the reservoir fluid-conducting passage 506, is greater than the critical liquid lifting velocity, such that separation of gases and liquids is mitigated, and while the reservoir fluid is disposed within the uphole-disposed space 108, the velocity of the gaseous portion of the reservoir fluid is sufficiently low such that the above-described separation, within the uphole-disposed space 108, is effected.

In this respect, in some embodiments, for example, for each one of the reservoir fluid-conducting passages 404, 506, the maximum cross-sectional flow area is smaller than the minimum cross-sectional flow area of the uphole-disposed space 108. In some of these embodiments, for example, the ratio of the minimum cross-sectional flow area of the uphole-disposed space 108 to the maximum cross-sectional flow area of the reservoir fluid conducting passage 404 is at least 1.5, and the ratio of the minimum cross-sectional flow area of the uphole-disposed space 108 to the maximum cross-sectional flow area of the reservoir fluid conducting passage 506 is at least 1.5. In some embodiments, for example, the reservoir fluid conductor 400 is a velocity string.

The flow diverter 500 further defines a gas-depleted reservoir fluid receiver 508 for receiving the gas-depleted reservoir fluid that has been separated from the reservoir fluid. While the assembly 300 is disposed within the wellbore 102 in the production effective orientation, the gas-depleted reservoir fluid receiver 508 is disposed vertically below the reservoir fluid discharging communicator 506.

In some embodiments, for example, flow of the separated gas-depleted reservoir fluid is conductible to the gas-depleted reservoir fluid communicator 508 via an established flow communication between the uphole-disposed space 108 and the gas-depleted reservoir fluid receiving communicator 508. In this respect, in some embodiments, for example, the wellbore string 200 and the assembly 300 are co-operatively configured such that, while the assembly 300 is disposed within the wellbore string 200 in the production effective orientation: (i) the gas-depleted reservoir fluid receiving communicator 508 is disposed below the reservoir fluid discharging communicator 410, (ii) an intermediate fluid passage 112 is established between the assembly 300 and the wellbore string 200 and effects flow communication between the reservoir fluid discharging communicator 506 (and, therefore, the uphole wellbore space 108) and the gas-depleted reservoir fluid receiving communicator 508. By virtue of the flow communication that is effected between the reservoir fluid discharging communicator 506 and the gas-depleted reservoir fluid receiving communicator 508 by the intermediate fluid passage 112, a gas-depleted reservoir fluid flow is conductible downhole for receiving by the gas-depleted reservoir fluid receiving communicator 508. In some embodiments, for example, the separating of gaseous material from the reservoir fluid includes separating that is effected while the reservoir fluid is being conducted downhole via the intermediate passage 112.

In some embodiments, for example, the intermediate fluid passage 112 is an annular space disposed between the assembly 300 and the wellbore string 200. In some embodiments, for example, the intermediate fluid passage 112 is defined by the space that extends outwardly, relative to the central longitudinal axis of the assembly 300, from an outermost surface of the assembly 300 to the wellbore string 200. In some embodiments, for example, the intermediate wellbore passage 112 extends longitudinally to the wellhead 106, between the assembly 300 and the wellbore string 200.

In some embodiments, for example, the flow diverter 500 defines an intermediate fluid passage-defining outermost surface 501 which co-operates with the wellbore string 200 for establishing the intermediate fluid passage 112. In this respect, the intermediate fluid passage 112 is disposed between the intermediate fluid passage-defining outermost surface 501 of the flow diverter 500 and the wellbore string 200.

In some embodiments, for example, the wellbore string 200 and the assembly 300 are further co-operatively configured such that, while the assembly 300 is disposed within the wellbore string 200 in a production effective orientation, in response to sealing disposition of the sealed interface effector 600 relative to the wellbore string 200, a sealed interface 602 is defined, and bypassing of the gas-depleted reservoir fluid receiving communicator 508, by the separated gas-depleted reservoir fluid, is prevented by the sealed interface 602. In this respect, in some embodiments, for example, the sealed interface 602 is established within the wellbore 102 above the downhole wellbore space 110 and below the gas-depleted reservoir fluid receiver 508. In some embodiments, for example, the disposition of the sealed interface 602 is such that flow communication, via the intermediate wellbore passage 112, between the uphole wellbore space 108 and the downhole wellbore space 110, is prevented. In this respect, the sealed interface functions to prevent, the gas-depleted reservoir fluid from bypassing the gas-depleted reservoir fluid receiving communicator 508, and, accordingly, diverts the flow of the gas-depleted reservoir fluid to the gas-depleted reservoir fluid receiver 508.

In some embodiments, for example, the sealed interface 602 is disposed within a vertical section of the wellbore 102. In some embodiments, for example, the sealed interface effector 600 includes a packer.

The flow diverter 500 further defines a gas-depleted reservoir fluid discharge communicator 510. While the assembly 300 is disposed in the production effective orientation, the gas-depleted reservoir fluid discharge communicator 510 is disposed above the gas-depleted reservoir fluid receiver 508. The gas-depleted reservoir fluid receiver 508 is disposed in flow communication with the gas-depleted reservoir fluid discharge communicator 510 via a gas-depleted reservoir fluid-conducting passage 512. In this respect, the flow diverter 500 defines the gas-depleted reservoir fluid-conducting passage 512, and isolates flow of the gas-depleted reservoir fluid, through the flow diverter 500, from contemporaneous flow of reservoir fluid through the flow diverter 500 via the reservoir fluid-conducting passage 506.

The gas-depleted reservoir fluid is discharged, via the gas-depleted reservoir fluid discharge communicator 510, from the flow diverter 500 and to the gas-depleted reservoir fluid conductor 700 for conducting to the surface 104 as flow 904. In this respect, the gas-depleted reservoir fluid conductor 700 is fluidly coupled to the reservoir fluid discharge communicator 510.

The pump 800 forms part of the gas-depleted reservoir fluid conductor 700. In this respect, the gas-depleted reservoir fluid conductor 700 includes an upstream conductor portion 702 and a downstream conductor portion 704. The upstream conductor portion 702 extends from the gas-depleted reservoir fluid discharge communicator 510 to the suction 802 of the pump 800. The downstream conductor portion 704 extends from the discharge 804 of the pump 800 to the surface 104.

The separation of the gaseous material from the reservoir fluid is also with effect that a liquid-depleted reservoir fluid is obtained. The liquid-depleted reservoir fluid is conducted uphole, in the gaseous phase, or at least primarily in the gaseous phase, with relatively small amounts of entrained liquid, as gaseous flow 906 via the intermediate fluid passage 112 that is disposed between the assembly 300 and the wellbore string 200.

The reservoir fluid produced from the subterranean formation 100, via the wellbore 102, including the gas-depleted reservoir fluid, the liquid-depleted reservoir fluid, or both, may be discharged at the surface 104 from the wellbore 102 through the wellhead 106 to a collection facility, such as a storage tank within a battery.

With reference now to FIGS. 2-15, there is shown an example embodiment of the flow diverter 500. The flow diverter 500 includes a body 500A and a body co-operator 500B. The body co-operator 500B is joined to the body 500A at a joint 514. In some embodiments, for example, the joining of the body co-operator 500B to the body 500 is to an outermost surface 524 of the body.

In some embodiments, for example, the body co-operator 500B is defined by a plurality of sections. In this respect, in some embodiments, for example, the body co-operator 500B includes an arcuate shell section 550 and an end cap 552. The end cap 552 is joined to one end 551 of the arcuate shell section 550 for sealing the end 551.

The body 500A defines the reservoir fluid receiving communicator 502, the gas-depleted reservoir fluid receiving communicator 508, the gas-depleted reservoir fluid-conducting passage 512, and the gas-depleted reservoir fluid discharging communicator 510.

The body 500A and the body co-operator 500B co-operate to define an externally-disposed reservoir fluid conducting passage 520. The externally-disposed reservoir fluid conducting passage 520 is disposed externally of the body 500A. The externally-disposed reservoir fluid conducting passage 520 is defined, in part, by the outermost surface 524 of the body 500A. In some embodiments, for example, the externally-disposed reservoir fluid conducting passage 520 has a length of at least 12 inches, measured along the central longitudinal axis 522 of the externally-disposed reservoir fluid conducting passage 520. In some embodiments, for example, the externally-disposed reservoir fluid conducting passage 520 is defined between the body co-operator 500B and the body 500A.

At least a portion of the reservoir fluid conducting fluid passage 506 is defined by the externally-disposed reservoir fluid conducting passage 520. In some embodiments, for example, the body 500A further defines a body-defined reservoir fluid conducting passage 526, and the reservoir fluid-conducting passage 506 further includes the body-defined flow reservoir fluid conducting passage 526, such that the body-defined reservoir fluid-conducting passage 526 is disposed in flow communication with the externally-disposed reservoir fluid conducting passage 520. In some embodiments, for example, the flow communication is established via an externally-disposed reservoir fluid conducting passage communicator 528, which is defined by the body 500A. In some embodiments, for example, the externally-disposed reservoir fluid conducting passage communicator 528 is defined within the outermost surface 524 of the body 500A.

In some embodiments, for example, the co-operation of the body 500A and the body co-operator 500B is with additional effect that the reservoir fluid discharging communicator 504 is defined by the joining of the body 500A and the body co-operator 500B.

The body co-operator 500B defines an outermost surface 516.

In some embodiments, for example, the outermost surface 516 of the body co-operator 500B defines a convex surface portion 532. The convex surface portion 532, of the outermost surface 516 of the body co-operator 500B, is a continuous surface portion, of the outermost surface 516 of the body co-operator 500B. The convex surface portion 532 is convex relative to the central longitudinal axis 522 of the externally-disposed reservoir fluid conducting passage 520.

In some embodiments, for example, the outermost surface 516 has a dimension, measured along a plane to which the central longitudinal axis 522 of the externally-disposed reservoir fluid conducting passage 520 is perpendicular, of at least 1.5 inches. In some embodiments, for example, the outermost surface 516 has a dimension, measured along a plane to which the central longitudinal axis 522 of the externally-disposed reservoir fluid conducting passage 520 is coincident, of at least 12 inches.

In some embodiments, for example, the outermost surface 516 has a surface area of at least 40 square inches. In some embodiments, for example, the convex surface portion 532 defines at least 70% of the outermost surface 516. In some embodiments, for example, the convex surface portion 532 defines at least 80% of the outermost surface 516. In some embodiments, for example, the convex surface portion 532 defines at least 90% of the outermost surface 516. In some embodiments, for example, the convex surface portion 532 defines the entirety of the outermost surface 516.

The joining of the body co-operator 500B to the body 500 is with effect that at least a portion of the intermediate passage-defining outermost surface 501 of the flow diverter 500 is defined by the convex surface portion 532 of the outermost surface 516 of the body co-operator 500B, such that the at least a portion of the intermediate passage-defining outermost surface 501 of the flow diverter 500 defines the convex surface portion 532.

In some embodiments, for example, the convex surface portion 532 of the outermost surface 516 of the body co-operator 500B defines at least one outermost surface-defined arc 518.

Each one of the at least one outermost surface-defined arc 518, independently, extends outwardly relative to the central longitudinal axis 522 of the externally-disposed reservoir fluid conducting passage 520.

In some embodiments, for example, each one of the at least one outermost surface-defined arc 518, independently, has a minimum arc length of at least 1.5 inches.

Referring to FIGS. 11 and 12, in some embodiments, for example, each one of the at least one outermost surface-defined arc 518, independently, is disposed within a respective arc-defining plane 530 that traverses the central longitudinal axis 522 of the externally-disposed reservoir fluid conducting passage 520, such that at least one arc-defining plane is defined. In some embodiments, for example, for each one of the at least one arc-defining plane 530, independently, the central longitudinal axis 522 of the externally-disposed reservoir fluid conducting passage 520 is disposed, relative to the arc-defining plane 530, at an angle selected from the group consisting of: (i) 90 degrees, and (b) an acute angle of greater than 45 degrees. In some embodiments, for example, for each one of the at least one arc-defining plane 530, independently, the central longitudinal axis 522, of the externally-disposed reservoir fluid conducting passage 520, is orthogonal to the arc-defining plane 530.

In some embodiments, for example, each one of the at least one outermost surface-defined arc, independently, is a circular arc.

In some embodiments, for example, the body co-operator 500B defines an innermost surface 534, and the innermost surface 534 defines a concave surface portion 536. The concave surface portion 536, of the innermost surface 534 of the body co-operator 500B, is a continuous surface portion, of the innermost surface 534 of the body co-operator 500B. The concave surface portion 536 is concave relative to the central longitudinal axis 522 of the externally-disposed reservoir fluid conducting passage 520.

In some embodiments, for example, the concave surface portion 536 of the innermost surface 534 of the body co-operator 500B defines at least one innermost surface-defined arc 540.

Each one of the at least one innermost surface-defined arc 540, independently, extends outwardly relative to the central longitudinal axis 522 of the externally-disposed reservoir fluid conducting passage 520.

In some embodiments, for example, each one of the at least one innermost surface-defined arc 540, independently, has a minimum arc length of at least one (1) inch.

Referring to FIGS. 11 and 12, in some embodiments, for example, each one of the at least one innermost surface-defined arc 540, independently, is disposed within a respective arc-defining plane 530 that traverses the central longitudinal axis 522 of the externally-disposed reservoir fluid conducting passage 520, such that at least one arc-defining plane is defined. In some embodiments, for example, for each one of the at least one arc-defining plane 530, independently, the central longitudinal axis 522 of the externally-disposed reservoir fluid conducting passage 520 is disposed, relative to the arc-defining plane 530, at an angle selected from the group consisting of: (i) 90 degrees, and (b) an acute angle “X” of greater than 45 degrees. In some embodiments, for example, for each one of the at least one arc-defining plane 530, independently, the central longitudinal axis 522, of the externally-disposed reservoir fluid conducting passage 520, is orthogonal to the arc-defining plane 530.

In some embodiments, for example, each one of the at least one innermost surface-defined arc 540, independently, is a circular arc.

In some embodiments, for example, the innermost surface 534 of the body co-operator 500B defines, in part, the external reservoir fluid conducting fluid passage 520.

In some embodiments, for example, relative to the convex surface portion 532, the concave surface portion 536 is disposed on an opposite side of the body co-operator 500B. In some embodiments, for example, a thickness of an arcuate wall portion 538 of the body co-operator 500B is defined by the minimum distance from the convex surface portion 532 to the concave surface portion 536, and the maximum thickness of the arcuate wall portion of the body co-operator is less than 0.1 inches.

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

Claims

1. A flow diverter for coupling to a reservoir fluid conductor, a gas-depleted reservoir fluid conductor, and a sealed interface effector for establishing a production assembly configured for disposition in a production effective orientation within a wellbore string of a wellbore, extending into a subterranean formation, for effecting production from the subterranean formation, wherein the flow diverter defines: wherein: the flow diverter includes a body and a body co-operator; the body defines: the body co-operator includes an outermost surface;

a reservoir fluid receiver;
a reservoir fluid discharging communicator;
a reservoir fluid conducting passage effecting flow communication between the reservoir fluid receiver and the fluid discharging communicator;
a gas-depleted reservoir fluid receiver;
a gas-depleted reservoir fluid discharging communicator; and
a gas-depleted reservoir fluid conducting passage effecting flow communication between the gas-depleted reservoir fluid receiver and the gas-depleted reservoir fluid discharging communicator;
the reservoir fluid conductor defines a reservoir fluid conductor receiver and a reservoir fluid conductor fluid passage for conducting reservoir fluid received by the reservoir fluid conductor fluid receiver, and the coupling of the reservoir fluid conductor to the flow diverter is with effect that reservoir fluid, receivable by the reservoir fluid conductor receiver is conductible to the reservoir fluid receiver of the flow diverter;
the gas-depleted reservoir fluid conductor defines a fluid passage, and the coupling of the gas-depleted reservoir fluid conductor to the flow diverter is with effect that gas-depleted reservoir fluid, dischargeable from the gas-depleting reservoir fluid discharging communicator of the flow diverter, is conductible to the surface by the fluid passage of the gas-depleted reservoir fluid conductor;
the production assembly is configured such that, while disposed within the wellbore string in a production effective orientation: the reservoir fluid receiver of the flow diverter is disposed downhole relative to the reservoir fluid discharging communicator of the flow diverter; the gas-depleted reservoir fluid receiver of the flow diverter is disposed downhole relative to the gas-depleted reservoir fluid discharging communicator of the flow diverter; the reservoir fluid discharging communicator of the flow diverter is disposed uphole relative to the gas-depleted reservoir fluid receiver of the flow diverter; and an intermediate fluid passage-defining outermost surface of the flow diverter co-operates with the wellbore string for establishing an intermediate fluid passage between the intermediate fluid passage-defining outermost surface of the flow diverter and the wellbore string;
the intermediate fluid passage is disposed for effecting flow communication between the reservoir fluid discharging communicator and the gas-depleted reservoir fluid receiver;
the reservoir fluid conductor receiver, the reservoir fluid conductor fluid passage, the reservoir fluid receiver of the flow diverter, the reservoir fluid conducting passage of the flow diverter, and the reservoir fluid discharging communicator of the flow diverter are co-operatively configured such that, while the production assembly is disposed within the wellbore string in the separation-effective orientation, the sealed interface effector is disposed in sealing disposition with the wellbore string such that a sealed interface is defined, and reservoir fluid flow is being received by the reservoir fluid conductor receiver, the received reservoir fluid flow is conducted to the reservoir fluid discharging communicator, via the reservoir fluid conductor fluid passage, the reservoir fluid receiver of the flow conductor, and the reservoir fluid conducting passage of the flow diverter, for discharging from the flow diverter via the reservoir fluid discharging communicator;
the gas-depleted reservoir fluid conducting passage of the flow diverter, the gas-depleted reservoir fluid receiver of the flow diverter, the gas-depleted reservoir fluid discharging communicator of the flow diverter, and the fluid passage of the gas-depleted reservoir fluid conductor are co-operatively configured such that, while the production assembly is disposed within the wellbore string in the production-effective orientation, the sealed interface effector is disposed in sealing disposition with the wellbore string such that a sealed interface is defined, and gas-depleted reservoir fluid flow is being received by the gas-depleted reservoir fluid communicator of the flow diverter, the received gas-depleted reservoir fluid flow is conducted, via the gas-depleted reservoir fluid conducting passage of the flow diverter, the gas-depleted reservoir fluid discharging communicator of the flow diverter, and the fluid passage of the gas-depleted reservoir fluid conductor, such that the gas-depleted reservoir fluid becomes disposed uphole relative to the gas-depleted reservoir fluid receiver;
the reservoir fluid discharging communicator of the flow diverter, the sealed interface effector, and the gas-depleted reservoir fluid receiver of the flow diverter are co-operatively configured such that, while the production assembly is disposed within the wellbore string in the production-effective orientation, the sealed interface effector is disposed in sealing disposition with the wellbore string such that a sealed interface is defined, and reservoir fluid flow is being discharged from the reservoir fluid discharging communicator: the reservoir fluid becomes disposed externally of the separator within a wellbore space within the wellbore string; a gas-depleted reservoir fluid is separated from the discharged reservoir fluid, within the wellbore space, in response to at least buoyancy forces; and bypassing of the gas-depleted reservoir fluid receiver, by the gas-depleted reservoir fluid, that is being conducted downhole via the intermediate wellbore passage, is prevented by the sealed interface effector, such that the gas-depleted reservoir fluid is received by the gas-depleted reservoir fluid receiver;
the reservoir fluid receiving communicator;
the gas-depleted reservoir fluid receiving communicator;
the gas-depleted reservoir fluid-conducting passage; and
the gas-depleted reservoir fluid discharging communicator;
the body co-operator is joined to the body at a joint with effect that at least a portion of the intermediate passage-defining outermost surface of the flow diverter is defined by the outermost surface of the body co-operator;
the body and the body co-operator co-operate to define an externally-disposed reservoir fluid conducting passage;
at least a portion of the reservoir fluid conducting fluid passage is defined by the externally-disposed reservoir fluid conducting passage.

2. The flow diverter as claimed in claim 1;

wherein:
the outermost surface of the body co-operator defines a convex surface portion that is convex relative to the central longitudinal axis of the externally-disposed reservoir fluid conducting passage, such that the at least a portion of the intermediate passage-defining outermost surface of the flow diverter defines the convex surface portion.

3. The flow diverter as claimed in claim 1;

wherein:
the externally-disposed reservoir fluid conducting passage is defined between the body co-operator and the body.

4. The flow diverter as claimed in claim 1;

wherein:
the externally-disposed reservoir fluid conducting passage is disposed externally of the body

5. The flow diverter as claimed in claim 1;

wherein:
the externally-disposed reservoir fluid conducting passage is defined, in part, by an outermost surface of the body.

6. The flow diverter as claimed in claim 1;

wherein:
the body further defines a body-defined reservoir fluid conducting passage; and
the reservoir fluid-conducting passage further includes the body-defined flow reservoir fluid conducting passage, such that the body-defined reservoir fluid-conducting passage is disposed in flow communication with the externally-disposed reservoir fluid conducting passage.

7. The flow diverter as claimed in claim 6;

wherein:
the body further defines an externally-disposed reservoir fluid conducting passage communicator; and
the flow communication, between the reservoir fluid-conducting passage and the externally-disposed reservoir fluid conducting passage, is effected via the externally-disposed reservoir fluid conducting passage communicator.

8. The flow diverter as claimed in claim 7;

wherein:
the externally-disposed reservoir fluid conducting passage communicator is defined within the body.

9. The flow diverter as claimed in claim 8;

wherein:
the externally-disposed reservoir fluid conducting passage communicator is defined within an outermost surface of the body.

10. The flow diverter as claimed in claim 1;

wherein:
the externally-disposed reservoir fluid conducting passage has a length of at least 12 inches, measured along the central longitudinal axis of the externally-disposed reservoir fluid conducting passage.

11. The flow diverter as claimed in claim 1;

wherein:
the body and the body co-operator co-operate to define the reservoir fluid discharging communicator.

12. The flow diverter as claimed in claim 1;

wherein:
the outermost surface of the body co-operator defines a convex surface portion that is convex relative to the central longitudinal axis of the externally-disposed reservoir fluid conducting passage, such that the at least a portion of the intermediate pas sage-defining outermost surface of the flow diverter defines the convex surface portion;
the body co-operator defines an innermost surface;
the innermost surface defines a concave surface portion; and
the concave surface portion is concave relative to the central longitudinal axis of the externally-disposed reservoir fluid conducting passage.

13. The flow diverter as claimed in claim 12;

wherein:
relative to the convex surface portion, the concave surface portion is disposed on an opposite side of the body co-operator;
a thickness of an arcuate wall portion of the body co-operator is defined by the minimum distance from the convex surface portion to the concave surface portion, and the maximum thickness of the arcuate wall portion of the body co-operator is less than 0.1 inches.

14. The flow diverter as claimed in claim 12;

wherein:
the innermost surface defines, in part, the external reservoir fluid conducting fluid passage.

15. The flow diverter as claimed in claim 1;

wherein:
the joint is a weld.

16. A system, for producing reservoir fluid from a reservoir, comprising the separator as claimed in claim 1;

wherein:
the separator is disposed within a wellbore in the separation effective orientation and configured for receiving at least reservoir fluids via the reservoir fluid receiver.
Patent History
Publication number: 20220341299
Type: Application
Filed: Apr 20, 2022
Publication Date: Oct 27, 2022
Inventors: Jeff Saponja (Calgary), Robbie Singh Hari (Calgary), Carl Stretch (Calgary)
Application Number: 17/725,185
Classifications
International Classification: E21B 43/12 (20060101); E21B 43/38 (20060101);