CA2281809A1 - Apparatus for controlling and monitoring a downhole oil/water separator - Google Patents
Apparatus for controlling and monitoring a downhole oil/water separator Download PDFInfo
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- CA2281809A1 CA2281809A1 CA002281809A CA2281809A CA2281809A1 CA 2281809 A1 CA2281809 A1 CA 2281809A1 CA 002281809 A CA002281809 A CA 002281809A CA 2281809 A CA2281809 A CA 2281809A CA 2281809 A1 CA2281809 A1 CA 2281809A1
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- separator
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- oil
- controller
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 title claims abstract description 48
- 238000012544 monitoring process Methods 0.000 title claims description 6
- 239000012530 fluid Substances 0.000 claims description 39
- 239000007787 solid Substances 0.000 claims description 9
- 238000004891 communication Methods 0.000 claims description 8
- 239000002245 particle Substances 0.000 claims description 2
- 238000000926 separation method Methods 0.000 abstract description 26
- 239000007788 liquid Substances 0.000 description 25
- 238000000034 method Methods 0.000 description 12
- 230000015572 biosynthetic process Effects 0.000 description 11
- 238000005755 formation reaction Methods 0.000 description 11
- 230000008569 process Effects 0.000 description 9
- 238000010586 diagram Methods 0.000 description 4
- 239000000835 fiber Substances 0.000 description 3
- 238000002347 injection Methods 0.000 description 3
- 239000007924 injection Substances 0.000 description 3
- 230000000694 effects Effects 0.000 description 2
- 229930195733 hydrocarbon Natural products 0.000 description 2
- 150000002430 hydrocarbons Chemical class 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 230000004044 response Effects 0.000 description 2
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 230000003292 diminished effect Effects 0.000 description 1
- 235000013882 gravy Nutrition 0.000 description 1
- 239000006210 lotion Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000003129 oil well Substances 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/34—Arrangements for separating materials produced by the well
- E21B43/38—Arrangements for separating materials produced by the well in the well
- E21B43/385—Arrangements for separating materials produced by the well in the well by reinjecting the separated materials into an earth formation in the same well
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/34—Arrangements for separating materials produced by the well
- E21B43/35—Arrangements for separating materials produced by the well specially adapted for separating solids
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- Life Sciences & Earth Sciences (AREA)
- Engineering & Computer Science (AREA)
- Geology (AREA)
- Mining & Mineral Resources (AREA)
- Physics & Mathematics (AREA)
- Environmental & Geological Engineering (AREA)
- Fluid Mechanics (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Geochemistry & Mineralogy (AREA)
- Centrifugal Separators (AREA)
Abstract
A computerized (e.g. intelligent) downhole oil/water separation system. A
hydrocyclone separator (40) is used downhole to separate oil from water.
Downhole sensors monitor parameters associated with the oil/water separation and provide signals representing the parameters to a controller (70). The controller controls operation of the system by generating control signals and providing the control signals to one or more control devices. The oil/water separation is optimized and well profitability is enhanced.
hydrocyclone separator (40) is used downhole to separate oil from water.
Downhole sensors monitor parameters associated with the oil/water separation and provide signals representing the parameters to a controller (70). The controller controls operation of the system by generating control signals and providing the control signals to one or more control devices. The oil/water separation is optimized and well profitability is enhanced.
Description
EIJROP. PATENTAMT NR.°79 S.7 ~R~ V1~ED ~
' ~ 1d~01/J'J) APQ,'~RATUS FOR COi~JTROLL3i\(G AyD MO1V]TCR1NG
A D04ViVHOLE O1L/WATEF~ SEPARATa9 Baci<ground cf the lnvenn~on Field of he Invention The invention relates generally to systems for separating water from hydrocarbons (e.g. oil) in a well and in particular to methods and apparatus for monitoring and controlling a downhole oil/wat~r separator.
a Prior Art in an oil well, a quanTity of water left from "well completion'' or from "water flooding" is mixed with the oil during production and both fluids flow to the surface from underground formations. The water is typically separated m at The surface and then injected back into the underground formations. As the vvater-oil ratio (WOR) increases, the cost of operating the wel' increases.
Much of the cost is in managing the ever increasing volumes of water that must be lifted to the surface, separated, treated, pipelined and injected back into the formations. As the WOR increases, the profitability of the weft 2u is diminished until it is no longer economically possible to continue production. This often results in leaving large amounts of oil in place in the formation.
The excessive cost of separating water from oil at the surface of a weil has lead to downhole separation systems. U.S, Patent 5,269,153 discloses a ?5 downhole separation system which is shown in FIGURE 1. The well 13 comprises a downhole oil/water separation system including a cyclone separator 1 1 having a separation chamber 15 wherein liquids of different densities ere separated. Mixed liquids enter through inlet 17 at a high tangential speed so as to generate the required centrifugal force for ~o subsequent separation and pass into separation chamber 15. A first outlet 19 is provided for liquids having a first density and a second outlet 21 is ! AMENDED S'~~~T
CA 02281809 1999-08-24 29/07 '99 THU 14:15 [TX/RX NO 5514]
14:15 EUROP. PATENTAMT NR.879 S.e ICWVISED) . ( t->~/t) LI~J~I) provided for liquids having a second density. A stream of mainly oil flows out or' outlet 19 and along recovery conduit 27. A steam of mainly water passes through outlet 21 imp disposal conduit 33 and is infected into the 'ormation through injection perforations 34.
While down hole separation systems have improved well performance, there is a need in the art for improved downhole oillwater separation systems. In particular, there is a need for downhole oillwater separation systems that can monitor parameters downhole and control 'he downhole oii/water si?parator based on monitored parameters so as to achieve the to proper separation and to optimize the performance of the separator. This is well appreciated when the feed entering the separator varies in properties such as oil and water viscosity which depends strongly on temperature and more importantly the water-oil ratio.
L~ Summary of the Invention' The above-discussed and other drawbacks and deficiencies of the prior art are overcome or alleviated by the apparatus for monitoring and contrclling a downhole oil/water separator of the present invention. The present invention is a computer controlled downhole oillwater separation system. A
?0 hydrocyclone separator is positioned downhole for receiving production fluid and separating oil and water contained in the production fluid. Sensors are positioned downhole for monitoring parameters and generating sensing signals corresponding to the parameters. A microprocessor based controller receives the sensing signals and provides controlling signals to one or ,more 25 control devices to optimize the operation of the downhole oil/water separation system.
The computer controlled downhole oil/water separation system reduces the amount of water pumped to the surface of the well, The system can also detect upset conditions when the water percentage becomes too high and ~o cease production from a zone before excessive water is pumped to the surface. By reducing the amount of water pumped to the surface, the AMENGSG SWE
' ~ 1d~01/J'J) APQ,'~RATUS FOR COi~JTROLL3i\(G AyD MO1V]TCR1NG
A D04ViVHOLE O1L/WATEF~ SEPARATa9 Baci<ground cf the lnvenn~on Field of he Invention The invention relates generally to systems for separating water from hydrocarbons (e.g. oil) in a well and in particular to methods and apparatus for monitoring and controlling a downhole oil/wat~r separator.
a Prior Art in an oil well, a quanTity of water left from "well completion'' or from "water flooding" is mixed with the oil during production and both fluids flow to the surface from underground formations. The water is typically separated m at The surface and then injected back into the underground formations. As the vvater-oil ratio (WOR) increases, the cost of operating the wel' increases.
Much of the cost is in managing the ever increasing volumes of water that must be lifted to the surface, separated, treated, pipelined and injected back into the formations. As the WOR increases, the profitability of the weft 2u is diminished until it is no longer economically possible to continue production. This often results in leaving large amounts of oil in place in the formation.
The excessive cost of separating water from oil at the surface of a weil has lead to downhole separation systems. U.S, Patent 5,269,153 discloses a ?5 downhole separation system which is shown in FIGURE 1. The well 13 comprises a downhole oil/water separation system including a cyclone separator 1 1 having a separation chamber 15 wherein liquids of different densities ere separated. Mixed liquids enter through inlet 17 at a high tangential speed so as to generate the required centrifugal force for ~o subsequent separation and pass into separation chamber 15. A first outlet 19 is provided for liquids having a first density and a second outlet 21 is ! AMENDED S'~~~T
CA 02281809 1999-08-24 29/07 '99 THU 14:15 [TX/RX NO 5514]
14:15 EUROP. PATENTAMT NR.879 S.e ICWVISED) . ( t->~/t) LI~J~I) provided for liquids having a second density. A stream of mainly oil flows out or' outlet 19 and along recovery conduit 27. A steam of mainly water passes through outlet 21 imp disposal conduit 33 and is infected into the 'ormation through injection perforations 34.
While down hole separation systems have improved well performance, there is a need in the art for improved downhole oillwater separation systems. In particular, there is a need for downhole oillwater separation systems that can monitor parameters downhole and control 'he downhole oii/water si?parator based on monitored parameters so as to achieve the to proper separation and to optimize the performance of the separator. This is well appreciated when the feed entering the separator varies in properties such as oil and water viscosity which depends strongly on temperature and more importantly the water-oil ratio.
L~ Summary of the Invention' The above-discussed and other drawbacks and deficiencies of the prior art are overcome or alleviated by the apparatus for monitoring and contrclling a downhole oil/water separator of the present invention. The present invention is a computer controlled downhole oillwater separation system. A
?0 hydrocyclone separator is positioned downhole for receiving production fluid and separating oil and water contained in the production fluid. Sensors are positioned downhole for monitoring parameters and generating sensing signals corresponding to the parameters. A microprocessor based controller receives the sensing signals and provides controlling signals to one or ,more 25 control devices to optimize the operation of the downhole oil/water separation system.
The computer controlled downhole oil/water separation system reduces the amount of water pumped to the surface of the well, The system can also detect upset conditions when the water percentage becomes too high and ~o cease production from a zone before excessive water is pumped to the surface. By reducing the amount of water pumped to the surface, the AMENGSG SWE
CA 02281809 1999-08-24 ~ 29/07 '99 THU 14:15 [TX/RX NO 5514]
14:16 EUROP. PATENTAfIT NR.879 S.9 (~t~VI~CDi ~ 1~,1) I~)J) expense of processing and injecting water back into the formation is ; educed and well profitability is enhanced.
The aoove-discussed and other features and advantages of the present invention will be appreciated and understood by those spilled in the art from the following detailed description and drawings. ' Brief Description of the Drawin4s F~eferring now to the drawings wherein like elements are numbered alike in the several FIGURES:
!U FIGURE 1 is a diagram of a conventional downhole hydrocyclone separator;
FIGURE 2 is a diagram of a down~hole hydrocyclone separator system of the present invention; and FIGURE 3 ~,s a block diagram of staged hydrocyclone separators in 1~ accordance with the present invention.
Detailed Descr lotion c~f the Invention I FIGURE 2 is a diagram of the oil/water separation system in accordance with the present invention.' The system includes a hydrocyclone zo ~ep2rator 40 having three fluid flow connections thereto (42, 44, 46). On.e tYydrocyclone separator connection is ~n inlet 42 for receiving production fluid containing a first liquid having a first density (e.g, oil) and a second r Iaquid having a second density (e.g. water). The input production fluid is fed at a high tangential speed so as to generate the required centrifugal force for 25 subsequent separation. The hydrocyclone separator is made up of a first section 41, a second section 43 and a third section 45. The second section i k 3 has an apex angle of approximately 5-7 degrees. The third section 45 is a shallow, conical tube having an apex angle of 3-5 degrees and increases the ime for separation.
3U ~ A second fluid flow connection is a first outlet conduit 44 for the first iquid and a third connection is a second outlet conduit 46 for the second »~iF~IGEG SAE
CA 02281809 1999-08-24 ~ 29/07 '99 THU 14:15 [TX/RX NO 5514]
14:16 EUROP. PATENTAMT NR.879 5.10 ,RY V1 QED i ~ L~~f) li )l) liquid. The hydrocyclone separator 40 is similar to conventional liquid/liquid hydrocyclone separators in which the heavier liquid (e.g. vvatar) is forced to the wall of -.~~e separator under centrifugal force and directed to the second out'et 46. The lighter liquid le.g. oil) is displaced towards the center by buoyancy forces and flows through first outlet conduit 44. A pump 100 constituting a fluid flow control device, is located uphole in first outlet conduit 44 to pump the oil ~o the surface if required.
The production fluid is flows into the wells, for example through production perforations 50 formed in the well casing. A~pump 52 l0 constituting a fluid flaw control device, has pump inlets 54 through whim production fluid is drawn and pumped along conduit 58 zo the hydrocyclone inlet 42. A motor 56 drives pump 52. The motor 56 may be any known type of motor including electric, hydraulic or pneumatic or be Iecated at the surface such as a surface driven PCP or rod pump motor (no; shown). As 1~ will be described below, the motor 56 is configured to respond to a controlling signal to change its RPM and thus the pump rate of pump 52.
Water is passed through second outlet conduit 46 and injected back into the formation at a different stratum different from the producing hydrocarbon formation along a line of demarcation or barrier 63 through injection 2o perforations 60. A packer 62 isolates the production perforations 50 from the injection perforations 60.
The downhole oil/water separation system includes a controller 70 ~Nhich monitors parameters of the downhole oil/water separation system and controls operation of the system. The controller 70 includes a 25 microprocessor and other associated components such as memory, I/0 ports, etc. that are known in the art and which can tolerate the harsh environment downhole (high temperature, corrosion, pressure, etc.). Sensors are employed throughout the downhole oil/water separation system for monitoring parameters of the system and forwarding sensing signals representative of these parameters to the controller 70. 1'he controller 70 may be located downhole as shown in FIGURE 2 or may be placed at the ~.,,~. r...--t ~ y.1"rA~~~ r'1 .~nG~ c 29/07 '99 THU 14:15 [TX/RX NO 5514]
14:16 EUROP. PATENTAMT NR.P~9 5.11 ~R~ViScG1 ~i.~;()Ii~))) surface in which signals are transmitted across the formation through wires, cables, fiber optic or wireless transmission, such as telemetry, An inlet sensor 72 is positioned at the inlet of the hydrocyclone separator 40, a firs outlet sensor 74 is positioned in the first outlet conduit 44 and a second outlet sensor 76 is positioned in the second outlet conduit 46. In the embodiment shown in FIGURE 2, the sensors are Connec:ed to the controller 70 through wires 80, 81 and 82, respectively. It is understood that other communication techniques may be employed. For example, the sensors may also communicate with the controller 70 through telemetry thereby excluding o the need for wires 80, 81 and 82. Sensor 94 is coupled to pump 52 and controller 70 through wires or telemetry and monitors the intake pressure at pump 52.
The controller 70 produces controlling signals and provides the controlling signals to one or more control devices. The fluid flow control a devices include the motor 56, a first control valve 90 positioned in the first outlet conduit 44, a second control valve 92 positioned in the second outlet conduit 46, an inlet control valve 93 positioned in the inlet of the separator 40 and pump 100. The first control valve 90 may be eliminated and f;ow through first conduit 44 may be controlled directly by controlling pump 100 through wire 84a. Alternatively, pump 100 and first control valve 90 may be used in conjunction. In the embodiment shown in FfGURE 2, the controller 70 is connected to the control devices through wires 83, 84, 85, 87 and 84a, respectively. It is understood that other communication techniques may be employed. For example, the controller 70 may also communicate 25 with the control devices through telemetry thereby eliminating the need for the wires. The controller 70 may also communicate with the surface of the well over wire, fiber optics 86 or through telemetry. As mentioned previously, the motor 56 may have a variety of configurations (electric, hydraulic, pneumatic, etc.l and is adapted to adjust the motor in response to 3O a controlling signal from controller 70. The motor 56 affects the volumetric flow rate and pressure along conduit 58 and the downhole separator inlet 42.
Pp~E~IO~~ ~~~c~
CA 02281809 1999-08-24 29/07 '99 THL1 14:15 [TX/RX NO 55141 16 EUROP. PATENTRMT ' NR.879 S.12 (RcVnSEu) ~ i~~~Ol~'7)) The volumetric feed rate in turn a~feczs the tangential spend and consequently the centrifugal gravi y developed for separation. An adjustable inlet v2lve 93 is installed at :he in et of the hydrocyclone separator. By the adjusting the cross sectional flow area, the feed velocity and therefore the centrifugal force can be maintain Id constant or higher independent of the volumetric flow rate, The valve olpening 93 can be controllec by wire 87 from the controller 70. Likewise, ~ the first control valve 90 and '.he second control valve 92 may have a vari ty of configurations, but must be able to incrementally open and close in response to controlling signals from the to controller 70, The inlet sensors 72 detect the flow rate, pressure, temperature and water percentage of the production fluid entering the inlet conduit 42.
Based on these parameters, the c ntroller 70 generates controlling signals i and provides the controlling sign Is to the appropriate control device or 1s control devices. For example, if he hydrocyclone separator is designed to optimally operate at a predetermined flow rate of inlet production fluid, the controller 70 can adjust the revoLl' tions-per-minute (RPM) of motor 56 to establish the ideal inlet flow rate, and in combination in with the valve setting 93 which adjusts the flow area, t a optimal centrifugal force can be ?o established. Similarly the inlet pr ssure, inlet temperature and inlet water percentage are used to control th system. If the water percentage at the inlet becomes too high, it may b determined that the formation ~s no longer producing sufficient amounts of il. In this case, the motor 56 may be increased to effect production of incremental oil.
25 The first outlet sensors 74 detect the pressure, temperature and water percentage az the first outlet con uit 44. Sensing signals corresponding tv these parameters are provided to controller 70 and the controller 70 generates controlling signals and provides the controlling signals to the appropriate control device or con rol devices. The controller 70 controls the 30 control devices so that tile water percentage at first outlet conduit 44 is a minimum. The second outlet sensors 76 monitor pressure, flow rate, water A~I~~~Ir~~r f~yr'~
CA 02281809 1999-08-24 29/07 '99 THU 14:15 [TX/RX NO 5514]
1;1~ EUROP. PATENTAMT NR.8~9 S.13 ~R ~V~SEt,) ,ulDlr))>
percentage, solid particle Concentration and/or other vvater quality parameters, such as pH, at the second outlet conduit 46. The controller 70 receives sensing signals from sensors 76 and generates the necessary controlling signals. One or .-pore of the control devices are controlled so that the water percentage in second outlet conduit 46 is optimized.
Specific examples of how the control devices are manipulated will now be described. The following control processes are exemplary and are not intended to represent al( the control processes that may be executed by the present invention. The control processes may be used alone or in l0 combination with other control processes.
In a first control pr ocess, the pump intake pressure is monitored by sensor 94 and a sensing signal is provided ~o the controller 70. Eased on tf~e pump intake pressure, the controller 70 sends controlling signals to the motor a 56 to adjust the motor speed so that the pump intake pressure is minimized.
By minimizing the pump 52 intake pressure, the well inflovv, and thus well production, is maximized.
Another control process is based on the oil concentration in zhe second output conduit 46 sensed by sensors 76. If the oil concentration at sensor 76 increases, second control valve 92 should be incrementally closed and/or zo first control valve 90 may be incrementally opened. Alternatively, the speed of pump 100 may be increased. All of these adjustments have the effect of increasing the oil flow rate through first outlet conduit 44. However, in this process the water concentration in the first liquid output conduit 44 sensed by sensors 74 should be maintained at an acceptable low level.
z5 In yet another control process, the oil concentration at the inlet conduit 42 is monitored to establish a minimum volumetric flow rate through first outlet conduit 44.. If the oil concentration is high at inlet conduit 42 as monitored by sensors 72, then the first control valve 90 is opened or the speed of pump 100 is increased to facilitate removal of the oil.
Alternatively, 30 if the oil concentration at inset 42 is low, then first control valve 90 is incrementally closed or the speed of pump 100 is reduced to prevent water riJIG'::.~::i ~. _..
CA 02281809 1999-08-24 29/07 '99 THU 14:15 [TX/RX NO 5514]
:17 EUROP. PATENTAMT NR.879 5.14 (RcV~SEL) ~W iOU9)) for exiting through first ounet conduit 44.
In yet another controi process, the separator pressure differential ratio is monitored and adjusted dependent upon the oii concentration at inlet 42, The separator pressure differential ratio is defined as:
;i,-let pressure at 42 - outlet pressure at 44)I(inlet pressore at 42 - outlet pressure at 46).
The ratio iden tifies what percentage of the liquid entering the separator az inlet 42 is distributed to the first outlet conduit 44 and the second outlet conduit 46. For a given oil concentration at the inlet 4.2, there is an optimal iu separator pressure differential ratio. Accordingly, the oil concentration az inlet 42 is monitored by sensors 72 and the first control valve 90 and/or pump 100 and the second control valve 92 are adjusted so that the separator pressure difi~erential ratio is optimized for the given inlet oil concentration.
In yet another process, when the water content in the first liquid conduit 44 exceeds an acceptable level the cross section area of valve 93 can be reduced to generate a higher veiocity and hence a higher centrifugal force for separation. The controller 70 also signals the pump motor 56 to increase RPM to pump against the back pressure established by the further restriction from the inlet valve 93 given that the volumetric feeding rate is ?0 held constant.
The separator system shown in Fig. 2 may also be provided with a pump (not shown) driven by a suitable motor, such as electric, hydraulics or pneumatic (not shown) positioned in the conduit 46 and controlled by controller 70. This pump increase the pressure of the water discharged from 2s the separator 40 for reinjection into the formation. This pump may be provided in addition to pumps 52 and 100, or in lieu of one or the other of these pumps. The sensors 72, 74, 76 and 94 may of any suitable type such as fiber optic, infrared, or ultrasonic.
The present invention can also be modified to provide for the removal ~o of solids from the production fluid containing solids, a first liquid (e.g.
oil) and a second liquid (e.g. water), A flow through filter (e.g. screen) maybe used s A~r,F_~n~n SH~Ff CA 02281809 1999-08-24 29/07 '99 THU 14:15 [TX/RX NO 5514]
17 EUROP. PATENTRMT NR.°~9 5.15 ~R :V~SE>:~l ~; ir/U!i~.~:1) to strain the sold material from the first and second liquids. Alternatively, staged hydrocyclone separators may be used as shown in FIGURE 3. A feed conduit 200 carries production fluid containing solids, a first liquid and a second liquid. A solid/liquid separator 202 separates the solids from the two liquids. The solids are omput through solid outlet conduit 20~ and the mixed liquids are output through conduit 206. A liquid/liquid separator 208 operates in accordance with the system described above with reference to FIGURE 2 and outputs the first liquid through conduit 210 and the second liquid through conduit 212.
Lo The present invention provides for intelligent Control of a downhole oil/water separator by including sensors, control devices and a controller downhole with the separator. The sensors monitor parameters of the separation system and the controller controls portions of the system to maximize oil/water separation. The controller can also determine when the water percentage is so high that production from a particular zone should be discontinued. This prevents excess water from being pumped to the surface and reduces the costs associated with processing and injecting water from the surface back into the formation, While preferred embodiments have been shown and described, various ?o modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the presgnt invention has been described by way of illustration and not limitation.
Al~c~lu~~ ~'r~c~
CA 02281809 1999-08-24 29/07 '99 THU 14:15 [TX/RX NO 5514)
14:16 EUROP. PATENTAfIT NR.879 S.9 (~t~VI~CDi ~ 1~,1) I~)J) expense of processing and injecting water back into the formation is ; educed and well profitability is enhanced.
The aoove-discussed and other features and advantages of the present invention will be appreciated and understood by those spilled in the art from the following detailed description and drawings. ' Brief Description of the Drawin4s F~eferring now to the drawings wherein like elements are numbered alike in the several FIGURES:
!U FIGURE 1 is a diagram of a conventional downhole hydrocyclone separator;
FIGURE 2 is a diagram of a down~hole hydrocyclone separator system of the present invention; and FIGURE 3 ~,s a block diagram of staged hydrocyclone separators in 1~ accordance with the present invention.
Detailed Descr lotion c~f the Invention I FIGURE 2 is a diagram of the oil/water separation system in accordance with the present invention.' The system includes a hydrocyclone zo ~ep2rator 40 having three fluid flow connections thereto (42, 44, 46). On.e tYydrocyclone separator connection is ~n inlet 42 for receiving production fluid containing a first liquid having a first density (e.g, oil) and a second r Iaquid having a second density (e.g. water). The input production fluid is fed at a high tangential speed so as to generate the required centrifugal force for 25 subsequent separation. The hydrocyclone separator is made up of a first section 41, a second section 43 and a third section 45. The second section i k 3 has an apex angle of approximately 5-7 degrees. The third section 45 is a shallow, conical tube having an apex angle of 3-5 degrees and increases the ime for separation.
3U ~ A second fluid flow connection is a first outlet conduit 44 for the first iquid and a third connection is a second outlet conduit 46 for the second »~iF~IGEG SAE
CA 02281809 1999-08-24 ~ 29/07 '99 THU 14:15 [TX/RX NO 5514]
14:16 EUROP. PATENTAMT NR.879 5.10 ,RY V1 QED i ~ L~~f) li )l) liquid. The hydrocyclone separator 40 is similar to conventional liquid/liquid hydrocyclone separators in which the heavier liquid (e.g. vvatar) is forced to the wall of -.~~e separator under centrifugal force and directed to the second out'et 46. The lighter liquid le.g. oil) is displaced towards the center by buoyancy forces and flows through first outlet conduit 44. A pump 100 constituting a fluid flow control device, is located uphole in first outlet conduit 44 to pump the oil ~o the surface if required.
The production fluid is flows into the wells, for example through production perforations 50 formed in the well casing. A~pump 52 l0 constituting a fluid flaw control device, has pump inlets 54 through whim production fluid is drawn and pumped along conduit 58 zo the hydrocyclone inlet 42. A motor 56 drives pump 52. The motor 56 may be any known type of motor including electric, hydraulic or pneumatic or be Iecated at the surface such as a surface driven PCP or rod pump motor (no; shown). As 1~ will be described below, the motor 56 is configured to respond to a controlling signal to change its RPM and thus the pump rate of pump 52.
Water is passed through second outlet conduit 46 and injected back into the formation at a different stratum different from the producing hydrocarbon formation along a line of demarcation or barrier 63 through injection 2o perforations 60. A packer 62 isolates the production perforations 50 from the injection perforations 60.
The downhole oil/water separation system includes a controller 70 ~Nhich monitors parameters of the downhole oil/water separation system and controls operation of the system. The controller 70 includes a 25 microprocessor and other associated components such as memory, I/0 ports, etc. that are known in the art and which can tolerate the harsh environment downhole (high temperature, corrosion, pressure, etc.). Sensors are employed throughout the downhole oil/water separation system for monitoring parameters of the system and forwarding sensing signals representative of these parameters to the controller 70. 1'he controller 70 may be located downhole as shown in FIGURE 2 or may be placed at the ~.,,~. r...--t ~ y.1"rA~~~ r'1 .~nG~ c 29/07 '99 THU 14:15 [TX/RX NO 5514]
14:16 EUROP. PATENTAMT NR.P~9 5.11 ~R~ViScG1 ~i.~;()Ii~))) surface in which signals are transmitted across the formation through wires, cables, fiber optic or wireless transmission, such as telemetry, An inlet sensor 72 is positioned at the inlet of the hydrocyclone separator 40, a firs outlet sensor 74 is positioned in the first outlet conduit 44 and a second outlet sensor 76 is positioned in the second outlet conduit 46. In the embodiment shown in FIGURE 2, the sensors are Connec:ed to the controller 70 through wires 80, 81 and 82, respectively. It is understood that other communication techniques may be employed. For example, the sensors may also communicate with the controller 70 through telemetry thereby excluding o the need for wires 80, 81 and 82. Sensor 94 is coupled to pump 52 and controller 70 through wires or telemetry and monitors the intake pressure at pump 52.
The controller 70 produces controlling signals and provides the controlling signals to one or more control devices. The fluid flow control a devices include the motor 56, a first control valve 90 positioned in the first outlet conduit 44, a second control valve 92 positioned in the second outlet conduit 46, an inlet control valve 93 positioned in the inlet of the separator 40 and pump 100. The first control valve 90 may be eliminated and f;ow through first conduit 44 may be controlled directly by controlling pump 100 through wire 84a. Alternatively, pump 100 and first control valve 90 may be used in conjunction. In the embodiment shown in FfGURE 2, the controller 70 is connected to the control devices through wires 83, 84, 85, 87 and 84a, respectively. It is understood that other communication techniques may be employed. For example, the controller 70 may also communicate 25 with the control devices through telemetry thereby eliminating the need for the wires. The controller 70 may also communicate with the surface of the well over wire, fiber optics 86 or through telemetry. As mentioned previously, the motor 56 may have a variety of configurations (electric, hydraulic, pneumatic, etc.l and is adapted to adjust the motor in response to 3O a controlling signal from controller 70. The motor 56 affects the volumetric flow rate and pressure along conduit 58 and the downhole separator inlet 42.
Pp~E~IO~~ ~~~c~
CA 02281809 1999-08-24 29/07 '99 THL1 14:15 [TX/RX NO 55141 16 EUROP. PATENTRMT ' NR.879 S.12 (RcVnSEu) ~ i~~~Ol~'7)) The volumetric feed rate in turn a~feczs the tangential spend and consequently the centrifugal gravi y developed for separation. An adjustable inlet v2lve 93 is installed at :he in et of the hydrocyclone separator. By the adjusting the cross sectional flow area, the feed velocity and therefore the centrifugal force can be maintain Id constant or higher independent of the volumetric flow rate, The valve olpening 93 can be controllec by wire 87 from the controller 70. Likewise, ~ the first control valve 90 and '.he second control valve 92 may have a vari ty of configurations, but must be able to incrementally open and close in response to controlling signals from the to controller 70, The inlet sensors 72 detect the flow rate, pressure, temperature and water percentage of the production fluid entering the inlet conduit 42.
Based on these parameters, the c ntroller 70 generates controlling signals i and provides the controlling sign Is to the appropriate control device or 1s control devices. For example, if he hydrocyclone separator is designed to optimally operate at a predetermined flow rate of inlet production fluid, the controller 70 can adjust the revoLl' tions-per-minute (RPM) of motor 56 to establish the ideal inlet flow rate, and in combination in with the valve setting 93 which adjusts the flow area, t a optimal centrifugal force can be ?o established. Similarly the inlet pr ssure, inlet temperature and inlet water percentage are used to control th system. If the water percentage at the inlet becomes too high, it may b determined that the formation ~s no longer producing sufficient amounts of il. In this case, the motor 56 may be increased to effect production of incremental oil.
25 The first outlet sensors 74 detect the pressure, temperature and water percentage az the first outlet con uit 44. Sensing signals corresponding tv these parameters are provided to controller 70 and the controller 70 generates controlling signals and provides the controlling signals to the appropriate control device or con rol devices. The controller 70 controls the 30 control devices so that tile water percentage at first outlet conduit 44 is a minimum. The second outlet sensors 76 monitor pressure, flow rate, water A~I~~~Ir~~r f~yr'~
CA 02281809 1999-08-24 29/07 '99 THU 14:15 [TX/RX NO 5514]
1;1~ EUROP. PATENTAMT NR.8~9 S.13 ~R ~V~SEt,) ,ulDlr))>
percentage, solid particle Concentration and/or other vvater quality parameters, such as pH, at the second outlet conduit 46. The controller 70 receives sensing signals from sensors 76 and generates the necessary controlling signals. One or .-pore of the control devices are controlled so that the water percentage in second outlet conduit 46 is optimized.
Specific examples of how the control devices are manipulated will now be described. The following control processes are exemplary and are not intended to represent al( the control processes that may be executed by the present invention. The control processes may be used alone or in l0 combination with other control processes.
In a first control pr ocess, the pump intake pressure is monitored by sensor 94 and a sensing signal is provided ~o the controller 70. Eased on tf~e pump intake pressure, the controller 70 sends controlling signals to the motor a 56 to adjust the motor speed so that the pump intake pressure is minimized.
By minimizing the pump 52 intake pressure, the well inflovv, and thus well production, is maximized.
Another control process is based on the oil concentration in zhe second output conduit 46 sensed by sensors 76. If the oil concentration at sensor 76 increases, second control valve 92 should be incrementally closed and/or zo first control valve 90 may be incrementally opened. Alternatively, the speed of pump 100 may be increased. All of these adjustments have the effect of increasing the oil flow rate through first outlet conduit 44. However, in this process the water concentration in the first liquid output conduit 44 sensed by sensors 74 should be maintained at an acceptable low level.
z5 In yet another control process, the oil concentration at the inlet conduit 42 is monitored to establish a minimum volumetric flow rate through first outlet conduit 44.. If the oil concentration is high at inlet conduit 42 as monitored by sensors 72, then the first control valve 90 is opened or the speed of pump 100 is increased to facilitate removal of the oil.
Alternatively, 30 if the oil concentration at inset 42 is low, then first control valve 90 is incrementally closed or the speed of pump 100 is reduced to prevent water riJIG'::.~::i ~. _..
CA 02281809 1999-08-24 29/07 '99 THU 14:15 [TX/RX NO 5514]
:17 EUROP. PATENTAMT NR.879 5.14 (RcV~SEL) ~W iOU9)) for exiting through first ounet conduit 44.
In yet another controi process, the separator pressure differential ratio is monitored and adjusted dependent upon the oii concentration at inlet 42, The separator pressure differential ratio is defined as:
;i,-let pressure at 42 - outlet pressure at 44)I(inlet pressore at 42 - outlet pressure at 46).
The ratio iden tifies what percentage of the liquid entering the separator az inlet 42 is distributed to the first outlet conduit 44 and the second outlet conduit 46. For a given oil concentration at the inlet 4.2, there is an optimal iu separator pressure differential ratio. Accordingly, the oil concentration az inlet 42 is monitored by sensors 72 and the first control valve 90 and/or pump 100 and the second control valve 92 are adjusted so that the separator pressure difi~erential ratio is optimized for the given inlet oil concentration.
In yet another process, when the water content in the first liquid conduit 44 exceeds an acceptable level the cross section area of valve 93 can be reduced to generate a higher veiocity and hence a higher centrifugal force for separation. The controller 70 also signals the pump motor 56 to increase RPM to pump against the back pressure established by the further restriction from the inlet valve 93 given that the volumetric feeding rate is ?0 held constant.
The separator system shown in Fig. 2 may also be provided with a pump (not shown) driven by a suitable motor, such as electric, hydraulics or pneumatic (not shown) positioned in the conduit 46 and controlled by controller 70. This pump increase the pressure of the water discharged from 2s the separator 40 for reinjection into the formation. This pump may be provided in addition to pumps 52 and 100, or in lieu of one or the other of these pumps. The sensors 72, 74, 76 and 94 may of any suitable type such as fiber optic, infrared, or ultrasonic.
The present invention can also be modified to provide for the removal ~o of solids from the production fluid containing solids, a first liquid (e.g.
oil) and a second liquid (e.g. water), A flow through filter (e.g. screen) maybe used s A~r,F_~n~n SH~Ff CA 02281809 1999-08-24 29/07 '99 THU 14:15 [TX/RX NO 5514]
17 EUROP. PATENTRMT NR.°~9 5.15 ~R :V~SE>:~l ~; ir/U!i~.~:1) to strain the sold material from the first and second liquids. Alternatively, staged hydrocyclone separators may be used as shown in FIGURE 3. A feed conduit 200 carries production fluid containing solids, a first liquid and a second liquid. A solid/liquid separator 202 separates the solids from the two liquids. The solids are omput through solid outlet conduit 20~ and the mixed liquids are output through conduit 206. A liquid/liquid separator 208 operates in accordance with the system described above with reference to FIGURE 2 and outputs the first liquid through conduit 210 and the second liquid through conduit 212.
Lo The present invention provides for intelligent Control of a downhole oil/water separator by including sensors, control devices and a controller downhole with the separator. The sensors monitor parameters of the separation system and the controller controls portions of the system to maximize oil/water separation. The controller can also determine when the water percentage is so high that production from a particular zone should be discontinued. This prevents excess water from being pumped to the surface and reduces the costs associated with processing and injecting water from the surface back into the formation, While preferred embodiments have been shown and described, various ?o modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the presgnt invention has been described by way of illustration and not limitation.
Al~c~lu~~ ~'r~c~
CA 02281809 1999-08-24 29/07 '99 THU 14:15 [TX/RX NO 5514)
Claims
CLAIM 1 A dewnhole system for separating dewnhole production fluid into a first separated fluid and a second separated fluid, the system comprising:
a separator (40) for separating the production fluid into the fluid and the second separated fluids; the separator having three fluid flow connections thereto, (42,44,46) with a first fluid flow connection including an inlet (42) for the flow of production fluid into the separator, a second fluid flow connection including a first outlet (44) from the separator for the discharge of the first saparated fluid and a third fluid flow connection including a second outlet (46) from the separator for the discharge of the second separated fluid;
at least one sensor (72, 74, 76) for monitoring parameters associated with said separator and producing a sensing signal; and a controller (70) fer receiving said sensing signal and generating control signals;
the improvement comprising;
a first fluid flow control device (90, 92. 93, 52, 100) in flow communication with one of said fluid flow connections (42,44,46); and a second fluid flow control device (90, 92, 93, 52, 100) in flow communication with another of said fluid flow connections, each device being responsive to control signals for controlling the flow of fluid through the separator (40) and thus of the operation of the system separator to optimize the operation of the system.
CLAIM 2 The system of claim 1 wherein at least one ef said control device comprises a control valve (90, 92,93) in flow communication with the respective fluid connection and positioned downhole.
CLAIM 3 The system of claim 1 wherein at least one of said control devices comprises a pump (52) in flow communication with the respective fluid connection and positioned downhole.
CLAIM 4 The system of claim 1 wherein said system includes a second (72, 74, 76)sensor in flow communication with another of the fluid flow connections (42. 44, 46).
CLAIM 5 The system of claim 1 wherein said sensor (72, 74, 76) monitors at least one of the parameters of flow rate, pressure, temperature, concentration of solid particles, pH and water percentage.
CLAIM 6 The system of claim 1 wherein said system includes a sensor (72, 74, 76) and a fluid control device (52, 90, 92. 93, 100) in flow communication with each of the three fluid flow connections (42, 44, 46).
CLAIM 7 The system of claim 1 wherein the controller (70) is positioned downhole.
CLAIM 8 The system of claim 1 wherein the controller (70) is positioned at the surface.
a separator (40) for separating the production fluid into the fluid and the second separated fluids; the separator having three fluid flow connections thereto, (42,44,46) with a first fluid flow connection including an inlet (42) for the flow of production fluid into the separator, a second fluid flow connection including a first outlet (44) from the separator for the discharge of the first saparated fluid and a third fluid flow connection including a second outlet (46) from the separator for the discharge of the second separated fluid;
at least one sensor (72, 74, 76) for monitoring parameters associated with said separator and producing a sensing signal; and a controller (70) fer receiving said sensing signal and generating control signals;
the improvement comprising;
a first fluid flow control device (90, 92. 93, 52, 100) in flow communication with one of said fluid flow connections (42,44,46); and a second fluid flow control device (90, 92, 93, 52, 100) in flow communication with another of said fluid flow connections, each device being responsive to control signals for controlling the flow of fluid through the separator (40) and thus of the operation of the system separator to optimize the operation of the system.
CLAIM 2 The system of claim 1 wherein at least one ef said control device comprises a control valve (90, 92,93) in flow communication with the respective fluid connection and positioned downhole.
CLAIM 3 The system of claim 1 wherein at least one of said control devices comprises a pump (52) in flow communication with the respective fluid connection and positioned downhole.
CLAIM 4 The system of claim 1 wherein said system includes a second (72, 74, 76)sensor in flow communication with another of the fluid flow connections (42. 44, 46).
CLAIM 5 The system of claim 1 wherein said sensor (72, 74, 76) monitors at least one of the parameters of flow rate, pressure, temperature, concentration of solid particles, pH and water percentage.
CLAIM 6 The system of claim 1 wherein said system includes a sensor (72, 74, 76) and a fluid control device (52, 90, 92. 93, 100) in flow communication with each of the three fluid flow connections (42, 44, 46).
CLAIM 7 The system of claim 1 wherein the controller (70) is positioned downhole.
CLAIM 8 The system of claim 1 wherein the controller (70) is positioned at the surface.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US3807697P | 1997-02-25 | 1997-02-25 | |
US60/038,076 | 1997-02-25 | ||
PCT/US1998/002621 WO1998037307A1 (en) | 1997-02-25 | 1998-02-05 | Apparatus for controlling and monitoring a downhole oil/water separator |
Publications (1)
Publication Number | Publication Date |
---|---|
CA2281809A1 true CA2281809A1 (en) | 1998-08-27 |
Family
ID=21897968
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA002281809A Abandoned CA2281809A1 (en) | 1997-02-25 | 1998-02-05 | Apparatus for controlling and monitoring a downhole oil/water separator |
Country Status (4)
Country | Link |
---|---|
AU (1) | AU6275898A (en) |
CA (1) | CA2281809A1 (en) |
NO (1) | NO994068L (en) |
WO (1) | WO1998037307A1 (en) |
Cited By (4)
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CN101793138A (en) * | 2010-03-10 | 2010-08-04 | 大庆油田有限责任公司 | Hydrocyclone and screw pump combined downhole oil-water separation method |
CN102701321A (en) * | 2012-05-31 | 2012-10-03 | 周军 | Oil-water separation and oil output remote quantitative multi-dimensional monitoring system |
AU2011242398B2 (en) * | 2010-04-23 | 2015-02-05 | Vulco S.A. | Stability control system for a hydrocyclone |
CN108252704A (en) * | 2017-12-29 | 2018-07-06 | 中国船舶重工集团公司第七八研究所 | A kind of pump-out type minor diameter gamma spectroscopy tool probe string-passing structure |
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NO305259B1 (en) | 1997-04-23 | 1999-04-26 | Shore Tec As | Method and apparatus for use in the production test of an expected permeable formation |
GB2345307B (en) * | 1999-01-04 | 2003-05-21 | Camco Int | Dual electric submergible pumping system installation to simultaneously move fluid with respect to two or more subterranean zones |
US6250390B1 (en) | 1999-01-04 | 2001-06-26 | Camco International, Inc. | Dual electric submergible pumping systems for producing fluids from separate reservoirs |
GB2384508B (en) * | 1999-04-16 | 2003-09-17 | Halliburton Energy Serv Inc | Downhole separator for use in a subterranean well and method |
US6357525B1 (en) | 1999-04-22 | 2002-03-19 | Schlumberger Technology Corporation | Method and apparatus for testing a well |
US6330913B1 (en) | 1999-04-22 | 2001-12-18 | Schlumberger Technology Corporation | Method and apparatus for testing a well |
US6382315B1 (en) | 1999-04-22 | 2002-05-07 | Schlumberger Technology Corporation | Method and apparatus for continuously testing a well |
US6347666B1 (en) | 1999-04-22 | 2002-02-19 | Schlumberger Technology Corporation | Method and apparatus for continuously testing a well |
NO313767B1 (en) | 2000-03-20 | 2002-11-25 | Kvaerner Oilfield Prod As | Process for obtaining simultaneous supply of propellant fluid to multiple subsea wells and subsea petroleum production arrangement for simultaneous production of hydrocarbons from multi-subsea wells and supply of propellant fluid to the s. |
GB0124613D0 (en) * | 2001-10-12 | 2001-12-05 | Alpha Thames Ltd | System and method for separating fluids |
US20050087336A1 (en) | 2003-10-24 | 2005-04-28 | Surjaatmadja Jim B. | Orbital downhole separator |
US7370701B2 (en) | 2004-06-30 | 2008-05-13 | Halliburton Energy Services, Inc. | Wellbore completion design to naturally separate water and solids from oil and gas |
US7429332B2 (en) | 2004-06-30 | 2008-09-30 | Halliburton Energy Services, Inc. | Separating constituents of a fluid mixture |
US7462274B2 (en) | 2004-07-01 | 2008-12-09 | Halliburton Energy Services, Inc. | Fluid separator with smart surface |
US7823635B2 (en) | 2004-08-23 | 2010-11-02 | Halliburton Energy Services, Inc. | Downhole oil and water separator and method |
GB2472151A (en) * | 2007-03-27 | 2011-01-26 | Schlumberger Holdings | Method of operating a downhole oil water separator |
US7828058B2 (en) | 2007-03-27 | 2010-11-09 | Schlumberger Technology Corporation | Monitoring and automatic control of operating parameters for a downhole oil/water separation system |
NO331292B2 (en) * | 2009-12-29 | 2016-04-22 | Aker Subsea As | cyclone Control |
US8812238B2 (en) | 2012-10-31 | 2014-08-19 | Halliburton Energy Services, Inc. | Systems and methods for analyzing flowback compositions in real time |
GB2514589B (en) | 2013-05-30 | 2020-01-29 | Nat Oilwell Varco Lp | Centrifuge for separating solids from solids laden drilling fluid |
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GB2194572B (en) * | 1986-08-29 | 1989-12-20 | Elf Aquitaine | A device for separating and extracting components having different densities from an effluent |
FR2603330B1 (en) * | 1986-09-02 | 1988-10-28 | Elf Aquitaine | PROCESS FOR PUMPING HYDROCARBONS FROM A MIXTURE OF THESE HYDROCARBONS WITH AN AQUEOUS PHASE AND INSTALLATION FOR IMPLEMENTING THE PROCESS |
FR2603331B1 (en) * | 1986-09-02 | 1988-11-10 | Elf Aquitaine | DEVICE FOR REGULATING THE FLOW OF WATER SEPARATED FROM ITS MIXTURE WITH HYDROCARBONS AND REINJECTED AT THE BOTTOM OF THE WELL |
US5269153A (en) | 1991-05-22 | 1993-12-14 | Artesian Building Systems, Inc. | Apparatus for controlling space heating and/or space cooling and water heating |
-
1998
- 1998-02-05 WO PCT/US1998/002621 patent/WO1998037307A1/en active Application Filing
- 1998-02-05 CA CA002281809A patent/CA2281809A1/en not_active Abandoned
- 1998-02-05 AU AU62758/98A patent/AU6275898A/en not_active Abandoned
-
1999
- 1999-08-24 NO NO994068A patent/NO994068L/en not_active Application Discontinuation
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CN101793138A (en) * | 2010-03-10 | 2010-08-04 | 大庆油田有限责任公司 | Hydrocyclone and screw pump combined downhole oil-water separation method |
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CN105057127B (en) * | 2010-04-23 | 2018-01-02 | 乌尔可公司 | The method for operating hydrocyclone |
CN102701321A (en) * | 2012-05-31 | 2012-10-03 | 周军 | Oil-water separation and oil output remote quantitative multi-dimensional monitoring system |
CN102701321B (en) * | 2012-05-31 | 2013-10-30 | 山东大学 | Oil-water separation and oil output remote quantitative multi-dimensional monitoring system |
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Also Published As
Publication number | Publication date |
---|---|
NO994068D0 (en) | 1999-08-24 |
WO1998037307A1 (en) | 1998-08-27 |
AU6275898A (en) | 1998-09-09 |
NO994068L (en) | 1999-10-19 |
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Legal Events
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EEER | Examination request | ||
FZDE | Discontinued |