US10385673B2 - Fluid driven commingling system for oil and gas applications - Google Patents

Fluid driven commingling system for oil and gas applications Download PDF

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US10385673B2
US10385673B2 US15/088,745 US201615088745A US10385673B2 US 10385673 B2 US10385673 B2 US 10385673B2 US 201615088745 A US201615088745 A US 201615088745A US 10385673 B2 US10385673 B2 US 10385673B2
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fluid
pressure
stream
turbine
energy
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US20160290116A1 (en
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Jinjiang Xiao
Rafael Lastra
Shoubo Wang
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Saudi Arabian Oil Co
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Saudi Arabian Oil Co
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Assigned to SAUDI ARABIAN OIL COMPANY reassignment SAUDI ARABIAN OIL COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: LASTRA, RAFAEL, WANG, SHOUBO, XIAO, JINJIANG
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    • 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
    • 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
    • E21B41/00—Equipment or details not covered by groups E21B15/00 - E21B40/00
    • 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
    • E21B43/12—Methods or apparatus for controlling the flow of the obtained fluid to or in wells
    • E21B43/121—Lifting well fluids
    • 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
    • E21B43/12—Methods or apparatus for controlling the flow of the obtained fluid to or in wells
    • E21B43/121—Lifting well fluids
    • E21B43/122—Gas lift
    • 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
    • E21B43/12—Methods or apparatus for controlling the flow of the obtained fluid to or in wells
    • E21B43/121—Lifting well fluids
    • E21B43/128—Adaptation of pump systems with down-hole electric drives

Definitions

  • ESPs downhole electric submersible pumps
  • ESPs are multistage centrifugal pumps having anywhere from ten to hundreds of stages.
  • Each stage of an electric submersible pump includes an impeller and a diffuser.
  • the impeller transfers the shaft's mechanical energy into kinetic energy in the fluid.
  • the diffuser then converts the fluid's kinetic energy into the fluid head or pressure necessary to lift the liquid from the wellbore.
  • ESPs are designed to run efficiently for a given fluid type, density, viscosity, and an expected amount of free gas.
  • Free gas, associated gas, or gas entrained in liquid is produced from subterranean formations in both oil production and water production. While ESPs are designed to handle small volumes of entrained gas, the efficiency of an ESP decreases rapidly in the presence of gas. The gas, or gas bubbles, builds up on the low-pressure side of the impeller, which in turn reduces the fluid head generated by the pump. Additionally, the volumetric efficiency of the ESP is reduced because the gas is filling the impeller vanes. At certain volumes of free gas, the pump can experience gas lock, during which the ESP will not generate any fluid head.
  • Non-associated gas production wells can also see multiphase streams.
  • Wet gas wells can have liquid entrained in the gas.
  • artificial lift can be used to maintain gas production where the pressure in the formation is reduced.
  • DGC downhole gas compressors
  • DGCs experience problems similar to ESPs, when the liquid entrained in the gas is greater than 10%.
  • a fluid management system positioned in a wellbore for recovering a multiphase fluid having a carrier fluid component and an entrained fluid component from the wellbore.
  • the fluid management system includes a downhole separator, the downhole separator configured to produce a carrier fluid and a separated fluid from the multiphase fluid, the carrier fluid having a concentration of the entrained fluid component, the carrier fluid having a carrier fluid pressure, the separated fluid having a separated fluid pressure, an artificial lift device, the artificial lift device fluidly connected to the downhole separator, the artificial lift device configured to increase the carrier fluid pressure to produce a turbine feed stream, the turbine feed stream having a turbine feed pressure, a turbine, the turbine fluidly connected to the artificial lift device, the turbine configured to convert fluid energy in the turbine feed stream to harvested energy, where the conversion in the turbine of fluid energy from the turbine feed stream to harvested energy produces a turbine discharge stream, the turbine discharge stream having a turbine discharge pressure, where the turbine discharge pressure is less than the turbine feed pressure, and a pressure boosting device, the pressure
  • the fluid management system further includes a mixer, the mixer fluidly connected to both the artificial lift device and the pressure boosting device, the mixer configured to commingle the turbine discharge stream and the pressurized fluid stream to produce a commingled production stream, the commingled production stream having a production pressure.
  • the artificial lift device is an electric submersible pump and the pressure boosting device is a compressor.
  • the artificial lift device is a downhole gas compressor and the pressure boosting device is a submersible pump.
  • a speed of the turbine is controlled by adjusting a flow rate of the turbine feed stream through the turbine.
  • the concentration of the entrained fluid component in the carrier fluid is less than 10% by volume.
  • the multiphase fluid is selected from the group consisting of oil entrained with gas, water entrained with gas, gas entrained with oil, gas entrained with water, and combinations thereof.
  • a method for harvesting fluid energy from the turbine feed stream to power a pressure boosting device downhole in a wellbore includes the steps of separating a multiphase fluid, the multiphase fluid having a carrier fluid component and an entrained fluid component, in a downhole separator to generate a carrier fluid and a separated fluid, the carrier fluid having a concentration of the entrained fluid component, the carrier fluid having a carrier fluid pressure, the separated fluid having a separated fluid pressure, feeding the carrier fluid to an artificial lift device, the artificial lift device configured to increase the carrier fluid pressure to create the turbine feed stream, the turbine feed stream having a turbine feed pressure, feeding the turbine feed stream to a turbine, the turbine configured to convert fluid energy in the turbine feed stream to harvested energy, extracting the fluid energy in the turbine feed stream to produce harvested energy, where the extraction of the fluid energy from the turbine feed stream produces a turbine discharge stream, the turbine discharge stream having a turbine discharge pressure, where the turbine discharge pressure is less than the turbine feed pressure, and driving a pressure boosting device
  • the method further includes the step of mixing the turbine discharge stream and the pressurized fluid stream in a mixer, the mixer configured to commingle the turbine discharge stream and the pressurized fluid stream to produce a commingled production stream, the commingled production stream having a production pressure.
  • the artificial lift device is an electric submersible pump and the pressure boosting device is a compressor.
  • the artificial lift device is a downhole gas compressor and the pressure boosting device is a submersible pump.
  • a speed of the turbine is controlled by adjusting a flow rate of the turbine feed stream through the turbine.
  • the concentration of the entrained fluid component in the carrier fluid is less than 10% by volume.
  • the multiphase fluid is selected from the group consisting of oil entrained with gas, water entrained with gas, gas entrained with oil, gas entrained with water, and combinations thereof.
  • the pressure boosting device is a compressor. In certain aspects, the pressure boosting device is a submersible pump. In certain aspects, a speed of the turbine is controlled by adjusting a flow rate of the energized stream through the turbine. In certain aspects, the energized stream is from an energized subterranean region. In certain aspects, the depressurized stream is from a depressurized subterranean region having a zonal pressure less than the energized subterranean region.
  • FIG. 1 is a flow diagram of an embodiment of the fluid management system.
  • FIG. 2 is a flow diagram of an embodiment of the fluid management system.
  • FIG. 3 is a flow diagram of an embodiment of the fluid management system.
  • the fluid management system targets artificial lift and production boost either downhole or at the surface.
  • a multiphase fluid is separated in a separator into a carrier fluid (a liquid dominated stream) and an entrained fluid (a gas dominated stream).
  • a pump is used to energize the liquid dominated stream.
  • the energized liquid dominated stream is then used to drive a turbine coupled to a compressor.
  • the compressor is used to compress the gas dominated stream.
  • the pump can be sized to provide sufficient power so that the pressure increase in both the liquid dominated stream and the gas dominated stream is sufficient to propel both streams to the surface.
  • FIG. 1 provides a flow diagram of an embodiment of the fluid management system.
  • Fluid management system 100 is a system for recovering multiphase fluid 2 .
  • Fluid management system 100 is placed downhole in the wellbore to increase the pressure of multiphase fluid 2 , to recover multiphase fluid 2 at the surface.
  • Multiphase fluid 2 is any stream being produced from a subterranean formation containing a carrier fluid component with an entrained fluid component.
  • carrier fluid components include oil, water, natural gas and combinations thereof.
  • entrained fluid components include oil, water, natural gas, condensate, and combinations thereof.
  • multiphase fluid 2 is oil with natural gas entrained.
  • multiphase fluid 2 is water with natural gas entrained.
  • multiphase fluid 2 is a combination of oil and water with natural gas entrained. In at least one embodiment, multiphase fluid 2 is natural gas with oil entrained. In at least one embodiment, multiphase fluid 2 is natural gas with condensate entrained.
  • the composition of multiphase fluid 2 depends on the type of subterranean formation. The amount of entrained fluid in multiphase fluid 2 can be between about 5% by volume and about 95% by volume.
  • Downhole separator 102 of fluid management system 100 receives multiphase fluid 2 .
  • Downhole separator 102 separates multiphase fluid 2 into carrier fluid 4 and separated fluid 6 .
  • Downhole separator 102 is any type of separator capable of separating a stream with multiple phases into two or more streams. Examples of separators suitable for use in the present invention include vapor-liquid separators, equilibrium separators, oil and gas separators, stage separators, knockout vessels, centrifugal separators, mist extractors, and scrubbers.
  • Downhole separator 102 is designed to maintain structural integrity in the wellbore. In at least one embodiment, downhole separator 102 is a centrifugal separator.
  • Carrier fluid 4 contains the carrier fluid component from multiphase fluid 2 .
  • fluids that constitute carrier fluid 4 include oil, water, natural gas and combinations thereof.
  • carrier fluid 4 has a concentration of the entrained fluid component.
  • the concentration of the entrained fluid component in carrier fluid 4 depends on the design and operating conditions of downhole separator 102 and the composition of multiphase fluid 2 .
  • the concentration of the entrained fluid component in carrier fluid 4 is between about 1% by volume and about 10% by volume, alternately between about 1% by volume and about 5% by volume, alternately between about 5% by volume and about 10% by volume, and alternately less than 10% by volume.
  • Carrier fluid 4 has a carrier fluid pressure. In at least one embodiment, the pressure of carrier fluid 4 is the pressure of the fluids in the formation.
  • Separated fluid 6 contains the entrained fluid component from multiphase fluid 2 .
  • Separated fluid 6 is the result of the separation of the entrained fluid component from the carrier fluid component in downhole separator 102 .
  • Examples of fluids that constitute separated fluid 6 includes oil, water, natural gas, condensate, and combinations thereof.
  • Separated fluid 6 contains a concentration of the carrier fluid component.
  • the concentration of the carrier fluid component in separated fluid 6 depends on the design and operating conditions of downhole separator 102 and the composition of multiphase fluid 2 .
  • the concentration of carrier fluid component in separated fluid 6 is between about 1% by volume and about 10% by volume, alternately between about 1% by volume and about 5% by volume, alternately between about 5% by volume and about 10% by volume, and alternately less than 10% by volume.
  • Separated fluid 6 has a separated fluid pressure. In at least one embodiment, the pressure of separated fluid 6 is the pressure of the fluids in the formation.
  • Carrier fluid 4 is fed to artificial lift device 104 .
  • Artificial lift device 104 is any device that increases the pressure of carrier fluid 4 and maintains structural and operational integrity under the conditions in the wellbore. The type of artificial lift device 104 selected depends on the phase of carrier fluid 4 . Examples of phases include liquid and gas.
  • carrier fluid 4 is a liquid and artificial lift device 104 is an electric submersible pump.
  • carrier fluid 4 is a gas and artificial lift device 104 is a downhole gas compressor.
  • Artificial lift device 104 increases the pressure of carrier fluid 4 to produce turbine feed stream 8 .
  • Turbine feed stream 8 has a turbine feed pressure. The turbine feed pressure is greater than the carrier fluid pressure.
  • Artificial lift device 104 is driven by a motor. Examples of motors suitable for use in the present invention include a submersible electrical induction motor and a permanent magnet motor.
  • Pressure boosting device 106 is any device that increases the pressure of separated fluid 6 and maintains structural and operational integrity under the conditions in the wellbore.
  • the type of pressure boosting device 106 selected depends on the phase of separated fluid 6 . Examples of phases include liquid and gas.
  • separated fluid 6 is a liquid and pressure boosting device 106 is a submersible pump.
  • separated fluid 6 is a gas and pressure boosting device 106 is a compressor.
  • Pressure boosting device 106 increases the pressure of separated fluid 6 to produce pressurized fluid stream 10 .
  • Pressurized fluid stream 10 has a pressurized fluid pressure. The pressurized fluid pressure is greater than the separated fluid pressure.
  • Turbine feed stream 8 is fed to turbine 108 .
  • Turbine 108 is any mechanical device that extracts fluid energy (hydraulic power) from a flowing fluid and converts the fluid energy to mechanical energy (rotational mechanical power).
  • Turbine 108 can be a turbine. Examples of turbines suitable for use include hydraulic turbines and gas turbines. The presence of a turbine in the system eliminates the need for more than one motor, which increases the reliability of the system.
  • Turbine 108 converts the fluid energy in turbine feed stream 8 into harvested energy 12 .
  • the speed of turbine 108 is adjustable. In at least one embodiment, changing the pitch of the blades of turbine 108 adjusts the speed of turbine 108 .
  • a bypass line provides control of the flow rate of turbine feed stream 8 entering turbine 108 , which adjusts the speed (rotations per minute or RPMs) of turbine 108 .
  • Changes in the flow rate (volume/unit of time) of a fluid in a fixed pipe results in changes to the velocity (distance/unit of time) of the fluid flowing in the pipe.
  • changes in the flow rate of turbine feed stream 8 adjusts the velocity of turbine feed stream 8 , which in turn changes the speed of rotation (RPMs) in turbine 108 .
  • the fluid management system is in the absence of a gearbox due to the use of a bypass line to control the speed of turbine 108 , the absence of a gearbox reduces the complexity of fluid management system 108 by eliminating an additional mechanical unit.
  • Turbine discharge stream 14 has a turbine discharge pressure. The turbine discharge pressure is less than the turbine feed pressure.
  • Artificial lift device 104 pressure boosting device 106 , and turbine 108 are designed such that the turbine discharge pressure of turbine discharge stream 14 lifts turbine discharge stream 14 to the surface to be recovered and the pressurized fluid pressure of pressurized fluid stream 10 lifts pressurized fluid stream 10 to the surface to be recovered.
  • Artificial lift device 104 is designed to provide fluid energy to turbine feed stream 8 so turbine 108 can generate harvested energy 12 to drive pressure boosting device 106 .
  • the combination of artificial lift device 104 , pressure boosting device 106 , and turbine 108 can be arranged in series, parallel, or concentrically. Artificial lift device 104 and pressure boosting device 106 are not driven by the same motor.
  • the fluid management system can be modular in design and packaging because the artificial lift device and the pressure boosting device are not driven by the same motor. The fluid management system is in the absence of a dedicated motor for the artificial lift device and a separate dedicated motor for the pressure boosting device.
  • the fluid management system When conditions downhole allow, the fluid management system is in the absence of any motor used to drive either the artificial lift device or the pressure boosting device. If a well is a strong well, there is enough hydraulic energy and the turbine can be driven by the carrier fluid, such as is shown in FIG. 3 .
  • strong well refers to a well that produces a fluid with enough hydraulic energy to be produced from the formation to the surface without the need for an energizing device and can drive a jet pump.
  • a “weak well” refers to a well that produces a fluid that does not have enough hydraulic energy to be produced from the formation to the surface and thus requires the an energizing device, such as a jet pump.
  • FIG. 2 provides an embodiment.
  • Turbine discharge stream 14 and pressurized fluid stream 10 are mixed in mixer 112 to produce commingled production stream 16 .
  • Commingled production stream 16 has a production pressure.
  • Mixer 112 is any mixing device that commingles turbine discharge stream 14 and pressurized fluid stream 10 in a manner that produces commingled production stream 16 at the surface.
  • mixer 112 is a pipe joint connecting turbine discharge stream 14 and pressurized fluid stream 10 .
  • commingled product stream 16 is not fully mixed.
  • artificial lift device 104 pressure boosting device 106 , and turbine 108 are designed so that the production pressure of commingled production stream 16 lifts commingled production stream 16 to the surface to be recovered.
  • the pressurized fluid pressure and the turbine discharge pressure allow the pressurized fluid stream 10 and turbine discharge stream 14 to be commingled in mixer 112 .
  • artificial lift device 104 and pressure boosting device 106 are contained in the same production pipeline or production tubing. In an alternate embodiment, artificial lift device 104 is contained in a separate production line from pressure boosting device 106 .
  • fluid management system 100 includes sensors to measure system parameters. Examples of system parameters include flow rate, pressure, temperature, and density.
  • the sensors enable process control schemes to control the process.
  • Process control systems can be local involving preprogrammed control schemes within fluid management system 100 , or can be remote involving wired or wireless communication with fluid management system 100 .
  • Process control schemes can be mechanical, electronic, or hydraulically driven.
  • Energized stream 20 is received by turbine 108 .
  • Energized stream 20 is any stream having sufficient pressure to reach the surface from the wellbore.
  • Energized stream 20 has an energized pressure.
  • energized stream 20 is from an energized subterranean region, the pressure of the energized subterranean region providing the lift for energized stream 20 to reach the surface.
  • energized stream 20 is downstream of a device to increase pressure.
  • Turbine 108 produces harvested energy 12 which drives pressure boosting device 106 as described with reference to FIG. 1 .
  • Pressure boosting device 106 increases the pressure of depressurized stream 22 to produce pressurized fluid stream 10 .
  • Depressurized stream 22 is any stream that does not have sufficient pressure to reach the surface from the wellbore.
  • depressurized stream 22 is from a depressurized subterranean region, the zonal pressure of the depressurized subterranean region being less than the energized subterranean region.
  • energized stream 20 is produced by a strong well and can be used to drive turbine 108 , which drives pressure boosting device 106 to increase the pressure of depressurized stream 22 which is produced by a weak well.
  • the fluid management system is used to produce fluids from separate wells, for example where a fluid from a strong well is used to produce a fluid from a weak well, the fluid management system will be located on a surface.
  • Fluid management system 100 can include one or more packers installed in the wellbore.
  • the packer can be used to separate fluids in the wellbore, isolate fluids in the wellbore, or redirect fluids to the different devices in the system.
  • fluid management system 100 can be located at a surface to recover multiphase fluid 2 .
  • surfaces includes dry land, the sea floor, and the sea surface (on a platform).
  • fluid management system 100 is in the absence of a packer.
  • a fluid management system located a surface can be used to boost the pressure of fluids in the same well or from neighboring (adjacent) wells.
  • a fluid management system located downhole can be used to boost the pressure of fluids in the same well.
  • fluid management system 100 is in the absence of a jet pump.
  • the combination of turbine and compressor in fluid management system 100 has a higher efficiency that a jet pump.
  • fluid management system 100 is in the absence of reinjecting into the wellbore or reservoir any portion of turbine discharge stream 14 , pressurized fluid 10 , or commingled production stream 16 .
  • Ranges may be expressed as from about one particular value to about another particular value. When such a range is expressed, it is to be understood that another embodiment is from the one particular value and/or to the other particular value, along with all combinations within said range.
  • first and second are arbitrarily assigned and are merely intended to differentiate between two or more components of an apparatus. It is to be understood that the words “first” and “second” serve no other purpose and are not part of the name or description of the component, nor do they necessarily define a relative location or position of the component. Furthermore, it is to be understood that that the mere use of the term “first” and “second” does not require that there be any “third” component, although that possibility is contemplated under the scope of the present invention.

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  • Physics & Mathematics (AREA)
  • Environmental & Geological Engineering (AREA)
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  • General Life Sciences & Earth Sciences (AREA)
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US15/088,745 2015-04-01 2016-04-01 Fluid driven commingling system for oil and gas applications Active 2037-01-16 US10385673B2 (en)

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US15/088,745 US10385673B2 (en) 2015-04-01 2016-04-01 Fluid driven commingling system for oil and gas applications
US16/439,498 US10947831B2 (en) 2015-04-01 2019-06-12 Fluid driven commingling system for oil and gas applications

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US15/088,745 US10385673B2 (en) 2015-04-01 2016-04-01 Fluid driven commingling system for oil and gas applications

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US10947831B2 (en) * 2015-04-01 2021-03-16 Saudi Arabian Oil Company Fluid driven commingling system for oil and gas applications

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GB201917435D0 (en) * 2019-11-29 2020-01-15 Parker Julian Process to extract work from raw high pressure hydrocarbon production fluids to power gas cleaning and contaminant disposal
AU2022283425A1 (en) * 2021-05-28 2023-12-14 Schlumberger Technology B.V. Compressor and turbine system for resource extraction system

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