Abstract:
A subsea rotary gas separator system has a separator located adjacent the discharge of the pump for separating gas from the high pressure liquid stream exiting the pump. Some of the high pressure liquid is recycled back to the inlet of the pump to maintain a liquid-rich inlet stream for the pump.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Technical Field 
         [0002]    The present invention relates in general to downhole gas separators and, in particular, to an improved system, method, and apparatus for a submersible pump assembly having a gas separator that produces a liquid stream for reintroduction upstream of the pump. 
         [0003]    2. Description of the Related Art 
         [0004]    Subsea wells typically connect to a subsea manifold that delivers the well fluid to a production platform for processing, particularly for the removal of water and gas. The oil is then transmitted to a pipeline or other facility for export from the production platform. Production of fluids from a medium to deep subsea environment requires compensation for the effects of cold temperatures, high ambient pressures and fluid viscosity as a function of break out of gas in the fluid stream. In flowing wells, particularly those with light API fluid, these conditions may be mitigated by the nature of the producing reservoir. In wells with low API oil and insufficient pressure to drive the fluid to the surface, some form of artificial lift will be required. 
         [0005]    One type of artificial lift for wells employs a submersible pump, which is a type that has been used for many years on land-based wells. One type of submersible pump assembly has an electrical motor, a rotary pump and a seal section located between the pump and the motor for equalizing wellbore pressure with the internal pressure of lubricant in the motor. In applications where there is a high free gas content in the fluid production stream, the gas content is typically separated upstream from the rotary pump intake. 
         [0006]    In other types of applications, the recycling of discharge liquids back to the suction to reduce the free gas content percentage also is known. However, in a traditional gas separation application, the gas stream has entrained liquids that are together recycled back to the inlet of the pump below the gas outlet. Although this design is workable for some application, an improved solution for increasing the hydraulic efficiency of the system and improving flow conditioning through the pump would be desirable. 
       SUMMARY OF THE INVENTION 
       [0007]    Embodiments of a system, method, and apparatus for a subsea well having a submersible pump assembly with a gas separator are disclosed. The gas separator is located adjacent the discharge of the submersible pump and separates gas from the high pressure liquid stream exiting the pump. 
         [0008]    The invention is particularly well suited for gaseous environments as a portion of the discharge is a high pressure liquid that is recycled back to the inlet of the pump to maintain a liquid-rich inlet stream for the pump. The recycled portion of the discharge, which is essentially 100% liquid, may be returned internally or externally relative to the pump housing. The remainder of the pump discharge is mixed flow. The separator may utilize a centrifuge or static device (e.g., enhanced gravity). In addition, the stream may be reintroduced via a jet pump venturi eductor whereby the stream acts as the power fluid. 
         [0009]    This design has the advantages of flow conditioning and some pressure recovery to improve the hydraulic efficiency of the system. Dispersal of gas homogeneously through the intake liquid is a significant aspect of pumping gassy fluids. The same venturi also may be linked at the vena contracta to a gas accumulation location in order to draw in and mix any gas accumulations. In one embodiment, the recycled liquid stream has entrained gas bubbles that are less than approximately 10 μm in size. A limited amount of gas acceptably enters the pump since a separator can only achieve one relatively clean stream. 
         [0010]    In other embodiments, the recycled liquid stream may have a feedback flow control that monitors fluid density and/or mass flow rate. In addition, the recycle feature of the invention may be suspended when the inlet flow for the pump exceeds a minimum threshold density. The venturi itself may be used as a flow conditioner to measure density by pressure drop or Coriolis effect. 
         [0011]    The foregoing and other objects and advantages of the present invention will be apparent to those skilled in the art, in view of the following detailed description of the present invention, taken in conjunction with the appended claims and the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    So that the manner in which the features and advantages of the present invention, which will become apparent, are attained and can be understood in more detail, more particular description of the invention briefly summarized above may be had by reference to the embodiments thereof that are illustrated in the appended drawings which form a part of this specification. It is to be noted, however, that the drawings illustrate only some embodiments of the invention and therefore are not to be considered limiting of its scope as the invention may admit to other equally effective embodiments. 
           [0013]      FIG. 1  is a sectional side view of one embodiment of a downhole assembly constructed in accordance with the invention; and 
           [0014]      FIG. 2  is a high level flow diagram of one embodiment of a method constructed in accordance with the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0015]    Referring to  FIG. 1 , embodiment of a system, method and apparatus for a subsea well having a submersible pump assembly with a gas separator are shown and described. The submersible pump assembly  11  may be located within a capsule  13  having an inlet  14  for receiving intake fluids having mixed liquids and gas, and an outlet  16  for discharging outlet fluid. Alternatively, the components of the submersible pump assembly  11  may be secured to each other inside a permanent well casing  13 . 
         [0016]    The pump assembly  11  may be supported by a support (not shown) located on the lower (i.e., left) side of housing  13 . A variety of other devices could be employed to mount the pump assembly  11  within housing  13 . The pump assembly  11  may be secured to the support to transmit thrust to the housing  13 . Pump assembly  11  is of a type that is conventionally installed downhole within a subsea well for pumping well fluids to the surface. 
         [0017]    The pump assembly  11  includes a submersible electrical motor  15 , such as a three-phase AC motor. Motor  15  is supplied with power through a power cable (not shown) that extends sealingly through the top or sidewall of the housing  13 . The motor  15  is coupled to a seal section  17  that protects the motor from ingress of production fluid, which could contaminate the clean lubricant contained within motor  15 . Seal section  17  also reduces any pressure differential between the exterior of motor  15  and the pressure of the lubricant within motor  15 . Seal section  17  is connected to a pump  19 , which may comprise a centrifugal pump or a static device with enhanced gravity. Motor  15 , seal  17 , and pump  19  may be mounted coaxially within housing  13 . 
         [0018]    In one embodiment, the pump  19  is made up of a plurality of stages of impellers and diffusers located within a cylindrical pump housing. Pump  19  has an intake  21  located at its upstream end. Pump  19  also has a discharge tube  23  that is in fluid communication with a gas separator  25 . The gas separator  25  is located downstream from the pump  19  and adjacent to the outlet  16  for receiving the outlet fluid from the pump  19 . 
         [0019]    The gas separator  25  discharges (1) a mixed flow stream  31  of gas and liquid to the outlet  16 , and (2) a recycled liquid stream  33 . In one embodiment, the mixed flow stream  31  is a substantially dry gas stream. The recycled liquid stream  33  may have gas bubbles on the order of approximately 10 μm. Thus, the recycled liquid stream  33  is essentially 100% liquid. In one embodiment, only a fraction of the total stream is recycled (e.g., 30%) and making this stream substantially liquid is possible provided that the inlet liquid percentage exceeds, for example, 40% liquid. An inlet fluid having at least 40% liquid is derived as the minimum amount of liquid when about 20% of the total input stream is recycled (with 100% liquid in recycle), as the maximum amount of gas that can be tolerated is about 30%. 
         [0020]    A conduit  35  extends from the gas separator  25  for recycling the liquid stream  33  to the inlet  14  for maintaining a liquid-rich inlet stream for the pump  19 . The conduit may be located external to the pump housing  13  as shown, or extend internally through the capsule/well casing (not shown). The conduit  35  may be provided with feedback flow control  37  for monitoring fluid density and/or mass flow rate of the liquid stream  33 . 
         [0021]    In one embodiment, the inlet  14  comprises a jet pump type venturi eductor  41  and the liquid stream  33  is reintroduced via the jet pump venturi eductor  41  as shown. If structure  13  is a capsule, the jet pump components may be integrally formed as part of the capsule. Alternatively, if structure  13  is a permanent well casing, the eductor  41  may be mounted to an insert, such as a packer. 
         [0022]    The jet pump venturi eductor  41  may comprise a flow conditioner for measuring a density of the intake fluid by pressure drop, mass flow rate or Coriolis effect. In the latter case, high pressure is recovered by reflowing the recycled liquid through the venturi. Recycling of the liquid stream  33  may be suspended when the intake flow for the pump exceeds a minimum threshold density. In another embodiment, the system includes a gas accumulator  43  for accumulating gas, wherein the jet pump venturi eductor  41  has a vena contracta  45  for introducing gas from the gas accumulator  43 . 
         [0023]    Referring now to  FIG. 2 , one embodiment of a method of producing production fluids from a well in accordance with the invention is shown. The method starts as indicated and comprises locating a submersible pump assembly in the well (step  101 ); drawing intake fluids comprising a liquid and a gas into an inlet of the submersible pump assembly (step  103 ); producing an outlet fluid with the submersible pump assembly (step  105 ); receiving the outlet fluid with a gas separator (step  107 ); discharging a mixed flow stream of gas and liquid from the gas separator to an outlet (step  109 ); discharging a liquid stream from the gas separator and recycling the liquid stream to the inlet for maintaining a liquid-rich inlet stream for the submersible pump assembly (step  111 ); before ending as indicated. 
         [0024]    In other embodiments, the method comprises discharging an essentially 100% liquid stream. The liquid stream quality is such that the entrained gas bubbles are less than approximately 10 μm in size. The method also may comprise receiving the intake fluids and liquid stream with a jet pump venturi eductor at the inlet, respectively. The method may further comprise accumulating gas with a gas accumulator, and introducing gas from the gas accumulator to the jet pump venturi eductor through a vena contracts. In still other embodiments, the method may comprise monitoring at least one of fluid density and mass flow rate a feedback flow control; and/or suspending recycling of the liquid stream when the intake fluids exceeds a minimum threshold density. 
         [0025]    While the invention has been shown or described in only some of its forms, it should be apparent to those skilled in the art that it is not so limited, but is susceptible to various changes without departing from the scope of the invention.