Patent ID: 12258851

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

General

The present invention will now be described with occasional reference to the specific embodiments of the invention. This invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for describing particular embodiments only and is not intended to be limiting of the invention. As used in the description of the invention and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

Unless otherwise indicated, all numbers expressing quantities of dimensions such as length, width, height, and so forth as used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless otherwise indicated, the numerical properties set forth in the specification and claims are approximations that may vary depending on the desired properties sought to be obtained in embodiments of the present invention. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from error found in their respective measurements.

Figures Detail

FIG.1is an exemplary downhole assembly101shown contained in a well casing102. For the purpose of this application the downhole assembly101is understood to be the entire assembly connected to the bottom of the downhole pump seating nipple and above the tail pipe. The downhole pump is attached to the bottom of the string of tubing and above the downhole assembly by the pump seating nipple. The top of the downhole assembly101is attached to the bottom of the downhole pump seating nipple. At the bottom of the downhole pump the seating nipple fluidly connects the downhole pump to the string of tubing. The string of tubing extends from the top of the downhole pump seating nipple to the surface. The downhole pump is adapted to artificially lift oil from the downhole assembly101to the surface. Oil is artificially lifted to the surface by pumping force exerted by the downhole pump and flows upward through the string of tubing.

Many wellbores are horizontal wells wherein horizontal directional drilling techniques are used to extract oil. Typically, the oil wellbore104extends from the surface downward into the ground. At a desired depth the wellbore104turns to a horizontal direction which is roughly parallel with the surface. The location where the wellbore104turns is considered the kickoff point. In a horizontal directional drilling application, the downhole assembly101is typically secured just above the kickoff point. The wellbore104is the hole drilled into the ground in which the casing102is placed. An anchoring device105is used to secure the downhole assembly101to the casing102. The downhole assembly101is also used in vertical wells. In a vertical well application, the downhole assembly101is secured at a desired depth.

A downhole assembly typically comprises a dip tube106, an anchoring device105, a sand separator107, a slotted body108, an upper perforated tube109, a lower perforated tube110, a first standard helix301, and a first reverse helix302. The slotted body108is comprised of one or more holes111(individually a hole111), an exterior surface112, an interior surface202, a bottom113, and a peak114. The holes111can be circular, slotted, a multitude of perforations, or any other configuration appreciated by a person of ordinary skill in the art. The slotted body108has a hollow interior that can accommodate solids, gases, and fluids to pass through. Oil with entrained gas may be located between the exterior surface112of the slotted body108and the casing102. The dip tube106is comprised of an inlet303, an upper connection205, an exterior face201, and a pipe204connecting the upper connection205with the inlet303.

Oil with entrained gas may be pulled into the holes111by force exerted from the downhole pump. The inlet303of the dip tube106is adapted to be at a lower elevation relative to the holes111. Typically, the inlet303of the dip tube106is located near the bottom113of the slotted body108. The downhole pump seating nipple is attached to the dip tube106such that a suction pressure from the downhole pump is present at the inlet303of the dip tube106. Suction at the inlet303of the dip tube106causes the oil to flow through the holes111, downward through the slotted body108, and to the inlet303of the dip tube106. The inlet303of the dip tube106is adapted such that oil can enter the dip tube106. Oil pulled into the dip tube106by the downhole pump then flows upward through the dip tube106, through the downhole pump, and up to the surface.

Oil and other liquid in the wellbore often contains entrained gases. Downhole pumps are not typically configured to efficiently pump liquid with entrained gases or free gas. If the free and entrained gas is not separated from the oil, the gas will be pulled into the downhole pump. When free or entrained gas is pulled into a downhole pump, the downhole pump's efficiency and capacity will be reduced. The gas will compress and expand with the action of the pump, therefore wasting the energy output of the downhole pump.

The two aspects of the present invention can be considered as the agitation device and the flow through assembly. The agitation device comprises the dip tube106, the first standard helix301, the first reverse helix302, and the slotted body108. The agitation device is adapted to cause entrained gas to be separated from oil and liquid. Shear stress and centrifugal force introduced by the agitation device cause the gas and liquid to separate. Liquid with entrained gas is pulled into the slotted body108near the peak114of the slotted body108. The dip tube106extends downward through the slotted body108and the inlet303is positioned near the bottom113of the slotted body108. Liquid with entrained gas which has been pulled into the holes111of the slotted body108is pulled downward to the inlet303of the dip tube106. Suction pressure from the downhole pump causes the liquid to be pulled into the dip tube106and artificially lifted to the surface by the downhole pump.

FIG.2is a cross section of a downhole assembly101with a dip tube106. The exterior face201of the dip tube106is understood to be the surface of the tube. On the exterior face201of the dip tube106, below the holes111of the slotted body108, a first standard helix301and a first reverse helix302is attached. The first reverse helix302is attached to the exterior face201at an elevation relatively lower than the first standard helix301. If more than two helixes are used, each subsequent helix would be lower.

The first standard helix301and the first reverse helix302are adapted such that they respectively extend from the exterior face201of the dip tube106to close proximity of the interior surface202of the slotted body108. Alternatively, the helixes may extend from the exterior face201of the dip tube106all the way to the interior surface202of the slotted body108. The helixes can be connected to both the interior surface202and the slotted body108or either the interior surface202or the exterior face. Given this configuration, the liquid with entrained gas which is pulled downward while in the slotted body108must circulate through the helixes. The standard helix and reverse helix configuration cause increased shear stress and centrifugal force. The stresses and forces cause the liquid and gas to separate. The helixes may further be perforated to allow gas to flow upward through the helixes and generate additional shear forces by allowing liquid to move between the vanes of the helix.

The various versions of helixes disclosed herein are referred to as helix or helixes. In addition, the term helix or helixes may be used to refer to either reverse helixes or standard helixes. A standard helix is a helix that is adapted to cause rotation in one direction. In contrast, a reverse helix is a helix that is adapted to cause rotation in the opposite direction as the standard helix.

The first helix is a helix that is configured to flow in one circular direction. The first reverse helix is a helix that is configured to flow in the opposite circular direction. Multiple helixes and reverse helixes can be configured in a particular embodiment. A helix is considered to be a plate with a desired pitch attached to a pipe. In the present invention, the pipe is the dip tube106. Different variations of pitch and length can be employed for use in the agitation device. The length and pitch of the helix for this invention are not important. What is important is the combination of a standard helix and a reverse helix. By combining a standard helix with a reverse helix, the shear stress incurred by the oil entrained with gas is increased, therefore causing the entrained gas to be released. Gas released is considered separated gas.

Multiple variations of helixes can be used in the agitation device. For example, multiple sets of standard helixes and reverse helixes can be adapted. Helixes with multiple plates can be used. A helix with multiple plates is a helix that has two distinct plates the run the length of the helix. A double helix is a helix with a second plate. A standard helix will be comprised of standard plates wherein in a reverse helix will be comprised of reverse plates. For example, a double helix that is a standard helix may have a first standard plate901and a second standard plate902. A double helix that is a reverse helix may have a first reverse place and a second reverse plate.

The helixes may be adapted with helix perforations1001to allow separated gas to move upward after being released from the oil. Helix perforations1001may include holes cut into the plates of the helixes. For example, a helix might have multiple holes cut on the center of the surface of a plate. Alternatively, a helix plate might have cuts at the inner or outer portion of the plate. The helixes are discussed further in the detail ofFIGS.9-10.

InFIG.2the dip tube106can be seen extending from the inlet303upward through the slotted body108, the lower perforated tube110, the anchoring device105, the upper perforated tube109, and to the top103of the downhole assembly101. The dip tube106is positioned near the center of each elements of which the dip tube106extends upward through. Oil with entrained gas is pulled into the holes111. The slotted body108has a hollow interior203which oil with entrained gas can flow through. The hollow interior203encompasses the space between the interior surface202of the slotted body108and the exterior face201of dip tube106.FIG.3is a downhole assembly101showing a first standard helix301and a first reverse helix302. The dip tube106along with the helixes are shown in an exploded view removed from the other elements of the downhole assembly101. The exemplary embodiment shown inFIG.3reflects the adaptation of one standard helix and one reverse helix. The helixes are located relatively lower in elevation compared to the holes111on the slotted body108.

InFIG.3a flow through assembly is adapted to the downhole assembly101. The flow through assembly comprises the lower perforated tube110, the upper perforated tube109, and the anchoring device105. Alternatively, the upper and lower perforated tube may be combined with the anchoring assembly as one piece. A more detailed description of the flow through assembly is provided in the description ofFIG.8.

FIG.4is a downhole assembly101showing two standard helixes and two reverse helixes. In this embodiment, a first standard helix301, a first reverse helix302, a second standard helix401, and a second reverse helix402are adapted to the dip tube106. The dip tube106along with the helixes are shown in an exploded view removed from the other elements of the downhole assembly101. The exemplary embodiment shown inFIG.4reflects the adaptation of two standard helixes and two reverse helixes. The helixes are located relatively lower in elevation compared to the holes111on the slotted body108.

FIG.5is a downhole assembly101showing four standard helixes and four reverse helixes. In this embodiment, a first standard helix301, a first reverse helix302, a second standard helix401, a second reverse helix402, a third standard helix501, a third reverse helix502, a fourth standard helix503, and a fourth reverse helix504, are adapted to the dip tube106. As many helixes can be adapted to the dip tube106as reasonably allowed by the size of the dip tube106. The dip tube106along with the helixes are shown in an exploded view removed from the other elements of the downhole assembly101. The exemplary embodiment shown inFIG.5reflects the adaptation of four standard helixes and four reverse helixes. The helixes are located relatively lower in elevation compared to the holes111on the slotted body108.

FIG.6is a downhole assembly101showing two standard helixes and one reverse helix. In this embodiment, a first standard helix301, a first reverse helix302, and a second standard helix401are adapted to the dip tube106. The dip tube106along with the helixes are shown in an exploded view removed from the other elements of the downhole assembly101. The exemplary embodiment shown inFIG.6reflects the adaptation of two standard helixes and one reverse helixes. The helixes are located relatively lower in elevation compared to the holes111on the slotted body108. As shown inFIG.6, an uneven number of standard helixes and reverse helixes can be adapted to the dip tube106.

FIG.7is a downhole assembly101showing a first standard helix301and a first reverse helix302. The dip tube106along with the helixes are shown in an exploded view removed from the other elements of the downhole assembly101. The exemplary embodiment shown inFIG.3reflects the adaptation of one standard helix and one reverse helix. The helixes are located relatively lower in elevation compared to the holes111on the slotted body108. The embodiment shown inFIG.7does not include a flow through assembly. A standard tubing anchor701is adapted to the downhole assembly101to secure the downhole assembly101to the casing102. In this embodiment, a standard tubing anchor701commonly used in the industry is adapted for use with the improved agitation device disclosed herein.

FIG.8is a detailed drawing of an exemplary flow through assembly. The second aspect of the invention is the flow through assembly. The flow through assembly is comprised of the lower perforated tube110, the upper perforated tube109, and the anchoring device105. A dip tube106extends through the approximate center of the elements of the flow through assembly. The lower perforated tube110has an inner surface802b. The upper perforated tube109has an inner surface802a. The anchoring device105has an inner surface802c. The three inner surfaces can be referenced as an inner surface802. Between the exterior face201of the dip tube106and the inner surface802of the lower perforated tube110, the upper perforated tube109, and the anchoring device105, is a flow channel through which separated gas may flow. The flow channel between the exterior face201of the dip tube106and the inner surface802aof the upper perforated tube109is the upper flow channel806. The flow channel between the exterior face201of the dip tube106and the inner surface802bof the lower perforated tubed110is the lower flow channel807. The lower flow channel807, the center flow channel801, and the upper flow channel806are fluidly connected such that gas can flow through the channels.

The upper perforated tube109has one or more upper perforations803which gas can flow through so to exit the upper perforated tube109. As shown inFIG.8, there are a multitude of upper perforations803. The lower perforated tube110has one or more lower perforations804which gas can flow through. As shown inFIG.8, there are a multitude of lower perforations804.

A anchoring device105further comprises a structure805that connects the downhole assembly101and the casing102. Separated gas flows between the casing102and downhole assembly101up past the anchoring device105and toward the surface. Once past the anchoring device105, the separated gas may continue to flow toward the surface between the casing102and the string of tubing. The structure805of the anchoring device105is an object which restricts the flow of the gas. The structure805of the anchoring device105is often configured to minimize its cross section so to allow reduce the restriction on the flow of gas.

The flow through assembly as disclosed herein, additionally allows separated gas to flows upward toward the surface from the agitation device by passing through the center flow channel801of the anchoring device105. The separated gas may enter the lower perforated tube110through the lower perforations804, flow through the center flow channel801of the anchoring device105, and out of the upper perforated tube109through the upper perforations803. This adaption allows for the gas to flow upward with a reduced amount of resistance from the structure805of the anchoring device105.

The lower perforated tube110may be fluidly connected to the peak114of the slotted body108such that the lower flow channel807is fluidly connected to the slotted body108. Fluids and gases may communicate through a fluid connection. Separated gas may flow through the slotted body108into the lower flow channel807. Alternatively, the downhole assembly101may be configured without a lower perforated tube110. In such embodiment the center flow channel801may be fluidly connected to the slotted body108. In such embodiment, the anchoring device105may be connected to the slotted body108or a pipe may connect the anchoring device105to the slotted body108.

FIG.9is an exemplary helix. The exemplary helix shown may be a first standard helix301attached to the exterior face201of the dip tube106. In the embodiment shown, the first standard helix301is comprised of a first standard plate901and a second standard plate902. The exemplary helix is a double helix. A reverse helix is a helix that rotates around the dip tube106in the rotational direction opposite to the standard helix301.

FIG.10is an exemplary helix. The exemplary helix shown may be a first standard helix301attached to the exterior face201of the dip tube106. In the embodiment shown, the first standard helix301is comprised of a first standard plate901and a second standard plate902. The exemplary helix is a double helix. In the exemplary helix, the first standard plate901and the second standard plate902further comprise of helix perforations1001. The embodiment shown reflects the use of holes cut in the plates.

Explanation of Exemplary Language

While various inventive aspects, concepts and features of the general inventive concepts are described and illustrated herein in the context of various exemplary embodiments, these various aspects, concepts and features may be used in many alternative embodiments, either individually or in various combinations and sub-combinations thereof.

Unless expressly excluded herein all such combinations and sub-combinations are intended to be within the scope of the general inventive concepts. Still further, while various alternative embodiments as to the various aspects, concepts and features of the inventions (such as alternative materials, structures, configurations, methods, devices and components, alternatives as to form, fit and function, and so on) may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed. Those skilled in the art may readily adopt one or more of the inventive aspects, concepts or features into additional embodiments and uses within the scope of the general inventive concepts even if such embodiments are not expressly disclosed herein. Additionally, even though some features, concepts or aspects of the inventions may be described herein as being a preferred arrangement or method, such description is not intended to suggest that such feature is required or necessary unless expressly so stated. Still further, exemplary or representative values and ranges may be included to assist in understanding the present disclosure; however, such values and ranges are not to be construed in a limiting sense and are intended to be critical values or ranges only if so expressly stated. Moreover, while various aspects, features and concepts may be expressly identified herein as being inventive or forming part of an invention, such identification is not intended to be exclusive, but rather there may be inventive aspects, concepts and features that are fully described herein without being expressly identified as such or as part of a specific invention. Descriptions of exemplary methods or processes are not limited to inclusion of all steps as being required in all cases, nor is the order that the steps are presented to be construed as required or necessary unless expressly so stated.