Downhole production system with flow diverter for gas separation

Abstract

There is provided a reservoir fluid production system, deployable within a wellbore, whose components are manufactured from polymeric materials, such as, for example, continuous fibers.

1 . A reservoir production system, disposed within a wellbore that is lined with a wellbore string, comprising: 
       a gas separator; 
       a pump; and 
       a gas-depleted reservoir fluid conductor; 
       wherein:
 the gas separator is fluidly coupled to the gas-depleted reservoir fluid conductor for supplying a gas-depleted reservoir fluid to the gas-depleted reservoir fluid conductor; 
 the gas-depleted reservoir fluid conductor includes a fluid conductor portion that is defined by the pump; 
 the pump is configured for pressurizing the gas-depleted reservoir fluid received from the gas separator, with effected that pressurized gas-depleted reservoir fluid is conducted to the surface via the gas-depleted reservoir fluid conductor; 
 the gas separator and the wellbore string are co-operatively configured such that there is established, within the wellbore, a reservoir fluid-receiving zone, a reservoir fluid-conducting passage, a separation zone, a gas-depleted reservoir fluid-conducting passage, and a liquid-depleted reservoir fluid-conducting passage; 
 the separation zone is disposed within a vertical portion of the wellbore and is disposed above the reservoir fluid-receiving zone; 
 the liquid-depleted reservoir fluid-conducting passage is disposed above the separation zone and extends to the surface; 
 the gas separator includes a flow diverter; 
 the flow diverter separates the reservoir fluid-conducting passage from the gas-depleted reservoir fluid-conducting passage; 
 the gas separator, the pump, and the gas-depleted reservoir fluid conductor are further co-operatively configured such that:
 while the reservoir fluid is emplaced within the reservoir fluid-receiving zone, the reservoir fluid-conducting passage is disposed for conducting the reservoir fluid upwardly as a flow from the reservoir fluid receiving zone to the separation zone; 
 while the reservoir fluid flow is being conducted by the reservoir fluid-conducted passage and becoming emplaced within the separation zone, the reservoir fluid flow is separated into a gas-depleted reservoir fluid flow and a liquid-depleted reservoir fluid flow in response to at least buoyancy forces, with effect that: (i) a downwardly flow of the gas-depleted reservoir fluid, from the separation zone, is established, and (ii) an upwardly flow of the liquid-depleted reservoir fluid, from the separation zone, is established; 
 while the gas-depleted reservoir fluid flow is being separated from the reservoir fluid flow within the separation zone, the gas-depleted reservoir fluid flow is received and diverted by the flow diverter to the gas-depleted reservoir fluid conductor for conduction to the surface; and 
 while the liquid-depleted reservoir fluid flow is being separated from the reservoir fluid flow within the separation zone and is being flowed upwardly from the separation zone, the liquid-depleted reservoir fluid is conducted to the surface via the liquid-depleted reservoir fluid-conducting passage; 
 
 the gas separator further includes:
 a reservoir fluid conductor; and 
 a sealed interface effector; 
 
 at least a portion of the reservoir fluid-conducting passage is defined within the reservoir fluid conductor;
 the sealed interface effector is mounted to the reservoir fluid conductor such that the reservoir fluid conductor is sealingly engaged to the wellbore string via the sealed interface effector; 
 the material of construction of the reservoir fluid conductor includes polymeric material; and 
 the sealed interface effector includes a swellable packer. 
 
 
     
     
         2 . The system as claimed in  claim 1 ; 
       wherein:
 the reservoir fluid conductor includes:
 a flow receiving communicator; 
 a flow discharging communicator; and 
 a reservoir fluid conductor flow passage; 
 wherein:
 the defining of at least a portion of the reservoir fluid-conducting passage, within the reservoir fluid conductor, is established by the reservoir fluid conductor flow passage; 
 the flow receiving communicator is effective for receiving the reservoir fluid from the reservoir fluid-receiving zone such that the conducting of the reservoir fluid, by the reservoir fluid-conducting passage, is effected while the reservoir fluid is being received by the flow receiving communicator from the reservoir fluid-receiving zone; 
 the reservoir fluid conductor flow passage is effective for conducting the reservoir fluid received by the flow receiving communicator to the flow discharging communicator; and 
 the flow discharging communicator is effective for discharging the reservoir fluid from the reservoir fluid conductor; and 
 the flow diverter, the wellbore string, the reservoir fluid conductor, and the sealed interface effector are co-operatively configured such that:
 an intermediate passage is disposed between the flow diverter and the wellbore string and defines another portion of the reservoir fluid-conducting passage; 
 the flow discharging communicator is disposed in flow communication with the reservoir fluid separation zone via the intermediate passage; and 
 while reservoir fluid is being discharged from the flow discharging communicator, the discharged reservoir fluid is diverted by the sealed interface effector to the intermediate passage for conduction to the reservoir fluid separation zone. 
 
 
 
 
     
     
         3 . The system as claimed in  claim 1 ; 
       wherein:
 the swellable packer is mounted to the reservoir fluid conductor. 
 
     
     
         4 . The system as claimed in  claim 1 ; 
       wherein:
 the reservoir fluid conductor is a velocity string. 
 
     
     
         5 . The system as claimed in  claim 4 ; 
       wherein:
 the velocity string is characterized by a maximum cross-sectional flow area, and the maximum cross-sectional flow area is smaller than the minimum cross-sectional flow area of the reservoir fluid-receiving space. 
 
     
     
         6 . The system as claimed in  claim 5 ; 
       wherein:
 the ratio of the minimum cross-sectional flow area of the reservoir fluid-receiving space to the maximum cross-sectional flow area of the reservoir fluid conducting passage portion, defined by the velocity string, is at least 1.5. 
 
     
     
         7 . (canceled) 
     
     
         8 . The system as claimed in  claim 4 ; 
       wherein:
 the velocity string extends through the heel portion. 
 
     
     
         9 . A reservoir production system, disposed within a wellbore that is lined with a wellbore string, comprising: 
       a gas separator; 
       a pump; and 
       a gas-depleted reservoir fluid conductor; 
       wherein:
 the gas separator is fluidly coupled to the gas-depleted reservoir fluid conductor for supplying a gas-depleted reservoir fluid to the gas-depleted reservoir fluid conductor; 
 the gas-depleted reservoir fluid conductor includes a fluid conductor portion that is defined by the pump; 
 the pump is configured for pressurizing the gas-depleted reservoir fluid received from the gas separator, with effected that pressurized gas-depleted reservoir fluid is conducted to the surface via the gas-depleted reservoir fluid conductor; 
 the gas separator and the wellbore string are co-operatively configured such that there is established, within the wellbore, a reservoir fluid-receiving zone, a reservoir fluid-conducting passage, a separation zone, a gas-depleted reservoir fluid-conducting passage, and a liquid-depleted reservoir fluid-conducting passage; 
 the separation zone is disposed within a vertical portion of the wellbore and is disposed above the reservoir fluid-receiving zone; 
 the liquid-depleted reservoir fluid-conducting passage is disposed above the separation zone and extends to the surface; 
 the gas separator includes a flow diverter; 
 the flow diverter separates the reservoir fluid-conducting passage from the gas-depleted reservoir fluid-conducting passage; 
 the gas separator, the pump, and the gas-depleted reservoir fluid conductor are further co-operatively configured such that:
 while the reservoir fluid is emplaced within the reservoir fluid-receiving zone, the reservoir fluid-conducting passage is disposed for conducting the reservoir fluid upwardly as a flow from the reservoir fluid receiving zone to the separation zone; 
 while the reservoir fluid flow is being conducted by the reservoir fluid-conducted passage and becoming emplaced within the separation zone, the reservoir fluid flow is separated into a gas-depleted reservoir fluid flow and a liquid-depleted reservoir fluid flow in response to at least buoyancy forces, with effect that: (i) a downwardly flow of the gas-depleted reservoir fluid, from the separation zone, is established, and (ii) an upwardly flow of the liquid-depleted reservoir fluid, from the separation zone, is established; 
 while the gas-depleted reservoir fluid flow is being separated from the reservoir fluid flow within the separation zone, the gas-depleted reservoir fluid flow is received and diverted by the flow diverter to the gas-depleted reservoir fluid conductor for conduction to the surface; and 
 while the liquid-depleted reservoir fluid flow is being separated from the reservoir fluid flow within the separation zone and is being flowed upwardly from the separation zone, the liquid-depleted reservoir fluid is conducted to the surface via the liquid-depleted reservoir fluid-conducting passage; 
 the gas separator further includes:
 a reservoir fluid conductor; and 
 a sealed interface effector; 
 
 at least a portion of the reservoir fluid-conducting passage is defined within the reservoir fluid conductor; 
 the sealed interface effector is mounted to the reservoir fluid conductor such that the reservoir fluid conductor is sealingly engaged to the wellbore string via the sealed interface effector; 
 the reservoir fluid conductor includes a flow passage-defining portion and a reinforcing layer; 
 the flow passage-defining portion includes an inner surface and an outer surface; 
 the inner surface defines the reservoir fluid conductor flow passage of the reservoir fluid conductor; 
 the reinforcing layer is coupled to the outer surface such that the reinforcing layer overlies at least a portion of the outer surface; 
 the material of construction of the flow passage-defining portion includes polymeric material; and 
 the reinforcing layer includes a plurality of continuous fibers. 
 
 
     
     
         10 . The system as claimed in  claim 9 ; 
       wherein:
 the reservoir fluid conductor includes:
 a flow receiving communicator; 
 a flow discharging communicator; and 
 a reservoir fluid conductor flow passage; 
 wherein:
 the defining of at least a portion of the reservoir fluid-conducting passage, within the reservoir fluid conductor, is established by the reservoir fluid conductor flow passage; 
 the flow receiving communicator is effective for receiving the reservoir fluid from the reservoir fluid-receiving zone such that the conducting of the reservoir fluid, by the reservoir fluid-conducting passage, is effected while the reservoir fluid is being received by the flow receiving communicator from the reservoir fluid-receiving zone; 
 the reservoir fluid conductor flow passage is effective for conducting the reservoir fluid received by the flow receiving communicator to the flow discharging communicator; and 
 the flow discharging communicator is effective for discharging the reservoir fluid from the reservoir fluid conductor; and 
 the flow diverter, the wellbore string, the reservoir fluid conductor, and the sealed interface effector are co-operatively configured such that:
 an intermediate passage is disposed between the flow diverter and the wellbore string and defines another portion of the reservoir fluid-conducting passage; 
 the flow discharging communicator is disposed in flow communication with the reservoir fluid separation zone via the intermediate passage; and 
 while reservoir fluid is being discharged from the flow discharging communicator, the discharged reservoir fluid is diverted by the sealed interface effector to the intermediate passage for conduction to the reservoir fluid separation zone. 
 
 
 
 
     
     
         11 . The system as claimed in  claim 9 ; 
       wherein:
 the continuous fibers are helically wound about the flow passage-defining portion with respect to a longitudinal axis of the flow passage-defining portion 
 
     
     
         12 . The system as claimed in  claim 11 ; 
       wherein:
 the helical winding is at a winding angle of from 40 degrees to 60 degrees. 
 
     
     
         13 . The system as claimed in  claim 9 ; 
       wherein:
 the continuous fibers are embedded within a polymeric matrix such that the reinforcing layer includes a reinforced polymeric material. 
 
     
     
         14 . The system as claimed in  claim 13 ; 
       wherein:
 the reinforced polymeric material is a continuous fiber reinforced thermoplastic material. 
 
     
     
         15 . (canceled) 
     
     
         16 . A downhole-deployable reservoir production system precursor, deployable within a wellbore lined with a wellbore string for establishing a reservoir production system within the wellbore, comprising: 
       an uphole counterpart including:
 a flow diverter; 
 a pump; and 
 a gas-depleted reservoir fluid conductor; 
 
       and 
       downhole counterpart including:
 a reservoir fluid conductor including:
 a flow receiving communicator; 
 a flow discharging communicator; and 
 a reservoir fluid conductor flow passage; 
 
 and 
 a sealed interface effector; 
 
       and 
       degradable material; 
       wherein:
 the uphole counterpart, the downhole counterpart, and the degradable material are co-operatively configured such that the uphole counterpart is connected to the downhole counterpart via a connection, and, while the downhole-deployable gas separator precursor is disposed within the wellbore, the connection is defeatable in response to degradation of the degradable material, with effect that a reservoir production system is obtained within the wellbore; 
 the reservoir production system comprises:
 a gas separator; 
 the pump; and 
 the gas-depleted reservoir fluid conductor; 
 wherein:
 the gas separator includes the flow diverter, the reservoir fluid conductor, and the sealed interface effector; 
 the gas separator is fluidly coupled to the gas-depleted reservoir fluid conductor for supplying a gas-depleted reservoir fluid to the gas-depleted reservoir fluid conductor; 
 the gas-depleted reservoir fluid conductor includes a fluid conductor portion that is defined by the pump; 
 the pump is configured for pressurizing the gas-depleted reservoir fluid received from the gas separator, with effected that pressurized gas-depleted reservoir fluid is conducted to the surface via the gas-depleted reservoir fluid conductor; 
 the gas separator and the wellbore string are co-operatively configured such that there is established, within the wellbore, a reservoir fluid-receiving zone, a reservoir fluid-conducting passage, a separation zone, a gas-depleted reservoir fluid-conducting passage, and a liquid-depleted reservoir fluid-conducting passage; 
 the separation zone is disposed within a vertical portion of the wellbore and is disposed above the reservoir fluid-receiving zone; 
 the liquid-depleted reservoir fluid-conducting passage is disposed above the separation zone and extends to the surface; 
 the flow diverter separates the reservoir fluid-conducting passage from the gas-depleted reservoir fluid-conducting passage; 
 the gas separator, the pump, and the gas-depleted reservoir fluid conductor are co-operatively configured such that:
 while the reservoir fluid is emplaced within the reservoir fluid-receiving zone, the reservoir fluid-conducting passage is disposed for conducting the reservoir fluid upwardly as a flow from the reservoir fluid receiving zone to the separation zone; 
 while the reservoir fluid flow is being conducted by the reservoir fluid-conducted passage and becoming emplaced within the separation zone, the reservoir fluid flow is separated into a gas-depleted reservoir fluid flow and a liquid-depleted reservoir fluid flow in response to at least buoyancy forces, with effect that: (i) a downwardly flow of the gas-depleted reservoir fluid, from the separation zone, is established, and (ii) an upwardly flow of the liquid-depleted reservoir fluid, from the separation zone, is established; 
 while the gas-depleted reservoir fluid flow is being separated from the reservoir fluid flow within the separation zone, the gas-depleted reservoir fluid flow is received and diverted by the flow diverter to the gas-depleted reservoir fluid conductor for conduction to the surface; and 
 while the liquid-depleted reservoir fluid flow is being separated from the reservoir fluid flow within the separation zone and is being flowed upwardly from the separation zone, the liquid-depleted reservoir fluid is conducted to the surface via the liquid-depleted reservoir fluid-conducting passage; 
 
 the reservoir fluid conductor flow passage defines a portion of the reservoir fluid-conducting passage; 
 the flow receiving communicator is effective for receiving the reservoir fluid from the reservoir fluid-receiving zone such that the conducting of the reservoir fluid, by the reservoir fluid-conducting passage, is effected while the reservoir fluid is being received by the flow receiving communicator from the reservoir fluid-receiving zone; 
 the reservoir fluid conductor flow passage is effective for conducting the reservoir fluid received by the flow receiving communicator to the flow discharging communicator; and 
 the flow discharging communicator is effective for discharging the reservoir fluid from the reservoir fluid conductor; 
 
 the flow diverter, the wellbore string, the reservoir fluid conductor, and the sealed interface effector are co-operatively configured such that:
 an intermediate passage is disposed between the flow diverter and the wellbore string and defines another portion of the reservoir fluid-conducting passage; 
 the flow discharging communicator is disposed in flow communication with the reservoir fluid separation zone via the intermediate passage; and 
 while reservoir fluid is being discharged from the flow discharging communicator, the discharged reservoir fluid is diverted by the sealed interface effector to the intermediate passage for conduction to the reservoir fluid separation zone. 
 
 
 
     
     
         17 . The gas-depleted reservoir fluid production system precursor as claimed in  claim 16 ; 
       wherein:
 the connection, via which the uphole counterpart is connected to the downhole counterpart, is a connection between the gas separator and the reservoir fluid flow conductor. 
 
     
     
         18 . A reservoir production system, disposed within a wellbore that is lined with a wellbore string, comprising: 
       a gas separator; 
       a pump; and 
       a gas-depleted reservoir fluid conductor; 
       wherein:
 the gas separator is fluidly coupled to the gas-depleted reservoir fluid conductor for supplying a gas-depleted reservoir fluid to the gas-depleted reservoir fluid conductor; 
 the gas-depleted reservoir fluid conductor includes a fluid conductor portion that is defined by the pump; 
 the pump is configured for pressurizing the gas-depleted reservoir fluid received from the gas separator, with effected that pressurized gas-depleted reservoir fluid is conducted to the surface via the gas-depleted reservoir fluid conductor; 
 the gas separator and the wellbore string are co-operatively configured such that there is established, within the wellbore, a reservoir fluid-receiving zone, a reservoir fluid-conducting passage, a separation zone, a gas-depleted reservoir fluid-conducting passage, and a liquid-depleted reservoir fluid-conducting passage; 
 the separation zone is disposed within a vertical portion of the wellbore and is disposed above the reservoir fluid-receiving zone; 
 the liquid-depleted reservoir fluid-conducting passage is disposed above the separation zone and extends to the surface; 
 the gas separator includes a flow diverter; 
 the flow diverter separates the reservoir fluid-conducting passage from the gas-depleted reservoir fluid-conducting passage; 
 the gas separator, the pump, and the gas-depleted reservoir fluid conductor are further co-operatively configured such that:
 while the reservoir fluid is emplaced within the reservoir fluid-receiving zone, the reservoir fluid-conducting passage is disposed for conducting the reservoir fluid upwardly as a flow from the reservoir fluid receiving zone to the separation zone; 
 while the reservoir fluid flow is being conducted by the reservoir fluid-conducted passage and becoming emplaced within the separation zone, the reservoir fluid flow is separated into a gas-depleted reservoir fluid flow and a liquid-depleted reservoir fluid flow in response to at least buoyancy forces, with effect that: (i) a downwardly flow of the gas-depleted reservoir fluid, from the separation zone, is established, and (ii) an upwardly flow of the liquid-depleted reservoir fluid, from the separation zone, is established; 
 while the gas-depleted reservoir fluid flow is being separated from the reservoir fluid flow within the separation zone, the gas-depleted reservoir fluid flow is received and diverted by the flow diverter to the gas-depleted reservoir fluid conductor for conduction to the surface; and 
 while the liquid-depleted reservoir fluid flow is being separated from the reservoir fluid flow within the separation zone and is being flowed upwardly from the separation zone, the liquid-depleted reservoir fluid is conducted to the surface via the liquid-depleted reservoir fluid-conducting passage; 
 
 the gas separator further includes:
 a reservoir fluid conductor; and 
 a sealed interface effector; 
 
 the reservoir fluid conductor includes:
 a flow receiving communicator; 
 a flow discharging communicator; and 
 a reservoir fluid conductor flow passage; 
 wherein:
 the reservoir fluid conductor flow passage defines a portion of the reservoir fluid-conducting passage; 
 the flow receiving communicator is effective for receiving the reservoir fluid from the reservoir fluid-receiving zone such that the conducting of the reservoir fluid, by the reservoir fluid-conducting passage, is effected while the reservoir fluid is being received by the flow receiving communicator from the reservoir fluid-receiving zone; 
 the reservoir fluid conductor flow passage is effective for conducting the reservoir fluid received by the flow receiving communicator to the flow discharging communicator; and 
 
 
 the flow discharging communicator is effective for discharging the reservoir fluid from the reservoir fluid conductor;
 the flow diverter, the wellbore string, the reservoir fluid conductor, and the sealed interface effector are co-operatively configured such that:
 an intermediate passage is disposed between the flow diverter and the wellbore string and defines another portion of the reservoir fluid-conducting passage; 
 the flow discharging communicator is disposed in flow communication with the reservoir fluid separation zone via the intermediate passage; 
 while reservoir fluid is being discharged from the flow discharging communicator, the discharged reservoir fluid is diverted by the sealed interface effector to the intermediate passage for conduction to the reservoir fluid separation zone; 
 a bubble coalescence zone is disposed between the flow discharging communicator and the intermediate passage; and 
 the minimum spacing distance from the flow discharging communicator to the flow diverter is at least five (5) feet. 
 
 
 
     
     
         19 . A top hold down pump comprising: 
       a barrel; 
       wherein:
 the barrel includes a flow passage-defining portion and a reinforcing layer 
 the flow passage-defining portion includes an inner surface and an outer surface; 
 the inner surface defines a flow passage of the barrel for conducting fluid being pressurized by the pump; 
 the reinforcing layer is coupled to the outer surface such that the reinforcing layer overlies at least a portion of the outer surface; 
 the material of construction of the flow passage-defining portion includes polymeric material; and 
 the reinforcing layer includes a plurality of continuous fibers. 
 
     
     
         20 . The top hold down pump as claimed in  claim 19 ; 
       wherein:
 the continuous fibers are helically wound about the flow passage-defining portion with respect to a longitudinal axis of the flow passage-defining portion 
 
     
     
         21 . The top hold down pump as claimed in  claim 20 ; 
       wherein:
 the helical winding is at a winding angle of from 40 degrees to 60 degrees. 
 
     
     
         22 . The top hold down pump as claimed in  claim 19 ; 
       wherein:
 the continuous fibers are embedded within a polymeric matrix such that the reinforcing layer includes a reinforced polymeric material. 
 
     
     
         23 . The top hold down pump as claimed in  claim 22 ; 
       wherein:
 the reinforced polymeric material is a continuous fiber reinforced thermoplastic material. 
 
     
     
         24 . (canceled)