Multi-stage gas separator
View Patent ↗A gas separator is configured to separate gas from a two-phase fluid. The gas separator includes a rotatable shaft, a plurality of separation stages and an outer housing. Each of the plurality of separation stages includes a rotor connected to the rotatable shaft, a diffuser downstream from the rotor and a crossover downstream from the diffuser. Each crossover is configured to remove gas from its respective separation stage. The outer housing includes a separate group of discharge ports for each separation stage to permit the removal of gas from each separation stage.
1. A gas separator configured to separate gas from a two-phase fluid, the gas separator comprising:
a rotatable shaft;
a plurality of separation stages, wherein each separation stage comprises:
a rotor connected to the rotatable shaft;
a diffuser downstream from the rotor; and
a crossover downstream from the diffuser, wherein each crossover is configured to remove gas from its respective separation stage;
an outer housing, wherein the outer housing includes a separate group of discharge ports for each separation stage to permit the removal of gas from each separation stage
a base;
a head;
intake ports adjacent the base; and
a flow-through bearing downstream from the intake ports and upstream from the plurality of separation stages.
2. The gas separator of claim 1 , wherein the rotor includes an inducer and an impeller.
3. The gas separator of claim 1 , wherein the diffuser comprises:
a diffuser rim; and
a plurality of diffuser vanes, wherein a first end of each of the plurality of diffuser vanes is connected to the diffuser rim and a second end of each of the diffuser vanes is unattached and terminates in a position proximate the rotatable shaft.
4. The gas separator of claim 3 , wherein the diffuser includes a separation ring that stabilizes the diffuser vanes during use.
5. The gas separator of claim 1 , wherein the crossover comprises:
an outer wall;
an inner wall;
and a shaft support configured to stabilize the rotatable shaft;
a liquid path defined by the annular space between the outer wall and the inner wall; and
an inner chamber defined by the space between the rotatable shaft and the inner wall.
6. The gas separator of claim 5 , wherein the crossover further comprises a plurality of gas ports configured to conduct gas from the inner chamber through the outer wall.
7. A gas separator configured to remove gas from a two-phase fluid, the gas separator comprising:
an outer housing;
a flow-through bearing; and
a diffuser, wherein the diffuser comprises:
a diffuser rim;
a plurality of diffuser vanes, wherein each of the plurality of diffuser vanes has a first end connected to the diffuser rim and a free-floating second end.
8. The gas separator of claim 7 , wherein the gas separator further comprises:
a rotor upstream from the diffuser, wherein the rotor is configured to induce a rotational flow profile in the two-phase fluid; and
crossover downstream from the diffuser, wherein the crossover is configured to capture gas present in a center radial portion of the gas separator while permitting fluid present in an outer radial portion of the gas separator to remain in the gas separator.
9. A submersible pumping system for use in a wellbore having two-phase fluids, the pumping system comprising:
a pump assembly;
a motor assembly;
a gas separator disposed between the pump assembly and the motor assembly;
a seal section disposed between the motor assembly and the gas separator; and
wherein the gas separator comprises:
a base connected to the seal section;
a head connected to the pump assembly;
intake ports adjacent the base;
a rotatable shaft driven by the motor assembly;
a plurality of separation stages, wherein each separation stage comprises:
a rotor connected to the rotatable shaft, wherein the rotor includes an inducer and an impeller;
a diffuser downstream from the rotor; and
a crossover downstream from the diffuser, wherein each crossover is configured to remove gas from its respective separation stage; and
an outer housing, wherein the outer housing includes a separate group of discharge ports for each separation stage to permit the removal of gas from each separation stage.
10. The pumping system of claim 9 , wherein the diffuser comprises:
a diffuser rim; and
a plurality of diffuser vanes, wherein a first end of each of the plurality of diffuser vanes is connected to the diffuser rim and a second end of each of the diffuser vanes is unattached and terminates in a position proximate the rotatable shaft.
11. The pumping system of claim 10 , wherein the diffuser includes a separation ring that stabilizes the diffuser vanes during use.
12. The pumping system of claim 9 , wherein the crossover comprises:
an outer wall;
an inner wall;
and a shaft support configured to stabilize the rotatable shaft;
a liquid path defined by the annular space between the outer wall and the inner wall; and
an inner chamber defined by the space between the rotatable shaft and the inner wall.
13. The pumping system of claim 12 , wherein the crossover further comprises a plurality of gas ports configured to conduct gas from the inner chamber through the outer wall.