Shell Western E&p Inc.

Robert D Cotherman

Keith F Way

A submersible pump system and method for producing oil from gassy wells is disclosed in which at least first- and second-stage gas separators protect a submersible pump from vapor lock. The pump communicates with the production tubing and is driven by a shaft extending from a motor, through the first- and second-stage gas separators. The first-stage gas separator has a first-stage inlet through the housing in communication with the production fluid from the producing formation. A primary means for separating gas components from the production fluid is in communication with the first-stage inlet and expels separated gas into the annulus through a first-stage gas outlet and advances the liquid component of the production fluid through the first-stage liquid outlet. The second-stage gas separator has a second-stage inlet communicating with the first-stage liquid outlet and leading to a secondary means for separating the gas from the production fluid. The separated gaseous components are expelled through the housing and into the annulus at a second-stage gas outlet while the retained liquid components of the production fluid are presented to the pump, or to additional separation stages, through a second-stage outlet. The production fluid ultimately entering the pump inlet is substantially limited to the liquid components of the production fluid which is pumped through a pump outlet and up the production tubing.

Method and apparatus for high-efficiency gas separation upstream of a

A method for constructing a multiple-stage gas separator assembly for downhole use upstream of a hydrocarbon producing submersible pump system is disclosed which has steps for forming a first-stage gas separator from a first conventional single-stage gas separator, connecting a coupling assembly to the first-stage gas separator at its downstream end, forming a second-stage gas separator from a second conventional single-stage gas separator by removing all lower flanges upstream of its fluid inlet, connecting the upstream end of the second-stage gas separator to the coupling assembly, and establishing a flow path from the first-stage liquid outlet to the second-stage inlet through the coupling assembly. A coupling assembly for joining first and second single-stage gas separators into a multiple-stage gas separator is also disclosed in which the coupling assembly has means for attaching to the downstream end of a first-stage gas separator, and a coupling housing defining a flow path between the liquid outlet of the first-stage gas separator and the fluid inlet of the second-stage gas separator. In an alternate embodiment, an adaptor is disclosed for inclusion into the coupling assembly which provides flow paths and a bushing for the second-stage gas separator formed from an alternate commercially available single-stage gas separator configuration.

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Houston, TX, United States of America

Robert D Cotherman