Procedure as follows (for fishing a 5500 series WhaleShark™ in 5.5″ casing):

a. RIH with short catch overshot for a 2 3/8″ EUE Special Clearance collar 2.910″ OD x 5″ long. Latch on and fish. If tool parts below the Top Sub proceed to step 2.

b. RIH with a tapered spear for separator body test has a 2.44″ x 3.19″ ID. Latch on and fish.

Note: If separator’s rigid bar and/or oval pump intake tube are preventing the tapered spear from entering the top of the separator body, RIH with a flat-bottom mill and dress off. Re-attempt tapered spear.

Dimensions: Volume between the top of the separator’s shroud intake (top of yellow section) to the internal sand weir is approximately 8 feet, but this volume is based on a residence volume for the maximum insert pump single stroke displacement possible for the casing size. For the 4.5″ casing separator, this volume equals 1 stroke from a pump that has a 360″ full stroke length with a 1.5″ pump (0.04 bbls). For the 5.5″ casing separator, this volume equals 1 full stroke from a pump that has a 360″ stroke length with a 2.0″ pump (0.06 bbls).

Minimum tensile strength is 41,000 lbsf or 18.000 kdaN.

Yes, a crossover is located at the base of the separator back to 2-3/8″ (4500 series) or 3-1/5″ EUE (5500 and 7000 series) is standard on all WhaleShark™ separators. Standard tubing joints can be run as mud joints for additional solids containment capacity and as a retrievable solids sump.

The thread type for the separator shroud is proprietary flush thread similar to stub acme.

Coating options can include ENC type or Teflon baked-on type. We can use the lower-cost Teflon baked-on type for the external part of separator shroud to reduce the risk of scale adhesion and therefore lower retrieval risks. Details upon request.

This unique separator separates almost all of the free gas from the liquid in the region above the upward-facing shroud’s intake (see Gas Separation Regional in diagram). The liquid entering the separator’s shroud is mostly degassed and flows downward to the solids weir (very little gas separation occurs inside the separator’s shroud). This is the reason why this separator has such a high gas separation capacity and rating.

Yes. The Pump Intake Tube is intentionally positioned vertically shallower than the point on the solids weir where fluid goes around the solids weir to the Pump Intake Tube. There is also a 12″ dip tube connected to the solids weir to further force the fluids below the oval pump intake tube and to enhance solids separation. The solids weir is fixed, so it does not matter what radial position it is siting in relative to inclination. We recommend not running the separator beyond 65 degrees inclination, as gravity-based gas and solids separation efficiencies diminish considerably.

A simple gravity-based separation process using an angled weir to settle solids to the opposite side of the oval Pump Intake Tube. The Pump Intake Tube’s intake point is intentionally positioned vertically shallower than the lowermost edge of the weir and the weir’s dip tube (where the degassed liquid travels around the weir and down its dip tube). Degassed liquid must then travel upward and across to the Pump Intake Tube, which forces the solids to gravitationally settle out downward into the sump and optional mud joints.

If the gas velocity in an annular cross-sectional area reaches a velocity where it can lift all the liquids (i.e., the liquid cannot fall back downward), separation of gas from the liquid will not occur and pump gas interference will be excessive (indicated by poor pump fillage and high annular fluid levels). If a TAC is the component with the smallest and most restrictive annular cross-sectional area, it will be the region of greatest critical liquid lift risk. Therefore, a TAC’s annular flow by cross-sectional area must be maximized. For example, an inadequate plan would be to run an annular restrictive packer (with packing element removed) as a TAC. Use a critical liquid lifting gas velocity/rate calculator to check such risks.

The Separation Region is where most of gas separation occurs. The cross-sectional area of the Separation Region is the largest offered by any downhole separator. Use your casing internal diameter (ID) minus the equivalent outside diameter (OD) area of a 1″ OD tube to calculate cross-sectional area for separation.

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