Proceedings of the ASME 2009 28th International Conference on Ocean, Offshore and Arctic Engineering
OMAE2009
May 31 - June 5, 2009, Honolulu, Hawaii, USA
Proceedings of the 28th International Conference on Offshore Mechanics and Arctic Engineering
May 31-June 5, 2009, Honolulu, Hawaii, USA
DESIGN AND EXPERIMENTAL STUDY OF HYDROCYCLONE IN SERIES AND IN
BRIDGE OF DOWNHOLE OIL/WATER SEPARATION SYSYTEM
Yong Zhang1,2
1 College of Mechanical Science and Engineering
Daqing Petroleum Institute
Daqing, Heilongjiang, China
ABSTRACT
Hydrocyclone, as the core part of the downhole oil/water
separation (DOWS) system, has been used for a long time. But
some issues restricted it from extensive and long term
utilization in terms of reinjection in the same oil well, offshore
oil production and so on. The design in this paper solved the
puzzle how to arrange the main devices and their flow channels
in the comparatively narrow well bore. Some special ideas
were designed to accomplish the function to get more handling
capacity by connecting hydrocyclones in bridge and to obtain
thicker rude oil by connecting hydrocyclones in series.
Experimental study has been carried on which shows the
hydrocyclones connecting both in series and in bridge can
satisfy the corresponding application in DOWS. This study can
arouse new efforts to separate more water in well bore than
ever which can greatly decrease the burden of water treatment
and gain more economic efficiency.
Key words: DOWS; hydrocyclone; structural design;
experimental study
INTRODUCTION
Produced water treatment is always the puzzle and
regarded as the method bringing no economic benefits. Its
output quantity is ever-increasing as oil fields’ turning to be
mature or old. It shows that in Daqing, the biggest oil field in
China, there is water cut over 90% and it expands more money
in water treatment than production itself. John A. Veil as the
manager of the Water Policy Program in the Environmental
Science Division of Argonne National Laboratory of USA
addressed on science and technology subcommittee on energy
and engineering of a conference in 2007 that approximately 15
to 20 billion bbl (barrels; 1 bbl = 42 U.S. gallons) of produced
water are generated each year in the United States from about
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OMAE2009
OMAE2009-79194
OMAE2009-79194
Minghu Jiang1, Lixin Zhao1, Feng Li1
2 Institute of Contemporary Manufacturing Engineering
Zhejiang University
Hangzhou, Zhejiang, China
900,000 wells. This is equivalent to a volume of 1.7 to 2.3
billion gallons per day. On offshore platform produced water
treatment unit has been the bottle-neck of the restriction of
dimension of production platform. (Bowers, B.E. et al. 2000
and Veil J.A. et al. 2005)
Downhole oil/water separation (DOWS) system is a
feasible method to decrease the pressure caused by more and
more product water to dispose of.
It is crucial to keep the economical efficiency of the high
water ratio oil well and the feasibility of water treatment in a
comparatively small platform of offshore oil field. Many
downhole separation methods were invented in the 1990s, most
of which were used in Canadian oil field on land. Then
enthusiasms for this technique fell off because some issues
restricted it from extensive and long term utilization in terms of
reinjection in the same oil well, offshore oil production and so
on. (Veil J.A. 2001 and Bangash and Yasser K. 2003)
Hydrocyclone as the core part of DOWS is the key factor.
In almost all project designs and engineering applications
before, there was a single hydrocyclone used because of the
restriction in the diameter of the well bore. So if the oil well
selected can not match the processing capacity of a given
hydrocyclone the system will fail. In the same time a single
hydrocyclone can not reach the requirement of cleaner water to
reinject it in the same well without pollution to formation.
Design to arrange two hydrocyclones in a compositive
DOWS is a natural idea. But some special methods can break
through the restriction of oil bore dimension and ensure the
processing effect. This is the key contents in our project and in
this paper.
SEPARATOR ARRAY CONFIGURATION
DOWS is a comparatively complex system. But if
separated with a thought of modularization it is only composed
1 Copyright © 2009 by ASME
 of some units with independent function. (Jeffery K.L. and
Dahmus J.P., 2001 and Umeda Y., et al., 2008)

a) Hydrocyclones in series for cleaner water

1—oil drain valve; 2, 11—one-way valve; 3—lift pump;

4, 6—protector; 5—motor; 7—oil/gas separator;
8 — pressure charging pump; 9 — centralizer; 10 — b) Hydrocyclones in series for thicker oil
hydrocyclone; 12—packer; 13—control valve; 14—by-pass
pipe
Fig.1. A typical DOWS with electrical submersible pump

As shown in Fig.1 a typical DOWS system is composed of

separator unit, pump unit, packers, centralizers, protector, one-
way valves, motor and some necessary pipes.
A perfect separator unit is design to a separator module.
No matter what a complex arrangement of hydrocyclones and
their flow rate we have, the separator module is an integrated
unit with adequate dimensions to fit a kind of specified well
bore. It can be equipped to other units of DOWS rapidly and
fulfill the requirement to seal. c) Hydrocyclones in series with overflow circulation for thicker
In this paper taper thread was used as separator module oil
interface under inch screw thread standard of casing and
tubing. This method ensures the possibilities of quick
connection, the whole rigidity of separator and freedom
disposing inner construction without any care of other units.

Hydrocyclone array configurations

Array configuration of hydrocyclones in series

The aim to array two hydrocyclones in series is to obtain
cleaner water and thicker oil flow. No matter the function of
second hydrocyclone is to deal with overflow for thicker oil
flow or under flow for cleaner water of the first one, second d) Hydrocyclones in series with underflow circulation for more
hydrocyclone will be used to rehandle the fluid. There are four oil
usual array configurations shown in Fig.2. Fig.2. Usual array configurations of hydrocyclones in series

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 Chart a) shows the array configuration of hydrocyclones in
series for cleaner water. Underflow of first hydrocyclone acts
as the inlet of second hydrocyclone and it will be clarified
again to get cleaner water avoiding the risk bring pollution into
implanted formation. There are the same overflow channel into
lift pump which will lift them up to the ground.
Chart b) shows the array configuration of hydrocyclones in
series for thicker oil. Still two hydrocyclone is located in series
and overflow of first hydrocyclone acts as the inlet of second
hydrocyclone. Obviously lighter phase (oil with a little water)
will be concentrate again. So it brings produced water with
higher oil content.
Chart c) shows the array configuration of hydrocyclones in
series with overflow circulation for thicker oil. And chart d)
shows the array configuration of hydrocyclones in series with
underflow circulation for more oil.
These are the modified structures of the array
configurations which are mentioned upwards. What is different
is that these structures circled one of their outlets for another
separation. The array configuration in chart c) circle overflow
of first hydrocyclone and it will bring thicker oil and the array
configuration in chart d) circle underflow of second
hydrocyclone for more oil.
No one is better than another and the choice of one of them
is just based on the requirement to specific oil well used for.
Array configuration of hydrocyclones in bridge
a) Hydrocyclones in bridge
b) Another drawing of hydrocyclones in bridge
Fig.3. Array configurations of hydrocyclones in bridge
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Generally the aim to array two hydrocyclones in bridge is
to obtain twice handling capacity. This only aim determines its
simple array configuration. As shown in Fig.4 it can be
described by two hydrocyclones with the same inlet, overflow
and underflow. In fact, even some other drawings can be used
to describe the array configuration of hydrocyclones in bridge
such as b) in Fig. 3, but these are only the modification of a) in
the final analysis.
STRUCTURE DESIGN
Emphasis was placed on the space arrangement during the
design. In fact this is also the biggest problem during the design
of DOWS with a single hydrocyclone. Several pipe lines are
used in every chart to show the array configuration principle in
Fig.2 and Fig.3. But it is impossible to put them in such a
limited space of casing pipe. Even if a complex design can be
found to array 5 or more pipe lines in the casing pipe, thin and
long pipe will bring huge hydraulic resistance. This
correspondingly brings difficult problems of pressurization and
seal and it is hard to get satisfactory treatment effect. So
annular space is used to replace all pipe lines connecting
separators, pump and connecting elements.
Just as its name implies annular space is formed by some
circular ring link by link. Annular space can give bigger flow
channel and more flexibility to array the separators. Some
special connecting elements can ensure some special flow
direction of specific flow medium.
Design of separator with hydrocyclones in series
The aim to array two hydrocyclones in series is to obtain
cleaner water and thicker oil flow.
The idea of functional module still can make the design
comparatively simple in this stage. This method reserved a
specific annular space for every specific flow medium, kept
hydrocyclone assembled with its inlet, cone and outlets,
designed standard taper thread as separator module interface
under the inch screw thread standard of casing and tubing, but
kept the dimensions variable. Then some special connecting
elements were designed to separate the annular spaces and it
can lead us final dimensions.
In this paper first version as a) in Fig. 2 is used to show
our design but concrete dimensions is hidden as sponsored fund
required. A set of 3-D models used in our design building by
Pro/Engineering software can show geometrical relationship
vividly and match the requirement of sponsored fund.
Fig.4. Assembly drawing of hydrocyclone
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 Primary idea to solve this puzzle is to design some kinds of
comparatively complex joints to connect comparatively simple
annular space.

Fig.5. Lower segment of separator shell holding a

hydrocyclone

Fig.4 shows assembly of hydrocyclone combining its

separating cone, inlet and tail pipe. Fig.5 shows its shell
a) b)
connecting with other modules.
Fig.8. joint between two hydrocyclones
This two parts can be assembled together easily by
matching lower joint of hydrocyclone up with lower hole of
Joint between two hydrocyclone is a good example of
separator shell and shape the necessary annular space as a
these key parts. There is the most complex flow channel in this
result. In the same time this method ensure pressure by
segment including underflow of first hydrocyclone (down
assemble and distortion releasing to separator shell and by
direction), inlet flow of second hydrocyclone (linking with
parity of reasoning to rigid shell of DOWS system. This can
underflow of first hydrocyclone) and overflow of second
prevent separator from distortion and the influence to
hydrocyclone (up direction). Based on the theory of separating
separating effect.
different fluid flow with annular space, joint here must bring
the function of flow distribution into play.
Inner circle of a) in Fig.8 matches with underflow of first
hydrocyclone. Along with the outer circle these can shape the
annular space of underflow of first hydrocyclone which is the
inlet of second hydrocyclone in the same time.
The small circular hole between inner circle and outer
circle is the channel to inlet zone of second hydrocyclone and it
Fig.6. Lower segment of hydrocyclone underflow chamber can be seen it in sub-face which will be connected with inlet
zone of second hydrocyclone. Of course some similar circular
hole or a fan-shaped hole can be made to increase the passage
area.
The radial and through hole in Fig.8 is the channel of
overflow of second hydrocyclone. It can keep overflow away
from underflow of first hydrocyclone by uncrossing with the
small circular hole as mentioned above. In fact outer wall of
this joint shapes the channel of overflow of second and first
Fig.7. Joint of hydrocyclone overflow hydrocyclone along with outmost pipe of DOWS system.
Some other joints are similar with this one. And the same
Some similar parts achieve similar function. As shown in design criterion is used to keep different fluid flow alone.
Fig.6 and Fig.7, no matter used for underflow or overflow these
similar joint is necessary to connect some parts and shape some
necessary annular spaces for different fluid flow.
But as it can be seen in Fig.2 crossover of flow channels of
inlet, overflow and underflow is unavoidable.
These two hydrocyclones have to be arrayed as separators
in term of up/down order to decrease radial dimension. So
some fluid flow such as overflow of second (lower)
hydrocyclone has to go through the space of first (upper)
hydrocyclone to join with overflow of first hydrocyclone. So
simple annular spaces will be insufficient and some parts
keeping one flow away from another one in opposite direction
will be necessary.
Fig.9. whole assemble of a DOWS with two hydrocyclone in
series

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Perspective drawing of the whole assemble of a DOWS
with two hydrocyclone in series gives us an understanding in
large scale. Many modules of different functions build up a
whole separator system and the DOWS itself is an easily
assembled module.
Design of separator with hydrocyclones in bridge
The aim to array two hydrocyclones in bridge is to obtain
twice handling capacity.
In some degree the design idea of separator with
hydrocyclones in bridge is similar with the design with
hydrocyclones in series, both of them have the difficulty to
space limitation. But arraying two hydrocyclone in bridge has
its own problem.
Generally the location of the two hydrocyclones in bridge
side by side is shown in a) of Fig.3. But what we all know is
that it is narrow for even one hydrocyclone. Although b) in
Fig.3 looks like a method to array two hydrocyclones up and
down by converting one hydrocyclone, it brings more
complexity to control more fluid channels.
In this paper a new array configuration was designed by
locating the two hydrocyclones off centre. Every hydrocyclone
is laid aboard one side off the centre line and these two can
overlap each other along axial direction.
Fig.10. second separating segment of DOWS with
hydrocyclones in bridge
The second separating segment of DOWS with
hydrocyclone in bridge is shown in Fig.10 to describe the off-
centre array configuration and the location of annular space.
Design method of specific parts is similar with the location of
hydrocyclone in series.
EXPERIMENTAL INVESTIGATION
Although there are some limitations such as the simulation
of formation pressure and temperature downhole, experimental
investigation in the laboratory can bring us working condition
of the modular separator units. Differential pressure simulation
method was used to realize the necessary pressure condition for
driving liquid to separate under the vortex centrifugal effect in
hydrocyclone. In the same time simulative liquid was heated up
to 50 ℃to ensure the simulative liquid with similar viscosity to
produced water.
Original data is from one of the oil wells with high water
content in Daqing oilfield. Nowadays its high water content
makes the oil well has less economical efficiency.
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An experimental bench was settled to support the separator
unit and some test devices were assembled together as
measuring unit, pump unit, pressure testing unit and so on. But
the other units in DOWS system such as protectors and packers
were substituted. One kind of engine oil of the same viscosity
with produced water was mixed with water as simulative
liquid. Ultraviolet spectrophotometer can tell us oil content in
inlet flow and outflow to get separation efficiency.
This research aims at finding one kind of new design
methods and an array configuration to locate two hydrocyclone
separators in a DOWS system. So as a matter of experience
only some typical points were chosen to test the separator unit.
In-depth experimental investigations are needed to find more
information about separator system’s optimum operating
parameters and separation efficiency.
The concept of concentration factor is imported to replace
usual concept named separating efficiency. So it can be omitted
of the numerical value of produced water and water quality
reinjected into formation and fit the requirement of our sponsor
fund because these data hasn’t been disclosed to cite.
Concentration factor is expressed mathematically by:
Ci
E=
Cd (1)
where Ci is an amount of oil content in separator’s inlet and Cd
deputes the oil content in the underflow. The separator in this
equation means a single hydrocyclone when hydrocyclone’s
separating efficiency is investigated and DOWS system when
investigating the efficiency of DOWS using downhole.
In the laboratory it is easily to sample at every stage of
separation and compare with each other. So some experimental
data selected randomly forms the charts as shown in Fig.11 and
Fig.12. These can give us several obvious results.
Fig.11. data from experiments with hydrocyclones in series
Fig.11 gives us a direct view of separating effect of DOWS
with two hydrocyclones in series. Handling capacity is
controlled by 4m3/h to match the designed capacity of a single
hydrocyclone. Pressure, as the most important parameter, is
used to control the ratio of fluid flow.
What is important is that in this figure only 7 sets of data
randomly were selected without considering the effect of split
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 ratio. So it can bring some information about separation
efficiency omitting a little variation because of the influence of
different split ratio.
It shows clearly in Fig.11 that concentration factor is
between 5 and 6 and it is comparatively stable. Concentration
factor by two hydrocyclones in series is above 10 although it is
comparatively fluctuant. In some degree it means the second
hydrocyclone is sensitive to the variation of operating
parameters and its inlet as the result of forepart. In fact,
corresponding separation efficiency and water quality
reinjected into formation has fulfilled the target of our project.
Fig.12. data from experiments with hydrocyclones in bridge
As it was mentioned before, general aim to array two
hydrocyclones in bridge is to obtain twice handling capacity.
Naturally handling capacity is magnified by 8m3/h as two
hydrocyclones in use. This array configuration brings some
fluctuation (as shown in Fig.12) of separating effect. And it is a
little lower than that of a single hydrocyclone. But its double
handling capacity is meaningful for oil well with larger
produced water volume.
CONCLUSIONS
It will break the bottle-neck of DOWS development with a
single separator in it by array two or more hydrocyclones in
series or in bridge. It is active demand of oil field in metaphase
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or anaphase whether getting cleaner water for reinjection or
larger handing capacity.
The design idea of treating necessary units of DOWS
system and necessary parts of separator unit as some kinds of
modules is a new thought which can handle the complex design
problem downhole.
It has the possibility to connect more separators (e.g. more
than two hydrocyclones) together because every separator unit
is an easily assembled module with standard joint.
In the same time it is worthy of note that how to find or
invent new kinds of downhole pump to fit the requirement of
high pressure and multi-way flow.
ACKNOWLEDGMENTS
We thank Mr. Cuncai Lu of China National Offshore Oil
Corporation (CNOOC) for his work in some experimental
investigation. And this research was sponsored by Heilongjiang
Natural Science Fund Project (E0307).
REFERENCES
Veil J.A., Quinn, J.J. (2005). “Performance of downhole
separation technology and its relationship to geologic
conditions”, 2005 SPE/EPA/DOE Exploration and Production
Environmental Conference: Enhancing Environmental
Performance, Galveston, TX, United States.
Bowers, B.E.; Brownlee, R.F. and Schrenkel, P.J. (2000),
“Development of a downhole oil/water separation and
reinjection system for offshore application”, SPE Journal,
15(2), 115-122.
Veil J.A., 2001. “Interest revives in downhole oil-water
separators”, Oil and Gas Journal, 99(9), 47-56.
Bangash, Yasser K. (2003). “Downhole Oil Water
Separation (DOWS) Systems in High-Volume/High HP
Application”, Eighth Latin American and Caribbean Petroleum
Engineering Conference, Port of Spain, Trinidad and Tobago.
Jeffery K.L., Dahmus J.P., 2001.“Modular product
architecture”, Design Studies, 22(5), 409-425.
Umeda Y., Fukushige S. etc, 2008. “Product
modularization for life cycle engineering”, CIRP Annals-
Manufacturing Technology 57, 13-16.
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