Angled Port Tubular Device for ESP Sand Inhibition
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Solution Overview
Problem
Existing solutions for preventing sand accumulation on electrical submersible pumps (ESPs) in oil and gas wells are inefficient, complex, and costly, leading to frequent failures and prolonged downtime due to sand settlement, which complicates restarts and increases maintenance costs.
Innovation Solution
A device with a central tubular portion and an annulus surrounding it, featuring angled ports and check valves, which allows fluid flow during operation while inhibiting particle entry into the tubular portion when the ESP is not in use, trapping particles in the annulus and preventing reverse fluid flow to prevent sand accumulation and facilitate easy restarts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing sand prevention devices are used, then sand accumulation on ESP is reduced, but device complexity and cost increase significantly
Solution Approach 1:
The device divides the production tubing into separate flow paths: a central tube for fluid flow and an annulus for particle trapping. This segmentation allows particles to be separated from the fluid stream without requiring complex mechanical components, resolving the contradiction between reliability and device complexity
Solution Approach 2:
The annulus acts as an intermediary space between the central tube and the ESP intake. Particles are trapped in this intermediate zone while fluid continues to flow through the central tube, preventing particle accumulation on the ESP without requiring direct intervention components at the pump inlet
2Reliability
If sand prevention devices are installed, then particle interference is reduced, but maintenance costs and downtime increase
Solution Approach 1:
The device enables self-cleaning operation where the fluid flow itself removes particles from the central tube through the ports. When the ESP stops, particles automatically settle in the annulus rather than on the pump, and when operation resumes, the flow automatically clears any particles, eliminating the need for manual intervention and reducing downtime
Solution Approach 2:
The device performs preliminary particle separation before particles can reach the ESP. By trapping particles in the annulus during idle periods and preventing them from entering the central tube, the system prepares the flow path in advance, ensuring immediate operational readiness without maintenance intervention
3Reliability
If ports are added to prevent particle entry, then particle accumulation on ESP is prevented, but fluid flow restriction increases
Solution Approach 1:
The device adds a radial dimension to particle separation by using ports that extend outward from the central tube into the annulus. This three-dimensional arrangement allows particles to be intercepted at multiple radial positions without significantly restricting axial fluid flow through the central tube, maintaining productivity while improving restart reliability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly enhances ESP reliability, efficiency, and timeliness of restarts by preventing particle interference, reducing maintenance costs and downtime, and ensuring continuous operation by effectively managing sand accumulation and fluid flow.
Implementation Method 1
A check valve is positioned between the tube and the production tubing string and operates to permit fluid flow from the lifting equipment to the surface, but prevents fluid flow from the tube to the lifting equipment
Implementation Method 2
The ports are angled in the direction of the lifting equipment and can be more dense closest to the lifting equipment... operable to inhibit particles from entering the tube when the lifting equipment is not operating
Data Source
AI summary
A device and method for inhibiting particle (e.g., sand) accumulation on down hole equipment, such as an ESP, particularly when the equipment is not in use. The device and methods permit the equipment to start and stop with fewer break downs and at greater efficiency. The device includes a central tubular section connecting the equipment to the production tubing string. The tubular section is surrounded by an annulus and a number of ports in the tubular section angled to allow fluid communication between the tubular section and the annulus during operation, but prevent particles from flowing from the annulus into the tubular section when not in use. A check valve between the tube and ESP assists in isolating the ESP from sand.