Charge Pump Gravity Gas Separator Well Pump
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Solution Overview
Problem
Centrifugal pumps used in hydrocarbon wells face inefficiencies when pumping fluids containing gas, as gas can still reach the pump despite gas separators, leading to reduced performance and potential damage.
Innovation Solution
A well pump assembly featuring a charge pump and a bypass member, such as a riser or shroud, that directs well fluid flow to facilitate gravity separation of gas and liquid before reaching the main pump intake, ensuring that only the heavier liquid portions are pumped by the main pump.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gravity gas separator is used to separate gas from liquid before the pump, then gas separation is improved, but some gas still reaches the pump when well fluid contains slugs or large bubbles
Solution Approach 1:
The pump system is divided into two separate pumping sections: a charge pump with intake positioned to receive fluid directly from the wellbore, and a main pump positioned above the charge pump. This segmentation allows the charge pump to handle gas-containing fluid first, separating gas from liquid before the liquid enters the main pump, thereby resolving the contradiction between gas separation effectiveness and pump performance.
Solution Approach 2:
The charge pump acts as an intermediary device between the wellbore and the main pump. It receives fluid containing gas slugs and large bubbles, performs preliminary gas separation, and delivers separated liquid to the main pump intake. This intermediary function protects the main pump from gas interference while maintaining overall system productivity.
2Reliability
If the charge pump intake is positioned below the main pump intake, then gas separation is enhanced, but the device complexity increases with additional sealing elements and flow path components
Solution Approach 1:
The charge pump and main pump are combined into a single integrated assembly sharing a common drive motor and coupled impellers. The charge pump intake is positioned at the lowest point of the assembly, and the main pump intake receives fluid from the charge pump discharge. This merging reduces overall complexity compared to separate systems while maintaining effective gas-liquid separation through the vertical arrangement and integrated sealing elements.
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
Effectively separates gas from liquid, enhancing the operational efficiency of the centrifugal pumps by ensuring primarily liquid is pumped, reducing wear and tear, and improving overall well fluid extraction efficiency.
Implementation Method 1
The bypass member defines a flow path from the discharge of the charge pump upward past the main pump intake, then downward to reach the main pump intake, thereby causing a gravity separation of liquid from gas in the well fluid
Implementation Method 2
An annular sealing element between the charge pump intake and the charge pump discharge has an inner diameter in sealing engagement with the charge pump and an outer diameter for sealing engagement with the casing to direct well fluid flowing up from below the sealing element into the charge pump intake
Implementation Method 3
The main pump may be a centrifugal pump having a plurality of stages, each stage having an impeller and a diffuser
Data Source
AI summary
A well pump assembly has a main pump suspended on a string of production tubing within casing in a well. A charge pump is located below the main pump. An annular sealing element between the charge pump intake and the charge pump discharge seals between the charge pump and the casing. A motor is coupled with the main pump and the charge pump. A bypass member has an open upper end above the main pump intake and a lower end above the sealing element. The bypass member defines a flow path from the discharge of the charge pump upward past the main pump intake, then downward to reach the main pump intake. The bypass member may be a bypass riser extending alongside the main pump, or it may be a shroud surrounding the main pump.