Charge Pump for ESP Gas Slug Handling

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Solution Overview

Problem

Electric submersible pumps (ESPs) face operational challenges due to gas accumulation, leading to 'gas lock' conditions and bearing damage when large gas slugs interrupt the continuous flow of reservoir liquid, causing reduced efficiency and increased maintenance needs.

Innovation Solution

Incorporating a charge pump assembly downstream of the fluid intake and upstream of the gas separator, which includes fluid movers and reservoirs to mix and buffer gas with liquid, allowing the gas separator to continue supplying a liquid phase enriched stream to the production pump, even during gas slug events, thereby extending the ESP's ability to handle gas slugs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a gas separator assembly is used to separate gas from liquid, then gas lock is prevented, but the system cannot handle large gas slugs that interrupt continuous liquid flow

Engineering Contradiction:

Improvegas lock preventionVSAvoidability to handle gas slugs

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The charge pump assembly performs preliminary action by maintaining continuous liquid flow to the gas separator before gas slugs arrive. The liquid stored in the charge pump assembly's reservoir and continuously circulated creates a buffer that ensures liquid is always available at the gas separator inlet, preparing the system to handle incoming gas slugs without interruption.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The charge pump assembly provides beforehand cushioning by maintaining a reservoir of liquid and continuous flow that cushions against the impact of gas slugs. This continuous liquid column acts as a buffer that absorbs the shock of gas slug arrival, preventing direct gas contact with the gas separator and maintaining operational reliability.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Use of energy by moving object

If the ESP operates without continuous liquid flow, then energy consumption is reduced during gas slug events, but bearing damage occurs due to loss of lubrication

Engineering Contradiction:

Improveenergy consumption during gas slugsVSAvoidbearing damage from lack of lubrication

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

The charge pump assembly ensures continuity of useful action by maintaining continuous liquid flow through the system even during gas slug events. The liquid continuously circulates through bearings and other moving parts, providing constant lubrication and cooling without interruption, thereby preventing bearing damage while maintaining system operation.

Inventive Principle:

Principle #20Continuity of useful action

3Productivity

If the gas separator is positioned immediately after the fluid intake, then gas separation is more efficient, but the system is more susceptible to gas lock during gas slug events

Engineering Contradiction:

Improvegas separation efficiencyVSAvoidoperational continuity during gas slugs

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The charge pump assembly serves as an intermediary between the fluid intake and the gas separator. It receives liquid from the intake, maintains continuous flow and stores liquid in its reservoir, then supplies this liquid to the gas separator. This intermediary role ensures the gas separator always receives liquid flow while the charge pump buffer protects against gas slug impacts, balancing separation efficiency with operational reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 charge pump assembly enhances the ESP's ability to sustain gas slugs, reducing the risk of gas lock and bearing damage, ensuring continuous operation and extending the operational life of the production pump.

Implementation Method 1

which includes fluid movers and reservoirs to mix and buffer gas with liquid

Methodology Applied

Scientific EffectGas-liquid mixing:

Implementation Method 2

reservoirs to mix and buffer gas with liquid, allowing the gas separator to continue supplying a liquid phase enriched stream

Methodology Applied

Scientific EffectFluid buffering:

Implementation Method 3

a gas separator assembly having a fourth drive shaft coupled to the third drive shaft and having an inlet in fluid communication with an outlet of the charge pump assembly

Methodology Applied

Scientific EffectGas-liquid separation: Centrifugal Separation

Data Source

PatentUS11867035B2Charge pump for electric submersible pump (ESP) assembly

Publication Date: 2024.01.09 HALLIBURTON ENERGY SERVICES INC

AI summary

An electric submersible pump (ESP) assembly. The ESP assembly comprises an electric motor; a seal section; a fluid intake; a charge pump assembly located downstream of the fluid intake and having an inlet in fluid communication with an outlet of the fluid intake, having a fluid mover coupled to a drive shaft, and having a fluid reservoir located downstream of the fluid mover; a gas separator assembly located downstream of the charge pump assembly and having an inlet in fluid communication with an outlet of the charge pump assembly; and a production pump assembly located downstream of the gas separator assembly and having an inlet in fluid communication with a liquid phase discharge port of the gas separator assembly.