Distributed Sand Catcher Baskets for Downhole Pump Plugging
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Solution Overview
Problem
Downhole pumps in hydrocarbon production systems are prone to plugging due to sand and abrasive solids settling on the pump during shutdown, leading to costly and time-consuming failures requiring work-over operations.
Innovation Solution
A downhole apparatus with a flow path containing unobstructed sections and baskets made of filter material to collect solids, ensuring complete coverage of the borehole section and preventing solids from reaching the pump, featuring a flapper valve for surge management and no moving parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a downhole pump is used to produce hydrocarbons from significant wellbore depths, then high production rates are achieved, but the pump becomes sensitive to sand and abrasive solids causing plugging and failure
Solution Approach 1:
A sand catcher apparatus is introduced as an intermediary device between the formation and the downhole pump. This apparatus contains a container with filter material that intercepts sand and abrasive solids before they can reach the pump, protecting the pump from plugging while allowing the pump to maintain high production rates
Solution Approach 2:
The sand catcher apparatus segments the flow path into an unobstructed section allowing fluid flow and a container section for solids collection. This segmentation separates the protective function from the production function, allowing the pump to operate at high productivity while the sand catcher handles solids removal
2Ease of operation
If the pump is shut down after pumping fluid to surface, then flow ceases and fluid levels equalise, but sand particles fall back towards the pump causing plugging
Solution Approach 1:
The sand catcher apparatus performs preliminary action by collecting sand and solids in the container during normal operation, before the shutdown occurs. When the pump shuts down and sand falls back towards the pump, the sand is already trapped in the container and cannot reach the pump, preventing plugging during shutdown operations
3Reliability
If baskets are placed in the flow path to collect solids, then solids coverage is improved, but flow area is reduced
Solution Approach 1:
The sand catcher apparatus applies local quality by placing the container with filter material only in the specific region where solids fall back towards the pump during shutdown, rather than obstructing the entire flow path. The unobstructed flow path section maintains adequate flow area while the localized container provides effective solids collection where needed
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
Prevents pump plugging by collecting solids, allowing self-cleaning during production restart and eliminating the need for rig-based work-over, thus reducing maintenance costs and downtime.
Implementation Method 1
the remaining flow path having a container to collect the solids fall back being partially make of a filter material
Implementation Method 2
Gravity acting on the sand particles present in the column of fluid above the pump causes the sand and any other solids to fall back towards the pump
Data Source
AI summary
A downhole apparatus for collecting solids fallback in the tubing of an oil producing borehole comprises two or more baskets to collect the solids fall back, each basket partially occupying a portion of the inner cross section of the tubing, leaving a portion of the inner cross section of the tubing having an unrestricted flow path. The baskets when considered in plan view along longitudinal axis of the tubing are distributed such that together they cover substantially the whole area of the tubing while leaving an unobstructed non-straight flowpath around the baskets.