Downhole Pump Intake Filter with Centrifugal Gas Separator
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Solution Overview
Problem
Existing downhole fluid filtration systems fail to effectively separate both solid particles and gas from fluids while maintaining a compact design compatible with existing submersible pumps, leading to reduced pump efficiency and potential damage due to abrasive solids and gas lock conditions.
Innovation Solution
A dual-use fluid filtration tool with a cylindrical housing and removable filter that allows gas and liquid to pass while preventing solid particles, utilizing a shaft with centralizing bearings and a two-stage mechanism involving a helical fan and paddle wheel to separate gas from liquid, ensuring the tool's outside diameter remains compatible with existing components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a filter is added to separate solid particles from fluid, then pump reliability is improved, but device complexity increases
Solution Approach 1:
The patent combines the filter assembly with the pump intake structure into a single integrated unit. The filter is positioned within the pump housing and connects directly to the intake ports, eliminating the need for separate external filtration equipment while still providing effective solid particle separation.
Solution Approach 2:
The pump housing serves multiple functions: it contains the motor, supports the pump impeller, and incorporates the filter assembly. This multi-functionality reduces the overall number of components needed in the system while maintaining reliable solid particle separation.
2Productivity
If a gas separation mechanism is added to prevent gas lock, then pump efficiency is improved, but device complexity increases
Solution Approach 1:
The gas separation mechanism is integrated into the pump housing and intake structure. The curved baffle walls and gas escape ports are formed as part of the pump housing geometry, combining gas separation functionality with the existing pump structure rather than adding separate gas separation equipment.
Solution Approach 2:
The curved baffle walls act as intermediary structures that redirect fluid flow to separate gas from liquid before entry into the pump. These baffles create flow patterns that allow gas to rise and escape through dedicated ports while liquid continues to the impeller, providing passive gas separation without complex mechanical components.
3Adaptability or versatility
If the outside diameter is reduced to fit existing components, then adaptability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The filter assembly and gas separation mechanisms are nested within the existing pump housing internal volume. The filter elements are positioned inside the housing cavity, and the baffle walls utilize the existing housing space, allowing the integrated design to fit within standard pump outside diameters without requiring oversized components.
Solution Approach 2:
The design modifies internal geometric parameters of the pump housing (such as baffle wall angles, filter element dimensions, and port positions) to optimize performance while maintaining compatibility with standard pump outside diameters. These parameter adjustments allow adaptation to existing components without compromising separation effectiveness.
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 tool effectively separates solids and gas from fluids, preventing pump damage and maintaining efficiency by ensuring that only liquid enters the pump, while maintaining a compact design that integrates seamlessly with existing submersible pumps and artificial lifting systems.
Implementation Method 1
Surrounding the interior chamber of the housing is a removable, cylindrical filter. The cylindrical filter has openings to permit gas and liquid to pass therethrough but to prevent solid particles over a certain size from passing into the interior chamber.
Implementation Method 2
A two-stage mechanism including a helical fan extending from and driven by the shaft and a paddle wheel extending from the shaft may be employed. Fluid in the chamber is directed toward a gas gathering chamber. The centrifugal force created by radially inducing a fluid causes liquid to migrate radially outward. Gas or gas bubbles will tend to remain near the axis of the interior chamber
Data Source
AI summary
A dual use fluid filtration tool to separate both solids and gas from a fluid. The fluid filtration tool is suspended from and connected to a downhole submersible pump having a motor which rotates a shaft. The tool includes a housing having a cylindrical wall with a plurality of perforations therethrough and an interior chamber therein. A removable cylindrical filter surrounds the interior chamber of the housing in order to filter solid particles. At least one centralizer bearing within the interior chamber of the housing centralizes the shaft which passes therethrough. The fluid in the interior chamber is radially induced in order to separate gas from fluid. The gas separated from the fluid is directed out of the chamber while the fluid remaining in the interior chamber is directed to the intake of the downhole pump.