Downhole Pump Intake With Annular Flow Paths For Gas Separation
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Solution Overview
Problem
Downhole pumps face inefficiencies and failures due to the presence of mixed-phase fluids in subterranean wells, where gas accumulation can lead to 'gas lock' and damage, necessitating effective separation of gases and liquids before reaching the pump.
Innovation Solution
The design of a downhole pump intake system with an outer and inner tubular member forming annular flow paths and a central shaft, featuring inlet apertures that facilitate gravity-based separation of gases and liquids, allowing only the liquid phase to reach the pump, thereby reducing the risk of gas lock and pump failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a downhole pump is used to lift mixed-phase fluids from a well, then production is achieved, but gas accumulation causes gas lock and pump failure
Solution Approach 1:
The intake system is divided into separate flow paths: an outer annular flow path for gas separation and an inner flow path for liquid delivery to the pump. This segmentation allows gases and liquids to be handled differently, with gases being separated and vented while liquids are delivered to the pump, preventing gas lock and improving reliability while maintaining productivity
Solution Approach 2:
The intake system acts as an intermediary component between the wellbore and the pump. It includes an outer tubular member with inlet apertures and an inner tubular member that creates annular flow paths, serving as a mediator that separates mixed-phase fluids before they reach the pump, thereby protecting the pump from gas accumulation while maintaining fluid production
2Productivity
If inlet apertures with large circumferential width are used, then fluid intake capacity is improved, but gas separation efficiency decreases
Solution Approach 1:
The inlet apertures are designed with specific local characteristics: circumferential width between 5% and 50% of the outer tubular member's circumference, and length-to-width ratios between 2.5 and 10.0. These localized dimensional properties optimize the balance between allowing sufficient fluid intake capacity while maintaining effective gas separation through the annular flow paths
3Device complexity
If a simple single-flow-path intake is used, then device complexity is reduced, but gas-liquid separation capability is insufficient
Solution Approach 1:
The intake system employs a nested structure where an inner tubular member is positioned within an outer tubular member, creating annular flow paths. This nested configuration enables gas-liquid separation functionality without requiring a completely separate external separation system, thus improving separation capability while limiting the increase in overall device complexity
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 intake system effectively separates gases and liquids, reducing the likelihood of gas lock and enhancing the operational life and efficiency of downhole pumps, leading to cost savings in hydrocarbon production.
Implementation Method 1
inlet apertures that facilitate gravity-based separation of gases and liquids, allowing only the liquid phase to reach the pump
Data Source
AI summary
An intake for a downhole pump includes an outer tubular member having a central axis. In addition, the intake includes an inner tubular member disposed within the outer tubular member. The inner tubular member is radially spaced from the outer tubular member to form an outer annular flow path radially positioned between the inner tubular member and the outer tubular member. Further, the intake includes a central shaft rotatably disposed within the inner tubular member. The central shaft is radially spaced from the inner tubular member to form an inner annular flow path radially positioned between the central shaft and the inner tubular member. Still further, the intake includes a plurality of inlet apertures extending radially through the outer tubular member and in fluid communication with the outer annular flow path. Each of the plurality of inlet apertures has a circumferential width W between 5% and 50% of a total circumference of the outer tubular member.