Downhole Sand Catcher Baskets for Pump Plugging Prevention
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Solution Overview
Problem
Downhole pumps in the hydrocarbon production industry face issues with sand and abrasive solids settling and plugging due to gravity, leading to pump failure and costly work-over operations when production is resumed after shutdown.
Innovation Solution
A downhole apparatus with strategically positioned baskets made of filter material that collect falling solids, allowing unobstructed fluid flow and preventing solids from reaching the pump, which can be arranged to cover the entire borehole section and include features like flapper valves for surge management and various mesh sizes for efficient solid collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If pump shutdown occurs, then fluid levels equalize quickly, but sand particles settle on pump causing plugging
Solution Approach 1:
The apparatus performs preliminary action by collecting sand particles in baskets before they can settle on the pump during shutdown. The baskets are positioned to intercept falling sand, preventing accumulation on pump components that would cause plugging when production resumes.
Solution Approach 2:
The baskets act as an intermediary between the fluid column and the pump, capturing sand particles that would otherwise directly contact the pump. This intermediate structure prevents the harmful interaction between settled sand and pump components.
2Productivity
If pump restarts after shutdown, then production resumes, but higher load causes motor burnout or rotor shaft breaking
Solution Approach 1:
The apparatus applies preliminary anti-action by preventing sand accumulation on the pump before restart occurs. The baskets continuously capture falling sand during shutdown periods, so when production resumes, there is no sand plug to cause excessive load, motor burnout, or rotor shaft failure.
3Adaptability or versatility
If pump interior has complex configuration, then pump functionality is achieved, but sand has no direct path through causing settlement
Solution Approach 1:
The invention extracts the sand separation function from the pump system by introducing external baskets that capture sand particles in the annulus space. This removes the harmful sand particles from the system before they can interact with the pump's complex internal configuration, preventing settlement while preserving pump functionality.
4Reliability
If sand collection apparatus is added, then sand prevention is improved, but device complexity increases
Solution Approach 1:
The apparatus is segmented into multiple independent baskets distributed around the annulus, each capable of capturing sand particles. This modular segmentation provides effective sand collection while maintaining simplicity, as each basket is a straightforward structure that can be independently positioned and functions autonomously.
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 apparatus effectively prevents solids from reaching the pump, allowing for self-cleaning and reducing the risk of pump failure, enabling cost-effective and time-efficient hydrocarbon production without the need for rig-based workovers.
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.