Dual ESP Multiphase Production With Gas Separation And Flow-Path Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electric submersible pumps (ESPs) face challenges in high gas/oil ratio formations due to gas locking, leading to reduced production and potential damage, and traditional casings are prone to corrosion when used to produce the gaseous phase.
Innovation Solution
Implementing a system with two tubing strings and gas separators for each ESP, allowing separate production of liquid and gaseous phases, and using gate mechanisms to control flow paths, eliminating the need for annulus production and reducing corrosion risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If electric submersible pumps are used in high gas/oil ratio formations, then production efficiency is improved, but gas locking occurs causing reduced production and potential pump damage
Solution Approach 1:
The patent divides the wellbore flow path into separate segments: one for liquid production through the ESP and another for gas production through the annulus. Gas separators are installed to segment the multiphase fluid into gas and liquid phases before they enter different flow paths, preventing gas from entering the ESP and causing gas locking while maintaining efficient liquid production
Solution Approach 2:
Gas separators act as intermediary devices between the multiphase formation fluid and the ESP. These separators remove gas from the fluid stream before it reaches the pump, protecting the ESP from gas locking while allowing continuous efficient operation. The intermediaries (gas separators) mediate between the high gas production need and the pump's liquid-only capability
2Productivity
If the wellbore annulus is used to produce the gaseous phase, then gas production is enabled, but corrosion of traditional iron-based casings occurs
Solution Approach 1:
The patent employs composite or corrosion-resistant casing materials in the wellbore annulus where gas is produced. Instead of traditional iron-based casings that corrode from corrosive species in the multiphase fluid, the system uses corrosion-resistant alloy casings or composite materials that can withstand the corrosive environment while enabling gas production through the annulus
Solution Approach 2:
The harmful corrosive species are extracted or isolated from the gas stream before it contacts the casing, or the gas production path is separated from the corrosive liquid phase. This allows gas production through the annulus while preventing corrosion by removing the corrosive elements from the interaction with the casing material
3Reliability
If multiple tubing strings with ESPs are installed, then gas locking is prevented and backup capability is provided, but device complexity increases
Solution Approach 1:
The system is segmented into multiple independent production strings, each with its own ESP and gas separator. This segmentation provides redundancy and backup capability - if one string fails, others can continue production. The modular segmented design manages complexity by creating independent, replaceable units rather than one complex interconnected system
Solution Approach 2:
Each tubing string with ESP and gas separator is designed as a universal module that can function independently. The same configuration serves both as primary production path and as backup for the other string. This multi-functionality reduces overall system complexity by using identical standardized modules rather than designing unique backup systems
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
This system prevents gas locking and corrosion, ensuring efficient multiphase fluid production by alternating ESP use and providing a backup in case of equipment failure, thus maintaining wellbore integrity and production efficiency.
Implementation Method 1
placing a gas separator on the inlet end of the ESP placed within a wellbore, such that at least a portion of the gaseous phase of the multiphase formation fluid will be separated prior to entry into the ESP
Data Source
AI summary
A system for producing a multiphase formation fluid may comprise a wellbore; a packer positioned within the wellbore; first and second electric submersible pumps (ESP) coupled to the packer each comprising an ESP inlet end and an ESP outlet and respectively comprising first and second openings into an interior of the first ESP outlet end and the second ESP outlet end respectively; first and second gas separators being coupled to the ESP inlet ends of the first and second ESPs respectively; first and second tubing strings coupled to the packer; a first gate mechanism positioned within or outside the first ESP outlet end and configured to not obstruct the first opening when de-actuated and obstruct the first opening when actuated; and a second gate mechanism positioned within or outside the second ESP outlet end and configured to not obstruct the second opening when de-actuated and obstruct the second opening when actuated.