Counter-Rotating Debris Cutter for ESP Reliability
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Solution Overview
Problem
During hydrocarbon extraction, well debris carried by well fluids can cause erosion, plug, or damage equipment, leading to potential catastrophic failures of electric submersible pumps and increased operating costs.
Innovation Solution
An electric submersible pump system with a well debris cutting tool that rotates in the opposite direction to grind debris carried by well fluids, using a turbine and counter-rotating cutting blade assemblies to reduce debris to sizes that can pass through the pump without clogging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If debris is left unhandled in well fluid, then equipment erosion and damage occurs, but adding debris handling equipment increases system complexity
Solution Approach 1:
The patent combines the debris grinding function with the existing pump system by integrating cutting blades into the pump housing and utilizing the pump's rotational motion to drive the grinding mechanism. This merging approach allows debris handling to be performed by the same equipment that already pumps the fluid, thereby improving reliability without significantly increasing overall system complexity.
Solution Approach 2:
The pump system is designed to perform multiple functions: it not only pumps the well fluid but also grinds debris through the integrated cutting blades. This multi-functionality allows a single piece of equipment to address both fluid transport and debris management, reducing the need for separate debris handling systems and thereby maintaining system simplicity while improving reliability.
2Productivity
If counter-rotating cutting blade assemblies are used to grind debris, then debris is effectively reduced to passable sizes, but the device complexity increases
Solution Approach 1:
Instead of using a single rotating cutting mechanism, the patent employs counter-rotating cutting blade assemblies that rotate in opposite directions. This inversion approach creates a more effective grinding action between the two sets of blades, significantly improving debris processing efficiency by shearing and crushing debris more thoroughly than a single-direction rotation could achieve.
Solution Approach 2:
The cutting blade assemblies are designed to rotate dynamically at different speeds and directions, with the first set rotating in one direction and the second set rotating in the opposite direction. This dynamic configuration allows for optimized debris grinding performance, creating multiple cutting zones that effectively reduce debris to passable sizes while adapting to varying debris conditions.
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
Extends the operational life of ESPs, improves reliability, and reduces field operating costs by effectively grinding debris to sizes that can flow through equipment without causing blockages.
Implementation Method 1
The turbine is configured to be positioned within the wellbore, downhole relative to the ESP and to rotate in response to flow of the well fluid through the turbine in the uphole direction
Implementation Method 2
The well debris cutting tool is configured to rotate in a second direction opposite the first direction and to grind debris carried by the well fluid in the uphole direction
Data Source
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Figure 2B
AI summary
A well tool assembly, system, and method for handling well debris is described. The assembly includes an electric submersible pump (ESP) configured to be positioned within a wellbore and a well debris cutting tool configured to be positioned downhole relative to the ESP within the wellbore. The ESP is configured to rotate in a first direction to pump well fluid in an uphole direction. The well debris cutting tool is configured to rotate in a second direction opposite the first direction and to grind debris carried by the well fluid in the uphole direction.