ESP Gas Evacuation Module for Corrosion Protection Without Gas Lock
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Solution Overview
Problem
Existing downhole pumping systems face issues with corrosive gases, such as hydrogen sulfide, that impair the efficiency and integrity of production tubing and pumps, while conventional gas separators trap gases, leading to gas lock conditions and reduced pump performance.
Innovation Solution
A pumping system with a gas separator, packer, and gas evacuation module that separates gases from liquids, collects them in an annular space, and uses a Venturi nozzle to mix and evacuate gases with liquid-dominant fluids, preventing gas accumulation and maintaining pump efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a packer is installed above the pump to block corrosive gases from contact with production tubing and casing, then corrosion protection is improved, but gas accumulates in the annular space below the packer causing gas lock conditions and pump inefficiency
Solution Approach 1:
The system divides the annular space into two functional zones: a gas collection space below the packer where gases are trapped, and a gas evacuation path through the pump assembly where gases are removed. This segmentation allows simultaneous corrosion protection and gas management.
Solution Approach 2:
The pump assembly acts as an intermediary device that performs dual functions: it maintains the packer's corrosion protection function while providing a gas evacuation pathway. The pump's mechanical structure mediates between the gas collection space and the annular space above the packer.
2Productivity
If a gas separator is used to remove gas from wellbore fluids, then pump efficiency is improved by preventing gas lock, but corrosive gases still contact production tubing and casing causing corrosion
Solution Approach 1:
The system extracts the gas separation function from the traditional gas separator location and integrates it into the pump assembly. The pump assembly now performs both pumping and gas separation functions, with gases being evacuated through the pump structure rather than through a separate upstream separator.
Solution Approach 2:
The pump assembly is designed to perform multiple functions simultaneously: it pumps liquids, separates gases from liquids, evacuates gases from the annular space, and protects against corrosion. This multi-functionality eliminates the need for separate dedicated components for each function.
3Object-affected harmful factors
If gas is allowed to accumulate in the annular space below the packer, then corrosion protection is maintained, but gas lock conditions develop and pump performance deteriorates
Solution Approach 1:
The system maintains continuous gas evacuation through the pump assembly, preventing gas accumulation that would lead to gas lock conditions. The pump continuously removes gases from the collection space while maintaining the packer's corrosion protection function, ensuring uninterrupted reliable operation.
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 system effectively protects downhole equipment from corrosive gases without impairing pump efficiency by evacuating gases, thus maintaining operational integrity and preventing gas lock conditions.
Implementation Method 1
The gas evacuation module includes a Venturi nozzle configured to mix the gas with liquid-dominant fluids received from the pump
Data Source
AI summary
A pumping system deployed in a wellbore is designed for producing two-phase fluids through production tubing to a wellhead, while protecting downhole tubulars and equipment from corrosive gases from the wellbore. The pumping system includes a pump, a gas separator upstream from the pump, a packer above the pump, and a gas evacuation module between the pump and the packer. The packer blocks the movement of gases through the annular space and forms a gas collection space between the packer and the pump. The gas evacuation module is configured to remove gas from the gas collection space and mix the gas with liquid-dominant fluids received from the pump. The gas separator includes an intake configured to receive the two-phase fluids, a gas discharge configured to eject gas-dominant fluids into the annular space, and a liquid discharge configured to provide the pump with liquid-dominant fluids.