External Recirculation Module for ESP Gas Lock Re-Priming
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Solution Overview
Problem
Existing submersible pumping systems face issues with gas lock due to excess gas in wellbore fluids, leading to loss of prime and inefficient re-priming, often causing pressure losses and erosion from recirculation valves.
Innovation Solution
A recirculation module with a mandrel and offset recirculation valve delivers priming fluid from production tubing to the pump assembly through dedicated lines, minimizing pressure drop and erosion by positioning the valve away from the primary flow path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If recirculation valves are placed in the discharge flow to enable re-priming, then the pump can be re-primed when gas lock occurs, but the valve experiences accelerated erosion from sand and solid particles
Solution Approach 1:
The recirculation valve is extracted from the discharge flow path and relocated to the suction side of the pump. This separation removes the valve from the harmful environment of high-velocity discharge flow containing sand and solid particles, eliminating erosion while preserving the re-priming function through the recirculation line
2Reliability
If recirculation valves are incorporated within the pump or production tubing to enable re-priming, then the pump can recover from gas lock, but pressure losses increase through the valve
Solution Approach 1:
The recirculation line is pre-configured to draw fluid from near the pump intake location rather than from distant discharge points. This preliminary positioning of the fluid source minimizes the length of recirculation path and reduces pressure losses while ensuring the valve receives adequate fluid for re-priming operations
Data Source
AI summary
A submersible pumping system for producing a fluid from a wellbore through production tubing to a wellhead includes a pump assembly that has at least one pump, a motor that drives the at least one pump, and a recirculation module. The recirculation module includes a recirculation mandrel positioned within the production tubing and a recirculation line extending from the recirculation valve to the pump assembly. The recirculation module delivers a volume of priming fluid from the production tubing to the pump assembly. In some embodiments, the recirculation module further includes a recirculation valve, which can be positioned in an offset relationship from the recirculation mandrel.