ESP Intake Centralization with Self-Orienting Sleeve
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Solution Overview
Problem
Electric submersible pumps (ESPs) face operational issues due to gas accumulation, leading to 'gas lock' phenomena where gas interferes with the intake of reservoir fluids, disrupting the normal operation of centrifugal pumps, especially in horizontal wellbores where gas and liquid phases separate, causing turbulent flow and remixing.
Innovation Solution
The ESP assembly incorporates centralizing wings and a self-orienting sleeve to maintain laminar flow by positioning the pump intake away from the lower side of the wellbore casing, allowing only liquid to enter while excluding gas, using centralizers to keep the intake centralized and a self-orienting sleeve that hangs down to block upper ports and allow liquid to flow through lower ports, promoting natural phase separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the pump intake is positioned near the lower side of the wellbore casing to maximize liquid intake, then the liquid flow rate is improved, but gas accumulates and causes gas lock phenomena disrupting pump operation
Solution Approach 1:
The pump intake is segmented into multiple intake ports distributed around its circumference, with different ports positioned at different heights. Lower ports are positioned to maximize liquid intake while upper ports are positioned to prevent gas accumulation, dividing the intake function into height-specific zones that resolve the contradiction between productivity and reliability
Solution Approach 2:
A self-orienting sleeve is introduced as an intermediary component between the pump intake and the wellbore casing. This sleeve orients itself vertically using buoyancy and gravity forces, positioning the intake ports optimally relative to the liquid-gas interface in the wellbore, thereby enabling both high liquid intake and gas exclusion simultaneously
2Ease of operation
If the ESP assembly is allowed to rotate freely in the wellbore, then ease of installation is improved, but phase separation is disrupted and turbulent flow occurs reducing efficiency
Solution Approach 1:
The self-orienting sleeve utilizes buoyancy and gravity forces to create a stable vertical orientation equilibrium position in the wellbore. By designing the sleeve with appropriate buoyancy characteristics, the system achieves a natural stable state where the intake ports are optimally positioned relative to the liquid-gas interface, maintaining phase separation and laminar flow without requiring active control or complex installation procedures
Solution Approach 2:
The self-orienting sleeve automatically orients itself to the correct position using the natural buoyancy and gravity forces present in the wellbore environment. This self-orienting mechanism eliminates the need for external alignment tools or complex installation procedures, achieving both ease of installation and maintained flow efficiency through autonomous positioning
3Productivity
If centralizer wings are added to maintain pump intake centralization and laminar flow, then flow efficiency is improved, but device complexity increases
Solution Approach 1:
The self-orienting sleeve performs multiple functions simultaneously: it acts as a flow conditioner to maintain laminar flow, a centralizer to position the pump intake correctly, and an automatic orientation device using buoyancy-gravity forces. By combining these functions into a single component, the design achieves improved flow efficiency without proportionally increasing device complexity
Solution Approach 2:
The invention merges the centralizer function and the flow conditioning function into the self-orienting sleeve component. Rather than adding separate centralizer wings and flow conditioners, the sleeve integrates both purposes, reducing the overall structural complexity while maintaining the benefits of centralized positioning and laminar flow
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 configuration effectively reduces gas entry into the pump, maintaining laminar flow and enhancing the efficiency of the ESP by selectively admitting liquid, reducing the gas-to-liquid ratio and minimizing wear on the centrifugal pump.
Implementation Method 1
The self-orienting sleeve is free to contact and block upward facing intake ports when the ESP assembly is disposed in a horizontal or offset position
Implementation Method 2
The self-orienting sleeve hangs down to block upper ports and allow liquid to flow through lower ports
Implementation Method 3
promoting natural phase separation
Data Source
AI summary
An electric submersible pump (ESP) assembly. The ESP assembly comprises a pump intake defining a plurality of intake ports disposed circumferentially around the pump intake, a first plurality of centralizer wings disposed radially about the pump intake on a downhole side of the intake ports, a second plurality of centralizer wings disposed radially about the pump intake on an uphole side of the intake ports, and a self-orienting sleeve disposed around the intake ports, captured by the first and second plurality of centralizer wings, and free to hang down on upward facing intake ports when the ESP assembly is disposed in a horizontal or offset position.