Cooling devices and methods for use with electric submersible pumps
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Solution Overview
Problem
Current ESP systems are not suitable for high-temperature applications, particularly geothermal systems, due to susceptibility to pump cavitation and thermal failures, which result in reduced run life and increased costs for oil production companies.
Innovation Solution
A cooling device for ESP systems that includes a cylindrical housing with a compressor, condenser, pressure reduction device, and evaporator, utilizing a magnetic coupling system to power the compressor and facilitate heat transfer, allowing for effective cooling of lubricating fluids and reducing motor operating temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ESP systems operate in high-temperature environments (above 100°C), then they can access geothermal resources and heavy oil reservoirs, but they suffer from pump cavitation and thermal failures reducing run life
Solution Approach 1:
The ESP system is divided into thermally isolated segments: the pump operates in the high-temperature reservoir environment while the motor is thermally protected through a cooling system with heat exchangers, creating distinct thermal zones within the same system
Solution Approach 2:
A cooling system acts as an intermediary between the motor and the high-temperature reservoir environment, using heat exchangers and circulating fluid to transfer heat away from the motor, thereby protecting it from thermal damage while allowing the pump to operate in hot conditions
2Temperature
If the motor interior temperature is allowed to rise with reservoir temperature, then the system can operate in high-temperature wells, but the motor components reach temperatures 50-100°F hotter than reservoir temperature causing thermal failure
Solution Approach 1:
The cooling system serves as a thermal intermediary, inserting heat exchangers and circulating fluid between the motor and the hot reservoir environment to actively manage heat transfer and maintain motor temperatures within safe operating limits
Solution Approach 2:
The cooling system proactively removes heat from the motor before thermal damage can occur, continuously circulating cooling fluid through heat exchangers to maintain motor temperatures below critical thresholds even when reservoir temperatures are extremely high
3Productivity
If ESP systems are used in steam-assisted oil-field applications with temperatures exceeding 400°F, then heavy oil can be mobilized and produced, but the motors and pumps are exposed to temperatures above their design limits
Solution Approach 1:
The system segments the thermal environment so that the pump can operate in the high-temperature steam-assisted reservoir (exceeding 400°F) while the motor is protected through a dedicated cooling system, allowing each component to operate within its optimal temperature range
Solution Approach 2:
The cooling system acts as a thermal mediator between the motor and the steam-assisted reservoir environment, using heat exchangers and circulating fluid to maintain motor temperatures within design limits while enabling the pump to produce heavy oil from high-temperature reservoirs
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 cooling device significantly reduces internal motor temperatures, leading to increased run life and improved reliability of ESP systems in high-temperature environments, such as deep wells and steam-assisted oil-field applications.
Implementation Method 1
utilizing a magnetic coupling system to power the compressor
Implementation Method 2
facilitate heat transfer
Implementation Method 3
cooling of lubricating fluids
Data Source
AI summary
Cooling devices for use with electric submersible pump motors include a refrigerator attached to the end of the electric submersible pump motor with the evaporator heat exchanger accepting all or a portion of the heat load from the motor. The cooling device can be a self-contained bolt-on unit, so that minimal design changes to existing motors are required.