ESP Packer Inversion to Prevent Gas Lock

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Solution Overview

Problem

Current electrical submersible pump assemblies face issues with gas accumulation and corrosive gas attacks on connectors and cables, leading to reduced efficiency and potential failure, particularly when free gas forms and rises above the intake, causing gas lock and damage.

Innovation Solution

The pump intake is positioned adjacent to and below the packer, with the pump stages located above, and a packer assembly is used to create a sealing engagement with the outer tubular member, preventing gas accumulation and corrosive gas exposure, while maintaining fluid communication through production tubing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the packer is positioned above the pump intake with electrical connectors located at the packer, then electrical power can be continuously supplied to the downhole motor, but gas accumulation occurs below the packer causing corrosive gas exposure and electrical connector failures

Engineering Contradiction:

Improveelectrical connector reliabilityVSAvoidcorrosive gas exposure

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent inverts the conventional arrangement by positioning the packer below the pump intake instead of above it. This reversal places the electrical connectors and power cable away from the gas accumulation zone, eliminating corrosive gas exposure while maintaining continuous electrical power supply to the downhole motor through the repositioned packer penetrators.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent changes the vertical dimensional arrangement of components. By moving the packer from an upper position to a lower position relative to the pump intake, the system redistributes components along the vertical dimension to separate electrical connectors from the gas-trapped zone, solving the corrosion problem without compromising electrical connectivity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If a shrouded pump system with stinger is used to prevent gas accumulation, then gas lock can be avoided, but new specialized components increase overall assembly cost

Engineering Contradiction:

Improvepump operation reliabilityVSAvoidassembly component complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent makes the packer serve multiple functions: it provides sealing engagement with the wellbore, supports the electrical power cable connection, and positions itself below the pump intake to prevent gas accumulation. This multi-functionality eliminates the need for separate specialized components like shrouds and stingers, reducing overall assembly complexity while maintaining reliable pump operation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent combines the functions of the packer and the gas prevention mechanism into a single integrated arrangement. The packer positioned below the pump intake simultaneously provides electrical connectivity and prevents gas lock, merging what would otherwise require separate specialized components into one unified system.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If the pod system with smaller cross-sectional area is used, then pump intake can be protected, but fluid velocity increases causing additional pressure loss and gas breakout

Engineering Contradiction:

Improveintake protectionVSAvoidfluid pressure

Core Design Contradiction:

ReliabilityVSStress or pressure

Solution Approach 1:

The patent takes preliminary action by positioning the packer below the pump intake before gas accumulation can occur. This preventive positioning stops gas from reaching the pump intake in the first place, eliminating the need for velocity-reducing designs and avoiding the pressure loss associated with smaller cross-sectional areas.

Inventive Principle:

Principle #10Preliminary action

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 reduces gas lock and electrical failures, maintains pump efficiency, and prevents corrosive gas damage, while allowing for the use of existing components, thus reducing overall costs and ensuring reliable hydrocarbon production.

Implementation Method 1

a packer assembly is used to create a sealing engagement with the outer tubular member, preventing gas accumulation and corrosive gas exposure

Methodology Applied

Scientific EffectSealing engagement:

Implementation Method 2

Due to the lower density of the free gas compared to the liquid, the gas pockets rise above the intake and are trapped just under the packer

Methodology Applied

Scientific EffectGas rise due to lower density: Gravitation

Data Source

PatentUS10989025B2Prevention of gas accumulation above ESP intake

Publication Date: 2021.04.27 SAUDI ARABIAN OIL CO

AI summary

A system for producing hydrocarbons from a subterranean well includes an electrical submersible pump assembly with a pump, intake, protector, and motor. A production tubing is in fluid communication with the electrical submersible pump assembly and has an inner bore sized to deliver fluids from the electrical submersible pump assembly to a wellhead assembly. A packer assembly is located between the pump and the intake, the packer assembly moveable to an expanded position with an outer diameter in sealing engagement with an inner diameter of an outer tubular member.