ESP Positioning in Slim Completions to Reduce Erosion
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Solution Overview
Problem
In slim hole wells, conventional completion arrangements lead to high flow velocities and erosion issues, causing premature failure of electrical submersible pumps (ESPs) and reduced hydrocarbon production due to spatial restrictions.
Innovation Solution
Positioning the ESP within the casing such that at least a portion extends outwardly from the production tubing, increasing interstitial space and reducing friction loss, while using subsurface prevention and electric inflow control valves to manage hydrocarbon flow and prevent erosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the tubing extends along the inner walls of the casing beyond the ESP, then well control is improved, but the interstitial space is reduced causing high flow velocities and erosion
Solution Approach 1:
The ESP is positioned to extend radially outwardly from the production tubing into the annular space between the tubing and casing. This dimensional change creates a new flow path through the interstitial space, increasing the effective flow area and reducing flow velocity to minimize erosion while maintaining well control capabilities.
2Loss of energy
If the ESP extends outwardly from production tubing, then interstitial space is increased reducing friction loss, but device complexity increases
Solution Approach 1:
The ESP is nested within the casing and positioned to extend through the production tubing, utilizing the existing annular space between the tubing and casing. This nesting approach allows the ESP to create a larger effective flow area without requiring additional external components or complex positioning mechanisms.
3Object-affected harmful factors
If production tubing terminates adjacent to pump discharge, then interstitial space is increased for reduced erosion, but subsurface safety valve installation becomes more difficult
Solution Approach 1:
The completion system is segmented into distinct functional zones: the ESP creates an extended flow path through the interstitial space, while separate safety valve and control valve systems are positioned at different locations along the tubing and casing to provide well control without interfering with the erosion-reduction geometry.
Data Source
AI summary
A system to enhance well control in slim completions in an oil well includes an electrical submersible pump (“ESP”) positioned within a casing and having at least a portion thereof extending outwardly from a production tubing positioned within the casing. The production tubing terminates adjacent a distal end portion of a pump discharge to thereby provide greater interstitial space between outer surfaces of the portion of the pump disposed to extend outwardly from the production tubing and inner walls of the casing. This increased interstitial space, for example, can assist in cost savings by reducing the rate of erosion damage to the ESP. Embodiments of the present invention can further include a valve connected to inner walls of the casing and positioned distal from the ESP to control the flow of hydrocarbons.