ESP Pump Separator Helical Flow Path
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Solution Overview
Problem
Existing electrical submersible pumping systems (ESP) for hydrocarbon wellbores face challenges in efficiently separating water from produced fluids, particularly due to increased complexity, weight, and capital costs when incorporating downhole separation systems, especially in lateral or deviated wellbores.
Innovation Solution
The system incorporates a housing with a separation chamber and a rotatable impeller having a fluid passage that creates a helical flow path with a reducing radius, enhancing swirl velocity and centrifugal separation of fluid components based on density, allowing for efficient separation of water and hydrocarbons within the wellbore.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a downhole separation system with rotating blades is added to the ESP system, then water separation from produced fluid is achieved, but the system length increases making deployment into lateral or deviated wellbores difficult
Solution Approach 1:
The patent combines the separation function with the existing pump discharge by integrating a separation chamber directly onto the pump assembly. The separation chamber receives fluid discharged from the pump impeller and uses the existing fluid flow to generate centrifugal separation, eliminating the need for a separate standalone separation system and reducing overall ESP system length.
Solution Approach 2:
The pump discharge structure serves dual purposes: it functions as both the pump outlet and as a centrifugal separator. The separation chamber utilizes the kinetic energy from the pump discharge to create swirling flow that separates water from hydrocarbons, making the pump system multi-functional without adding separate dedicated separation equipment.
2Reliability
If a downhole separation system with rotating blades is added to the ESP system, then water separation from produced fluid is achieved, but the weight and capital costs of the ESP system increase
Solution Approach 1:
The separation chamber is integrated as part of the pump assembly structure, sharing common housing and mechanical components with the pump. This merging of functions eliminates duplicate structures and reduces the total weight of the ESP system compared to having separate pump and separator units.
Solution Approach 2:
The same structural components serve multiple functions: the pump housing also serves as part of the separation chamber structure, and the fluid flow path is utilized for both pumping and separation operations. This multi-functionality reduces material requirements and overall system weight.
3Reliability
If a downhole separation system with rotating blades is added to the ESP system, then water separation from produced fluid is achieved, but the device complexity increases
Solution Approach 1:
The separation chamber is integrated with the pump assembly, sharing common housing, shaft, and drive mechanisms. This consolidation reduces the number of separate components and interconnections required, simplifying the overall system architecture compared to having independent pump and separator units.
Solution Approach 2:
The pump discharge flow is utilized dual-purpose: to deliver produced fluid upward and to generate centrifugal force for separation in the separation chamber. This eliminates the need for separate drive mechanisms and control systems for pumping and separation, reducing device complexity.
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 separates higher and lower density fluids within the wellbore, reducing system complexity and costs while enabling efficient fluid management and reservoir pressure balancing.
Implementation Method 1
separating water from the produced fluid with a centrifugal separation
Implementation Method 2
the fluid is separated so that components of the fluid proximate an outer radius of the separation chamber have a density that is higher than a density of fluids that are distal from the outer radius of the separation chamber
Data Source
AI summary
A system and method of producing fluid from a wellbore, and that separates water from the fluid. The system includes an electrical submersible pumping system with a pump having impellers and diffusers, and a separation system at a discharge end of the pump. The separation system includes a helical flow path and separation chamber downstream of the path. Directing the fluid through the helical flow path centrifugally separates the water from the fluid. Thus when the fluid flows into the separation chamber from the helical flow path, the water migrates to the outer radius of the separation chamber. The separated water flows through ports on the outer sidewall of the separation chamber, and the lower density portion of the fluid flows through a port proximate a middle portion of the separation chamber.