ESP Recirculation Coupling for Motor Cooling
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Solution Overview
Problem
Submersible pumping systems in wellbores often fail to cool the pump motor effectively when the pump intake is below the perforations, leading to reduced efficiency and potential motor damage due to lack of fluid contact.
Innovation Solution
A downhole submersible pumping system with a recirculation coupling that directs a portion of the pumped fluid from the lower pump discharge to the upper pump intake and a recirculation line that discharges the remaining fluid onto the pump motor, providing cooling by circulating fluid across the motor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the pump intake is placed below the perforations to enable pumping, then the pump can effectively move fluids from the wellbore, but the pump motor is not cooled by produced fluid leading to reduced efficiency and potential damage
Solution Approach 1:
The pump system is divided into multiple pump stages (first pump, second pump, third pump) with the motor positioned between them. The recirculation line segments the fluid flow path, creating a separate cooling circuit that diverts fluid from the main discharge line to cool the motor, allowing the motor to be thermally managed without compromising the pumping configuration
Solution Approach 2:
A recirculation line acts as an intermediary fluid pathway between the pump discharge and the motor cooling surface. This intermediate channel redirects a portion of the pumped fluid specifically for cooling purposes, mediating between the pumping function and the thermal management requirement without disrupting either function
2Temperature
If multiple pumps and a recirculation line are added to provide motor cooling, then the motor cooling is improved, but the system complexity increases
Solution Approach 1:
The cooling function is merged into the existing pumping system by utilizing the produced fluid that is already being pumped. The recirculation line taps into the existing fluid flow and redirects it for cooling, combining the pumping and cooling functions into a single integrated system rather than adding a completely separate cooling mechanism
Solution Approach 2:
The pumped produced fluid serves dual purposes: it performs the primary pumping function and simultaneously provides cooling for the motor through the recirculation line. The system uses its own operating fluid (the produced fluid) to cool itself, eliminating the need for external cooling systems or additional fluids
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
Effectively cools the pump motor by circulating produced fluid across its surface, enhancing operational efficiency and extending the motor's lifespan by maintaining optimal operating conditions.
Implementation Method 1
a recirculation line having an intake in fluid communication with the recirculation coupling and an exit configured to discharge fluid from the recirculation line onto the pump motor
Implementation Method 2
Effectively cools the pump motor by circulating produced fluid across its surface
Data Source
AI summary
A submersible pumping system for use downhole, wherein the system includes a first pump, a second pump, a recirculation coupling between the first and second pumps, and a recirculation line for directing cooling flow across the pump motor. The pumps and coupling are independent modular items connected together. Optionally, a multi-stage pump may be retrofitted with the coupling for creating a cooling flow.