ESP Sand Collector Structure for Shutdown Solids Capture
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Solution Overview
Problem
Electric submersible pumps (ESPs) face premature wear and seizing due to sand and solids settling on top of the pump when fluid flow ceases, leading to costly and time-consuming work-overs.
Innovation Solution
A sand collector is integrated into the tubing string above the pump, featuring a baffle and filter system to capture and redirect sand and solids away from the pump during shutdown, utilizing baffles and filters to guide solids into an annulus and collect them before reactivation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the pump is shut down to stop pumping, then fluid flow ceases and energy consumption is reduced, but sand and solids settle on the pump causing wear and potential seizing
Solution Approach 1:
The sand collector is positioned above the pump to intercept sand and solids before they can settle on the pump during shutdown. This preliminary action of capturing solids in advance prevents the harmful effect of sand accumulation on the pump, allowing the pump to remain protected even when shut down for energy conservation.
2Reliability
If the pump operates continuously to prevent sand settling, then pump reliability is maintained, but energy consumption increases and production costs rise
Solution Approach 1:
The sand collector acts as an intermediary device between the fluid column and the pump. It captures sand and solids from the fluid, preventing them from reaching the pump. This intermediary structure allows the pump to be shut down without direct exposure to sand, enabling energy savings while maintaining reliability through the protective barrier.
3Reliability
If a sand collection device is added to protect the pump, then pump reliability is improved, but device complexity and installation cost increase
Solution Approach 1:
The sand collection function is extracted as a separate, standalone device positioned above the pump rather than integrating complexity into the pump itself. This external sand collector can be independently installed and maintained, protecting the pump while keeping the overall system architecture relatively simple and modular.
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
Prevents sand and solids from entering the pump, reducing wear and potential seizing, thereby minimizing the need for expensive and time-consuming work-overs.
Implementation Method 1
Gravity acting on the sand particles present in the column of fluid above the pump (which could be several thousand feet) causes the sand and any other solids to fall back toward the pump
Data Source
AI summary
A sand collector includes a housing and an insert. The insert has a sleeve concentrically disposed in the housing to form an annulus. An upper end of the sleeve is connected to an upper end of the housing so an upper end of the annulus is closed. A lower end of the sleeve is closed to form a collection chamber, and a lower end of the sleeve is spaced from the lower end of the housing so a gap is formed between the lower end of the sleeve and the lower end of the housing. The sleeve has at least one flow port adjacent the upper end thereof to permit the flow of fluid up through the annulus and the sleeve when fluid is flowing upward and to collect sand and other solids in the collection chamber when fluid is flowing downward.