ESP Separator Shroud Weight Support and Cable Protection
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Solution Overview
Problem
Existing ESP systems face inefficiencies and potential damage due to solid particles and gas bubbles in downhole fluids, as conventional separators rely on suspending equipment that may not effectively manage weight and fluid flow, leading to reduced performance.
Innovation Solution
An ESP/separator assembly with a tubular shroud positioned circumferentially around the pump and motor, supporting the weight of a separator, which allows fluid to pass through the shroud and into the pump, while positioning the electrical cable radially between the pump and shroud to minimize diameter and maximize support, ensuring efficient fluid flow and weight distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional separators are suspended from the pump and motor, then the separator can be positioned to remove gas and sand, but the weight of the separator reduces the lifting capacity and may cause instability
Solution Approach 1:
A shroud is introduced as an intermediary component between the pump/motor assembly and the separator. The shroud provides a dedicated support structure that transfers the separator's weight away from the pump and motor, allowing the separator to be positioned effectively for gas and sand removal without compromising the lifting capacity or stability of the pump-motor assembly.
2Use of energy by moving object
If the electrical cable is positioned close to the pump, then power transmission is efficient, but the cable is vulnerable to damage from gas bubbles and solid particles
Solution Approach 1:
The shroud serves as a protective intermediary that positions the electrical cable within its interior space. This shielding arrangement protects the cable from direct contact with harmful gas bubbles and solid particles in the fluid stream, while still allowing efficient power transmission to the motor.
Solution Approach 2:
The electrical cable is nested within the interior of the shroud, creating a protected pathway. This nested configuration allows the cable to be positioned close to the pump for efficient power transmission while being shielded from damage by the shroud structure.
3Device complexity
If the pump is positioned centrally in the shroud, then the structure is simple, but the cable cannot be properly positioned and diameter is increased
Solution Approach 1:
The pump is positioned asymmetrically within the shroud, offset from the central axis. This asymmetric arrangement creates space on one side of the shroud interior for the electrical cable to be properly positioned, allowing for a more compact diameter while maintaining structural simplicity.
Solution Approach 2:
The pump is positioned in a specific radial location within the shroud rather than centrally, utilizing the radial dimension to create space for cable positioning. This dimensional arrangement allows the cable to be routed through the shroud interior without increasing the overall diameter.
Data Source
AI summary
An ESP/separator assembly (10) is positioned downhole in a well on a tubular string (18) to pump downhole fluids to the surface. The assembly includes an electric submersible pump (12) and an electrically powered motor (20) positioned below the pump. An electrical cable (22) extends downhole past the motor and to the pump. A generally cylindrical shroud (26) is positioned circumferentially about the pump, the motor, and a portion (24) of the cable extending past the pump and to the motor. A separator (60) is provided at the lower end of the shroud, such that the shroud supports substantially the weight of the separator.