ESP Gas Handling Shroud Inlet for Fluid Separation
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Solution Overview
Problem
The presence of gas in reservoir fluid entering an electric submersible pump (ESP) can cause inefficiencies and damage due to reduced fluid density, gas locking, and thermal shock to pump bearings, leading to reduced production and shortened equipment life.
Innovation Solution
A gas handling inverted shroud assembly that passively reduces the gas void fraction by using directing vanes and tapers to separate gas from liquid, allowing gas to escape before reaching the pump intake, and incorporating gas ports to release accumulated gas, thereby improving pump efficiency and extending equipment life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If gas is allowed to enter the pump intake, then the pump can handle gas-containing fluid, but gas lock occurs and production flow rate is reduced
Solution Approach 1:
The pump intake system is segmented into separate zones: an outer annular region that directs liquid-phase fluid to the pump intake, and an inner region where gas accumulates and is diverted away. This segmentation allows the system to handle gas-containing fluid while preventing gas from entering the pump, maintaining production flow rate.
Solution Approach 2:
Gas is extracted from the gas-containing fluid before it reaches the pump intake. The system separates the gas phase from the liquid phase and diverts the gas away from the pump, allowing only liquid-phase fluid to enter the pump intake, thereby preventing gas lock while maintaining versatility in handling gas-containing reservoir fluid.
2Stability of the object's composition
If gas bubbles out of liquid suspension near the pump intake, then gas can be separated from liquid, but gas lock prevents further liquid intake
Solution Approach 1:
A gas handling shroud acts as an intermediary structure between the reservoir fluid and the pump intake. This shroud intercepts gas bubbles that form near the pump intake and redirects them away from the pump inlet, while allowing liquid-phase fluid to pass through to the pump. This maintains continuous liquid intake while achieving gas-liquid separation.
Solution Approach 2:
The system performs preliminary gas removal action before the fluid reaches the pump intake. By positioning the gas handling shroud upstream of the pump inlet, gas bubbles are captured and diverted in advance, preventing gas lock before it can occur and ensuring continuous liquid intake.
3Object-affected harmful factors
If liquid phase fluid is removed to allow gas escape, then gas lock is prevented, but pump bearings lose lubrication and overheat
Solution Approach 1:
The system applies local quality by allowing liquid-phase fluid to remain in contact with pump bearings for lubrication while simultaneously removing gas from other regions. The gas handling shroud is positioned to divert gas away from the pump intake while maintaining liquid flow to the bearings, preventing gas lock without causing bearing overheating.
4Quantity of substance
If a gas handling device is added to the pump system, then gas void fraction is reduced, but device complexity increases
Solution Approach 1:
The gas handling shroud operates passively using the natural flow of reservoir fluid and buoyancy forces of gas bubbles. It requires no external power source or active control mechanisms, reducing the increase in device complexity while effectively reducing gas void fraction in the fluid entering the pump.
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
The solution effectively reduces the gas void fraction of the fluid entering the pump, preventing gas locking and thermal shock, enhancing the performance and longevity of the ESP by ensuring consistent lubrication and reducing the risk of microcracking in the pump bearings.
Implementation Method 1
separating a flowing reservoir fluid into a high gas void fraction fluid and a low gas void fraction fluid by an inverted shroud assembly
Implementation Method 2
The shroud assembly may include a shroud clamp that comprises ports that allow the gas to escape into a wellbore above the ESP assembly
Implementation Method 3
the liquid phase fluid that would otherwise lubricate the bearings is missing. When liquid phase fluid then is reintroduced to the pump, the heated bearings may experience thermal shock as they cool rapidly
Data Source
AI summary
An electric submersible pump (ESP) assembly. The ESP assembly comprises an electric motor, a centrifugal pump mechanically coupled to the electric motor, and a gas handling inverted shroud assembly.