ESP Solids Catcher with Offset Pump and Annular Flow Path
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Solution Overview
Problem
In hydrocarbon well development, the deposition of solids on electrical submersible pumping systems (ESPs) leads to frequent trips, failures, and jams, necessitating costly and time-consuming reinstallation procedures due to solids fallback into ESP stages.
Innovation Solution
A solids catcher system is introduced, comprising an inner and outer annulus with a chamber, where the pump is offset from the central axis, directing fluid streams carrying solids through the outer annulus and chamber to form a solids accumulation zone, preventing solids from falling back into the ESP stages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sand trap device is employed to prevent solids from falling back into ESP stages, then ESP reliability is improved, but device complexity increases due to the additional solids catcher structure
Solution Approach 1:
The solids catcher is nested within the existing tubing-ESP system, with the chamber positioned between the tubing and ESP string. The inner annulus and outer annulus create concentric flow paths that are integrated into the existing well architecture, allowing the solids separation function to be added without requiring complete system redesign or additional surface equipment.
Solution Approach 2:
The solids catcher divides the flow path into distinct segments: the outer annulus for initial solids deposition, the chamber with accumulation zone for solids collection, and the inner annulus for cleaned fluid return. This segmentation allows solids to be separated and accumulated in a dedicated zone while maintaining continuous fluid flow through the ESP.
2Ease of operation
If the pump is disposed offset from the central axis to create a solids accumulation zone, then solids management is improved, but manufacturing precision requirements increase
Solution Approach 1:
The pump is intentionally positioned offset from the central axis of the tubing, creating an asymmetric flow pattern within the solids catcher. This asymmetric positioning is fundamental to the device's operation, as it directs the fluid stream to follow a path that maximizes solids deposition in the accumulation zone while maintaining efficient flow through the inner annulus.
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 system effectively reduces ESP failures and reinstallation needs by creating a solids accumulation zone, allowing for controlled solids deposition and efficient fluid flow, thereby minimizing operational disruptions and costs.
Implementation Method 1
a fluid stream carrying solids flowing from the pump, wherein the fluid stream carrying solids is configured to follow a path delimited by the outer annulus and the chamber until the fluid stream deposits the solids in the solids accumulation zone
Data Source
AI summary
A system includes a solids catcher that is centered with respect to a central axis of a tubing. The system includes an inner annulus, an outer annulus, and a chamber between the inner annulus and the outer annulus. A solids accumulation zone is formed in the chamber. A pump disposed offset from the central axis of the tubing. The pump is fluidly connected to the solids catcher through the outer annulus. A fluid stream carrying solids flowing from the pump. The fluid stream carrying solids is configured to follow a path delimited by the outer annulus and the chamber until the fluid stream deposits the solids in the solids accumulation zone and departs the solids catcher via the inner annulus into a tubing.