ESP Static Mixer for High-GOR Gas Slug Conditioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The presence of high volumes of free gas in electrical submersible pumps (ESP) systems leads to repetitive trips, poor performance, and mechanical damage due to gas slugs and cavitation, which affect the discharge pressure and operational efficiency.
Innovation Solution
Incorporating a static mixer below the ESP intake to condition and homogenize the two-phase liquid-gas mixture, dispersing gas into small bubbles within the oil phase, thereby preventing gas buildup and ensuring smooth fluid flow into the pump stages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If free gas and gas fraction at the pump inlet increases, then gas handling capacity improves, but repetitive ESP trips and poor performance occur
Solution Approach 1:
The static mixer is installed upstream of the pump inlet to pre-condition the two-phase mixture before it enters the pump. The mixer elements create turbulence and distribute gas bubbles uniformly throughout the liquid phase in advance, preventing gas slug formation at the pump inlet and eliminating the need for reactive gas handling measures after gas problems occur
Solution Approach 2:
The static mixer acts as an intermediary device between the reservoir and the pump, modifying the two-phase flow characteristics. The mixer elements serve as a mediating structure that facilitates gas-liquid interaction and distribution, transforming the incoming heterogeneous mixture into a more uniform flow pattern that the pump can handle reliably
2Quantity of substance
If free gas volume increases, then gas handling capability improves, but discharge pressure decreases
Solution Approach 1:
The static mixer changes the flow parameters of the two-phase mixture by creating turbulence and altering the gas-liquid distribution pattern. This parameter change transforms large gas slugs into smaller, more uniformly distributed bubbles, allowing the pump to maintain discharge pressure while handling higher gas volumes through improved flow homogeneity
3Quantity of substance
If gas slugs build up at the inlet, then gas fraction increases, but gas block occurs
Solution Approach 1:
The static mixer applies preliminary anti-action by preventing gas slug buildup before it can cause gas block. The mixing elements create continuous turbulence that actively breaks up forming gas slugs and redistributes gas bubbles, counteracting the natural tendency of gas to coalesce and block the inlet before the mixture reaches 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 static mixer enhances ESP performance by reducing trips and mechanical damage, maintaining efficient fluid lift operations, and handling higher gas volume fractions without locking or cavitation, thus optimizing pump efficiency and extending equipment life.
Implementation Method 1
the static mixer conditions and homogenizes the two phase (liquid-gas) mixture
Implementation Method 2
dispersing gas into small bubbles within the oil phase
Implementation Method 3
ensuring smooth fluid flow into the pump stages
Data Source
AI summary
An electrical submersible pump (ESP) completion is used in a reservoir. The ESP completion includes an ESP and a static mixer placed below an intake of the ESP within the reservoir. A two-phase (liquid-gas) mixture flows from the reservoir through a tubing-casing annulus to the static mixer. The static mixer conditions and homogenizes the two phase (liquid-gas) mixture. The mixture flows to a tubing-casing annulus through perforated joints to enter the intake of the pump.