Flow Diverter Valve for ESP Operational Life Extension
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Solution Overview
Problem
Electric submersible pumps (ESPs) in well completion systems have a limited operational life, requiring frequent replacements that are time-consuming and costly due to the need for periodic workover operations.
Innovation Solution
A system combining a flow diverter valve with an electric submersible pumping system, where the flow diverter valve automatically directs well fluid to bypass the ESP when it's not operating and to the ESP when it's operating, extending the ESP's life by ensuring fluid flow only during operation, and includes features like one-way flow restrictors and an automatically shiftable mandrel for fluid control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If the ESP is continuously exposed to fluid flow to ensure production, then production is maintained, but the operational life of the ESP is reduced
Solution Approach 1:
The flow diverter valve dynamically switches between two positions: directing fluid flow to the ESP when it is operating, and bypassing the ESP when it is not operating. This dynamic flow control allows the system to adapt to the operational state of the ESP, minimizing exposure to fluid flow during non-operational periods while maintaining production capability when the ESP is running.
Solution Approach 2:
The flow diverter valve acts as an intermediary device between the wellbore fluid flow and the ESP. It controls and regulates the interaction between the fluid and the pump, allowing the system to decouple continuous fluid flow from continuous ESP operation, thereby extending ESP life without compromising overall production capability.
2Reliability
If the ESP is replaced frequently to maintain production, then production reliability is maintained, but time and cost for workover operations increase
Solution Approach 1:
The flow diverter valve is pre-installed in the completion system before the ESP is deployed. This preliminary installation enables the valve to immediately begin protecting the ESP from unnecessary fluid exposure as soon as the ESP starts operating, extending its operational life and reducing the frequency of replacements without requiring any preliminary work on the ESP itself.
3Ease of operation
If the flow diverter valve is manually operated, then fluid flow can be controlled, but system complexity and operational requirements increase
Solution Approach 1:
The flow diverter valve is designed to automatically respond to the operational state of the ESP without requiring manual intervention. The valve self-regulates fluid flow based on whether the ESP is running or not, eliminating the need for complex control systems or human operators to manage the flow diversion, thereby simplifying the overall system while maintaining effective fluid control.
Data Source
AI summary
A technique provides a system and methodology for enhancing the operational life of an electric submersible pumping system. A completion is combined with a flow diverter valve and is positioned downhole in a wellbore. An electric submersible pumping system is coupled into the completion and the flow diverter valve is oriented to control fluid flow with respect to the electric submersible pumping system. For example, the flow diverter valve may be automatically operable to direct well fluid to the electric submersible pumping system when the pumping system is operating and to direct well fluid to bypass the electric submersible pumping system when the pumping system is not operating.