Gas Separator Curved Flow Path Reduces Pumping Head
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Solution Overview
Problem
Electric submersible pumps (ESPs) face inefficiencies due to head degradation and gas locking when handling high percentages of free gas, primarily because the existing gas separators cause a sharp right-angle turn for lighter wellbore fluid to exit, leading to increased fluid pressure and pumping head requirements.
Innovation Solution
The implementation of a gas separator with a venting portion and diverter guide vanes that direct heavier fluid into the pump intake and lighter fluid towards a venting port, along with a slinger to impel fluid, aids in momentum change and reduces flow resistance, enhancing the flowpath efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a sharp right-angle turn is used for lighter wellbore fluid to exit the gas separator, then the gas separator can be compact in size, but the fluid pressure increases and pumping head requirements increase
Solution Approach 1:
The patent replaces the sharp right-angle turn with a curved flow path in the venting portion. The curved geometry allows lighter wellbore fluid to change direction gradually from radial inward flow to axial upward flow, reducing flow resistance and pressure increase while maintaining a compact separator design.
Solution Approach 2:
The patent introduces a three-dimensional curved flow path that transitions fluid from a two-dimensional radial plane to a three-dimensional spiral trajectory. This dimensional transition allows the fluid to navigate the turn more efficiently by distributing the momentum change across multiple spatial dimensions, reducing pressure losses.
2Volume of moving object
If a sharp right-angle turn is used for lighter wellbore fluid to exit the gas separator, then the gas separator can be compact in size, but the pumping head requirements increase
Solution Approach 1:
The curved flow path geometry reduces flow resistance and turbulence in the venting portion, decreasing the energy required to move lighter wellbore fluid from the separation chamber to the annulus. This lowers the pumping head requirement while maintaining compact separator dimensions.
Solution Approach 2:
The patent converts the harmful effect of sharp turns (high pressure loss) into a beneficial curved flow path that utilizes centrifugal force and fluid momentum more efficiently. The curved geometry transforms what would be energy-wasting turbulence into controlled rotational flow, reducing overall energy consumption.
3Use of energy by moving object
If the flow path is modified to reduce pressure increase, then pumping head requirements decrease, but the device complexity increases
Solution Approach 1:
The curved flow path is integrated directly into the venting portion housing geometry, eliminating the need for separate mechanical components. This approach reduces device complexity by using the structural form itself to achieve the flow control function, rather than adding separate flow-directing elements.
Solution Approach 2:
The venting portion serves multiple functions: it provides the exit path for lighter wellbore fluid, establishes the curved flow pattern to reduce pressure loss, and acts as a structural component of the gas separator. This multi-functionality reduces overall device complexity by combining several functions into a single element.
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
This design reduces the total pumping head required to lift fluid to the surface and increases the flow rate of high gas content fluid, improving the overall efficiency of the ESP assembly.
Implementation Method 1
The wellbore fluid is rotated within the separator, centrifugally separating heavier wellbore fluid from lighter wellbore fluid
Implementation Method 2
Diverter guide vanes are formed in a flowpath of the lighter fluid for aiding in a directional change of momentum
Data Source
AI summary
A gas separator having an improved flowpath for lighter fluids having a higher concentration of gas decreases total pumping head for an ESP assembly. The ESP assembly includes a rotary primary pump, a motor coupled to the primary pump for driving the pump, a seal assembly between the primary pump and the motor, and a gas separator between the seal assembly and the primary pump. An outlet of the gas separator feeds an intake of the primary pump, and a rotating shaft operationally couples the primary pump to the motor and passes through the seal assembly and the gas separator. The gas separator contains a venting portion, and a diverter positioned within the venting portion having diverter guide vanes formed in a flowpath of the lighter fluid for aiding in a directional change of fluid momentum. A slinger is positioned within the diverter for impelling fluid through the venting port.