Rotary Gear Pump for High-Temperature Heavy Oil Extraction

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Solution Overview

Problem

Current artificial lift systems for oil production, such as pump jack, progressive cavity, electric submersible, jet, and gas lift systems, are inefficient and unsuitable for extracting heavy, sandy, gaseous, or corrosive high-temperature oil and water slurries due to limitations in temperature range, viscosity handling, contamination susceptibility, and operational control, especially in horizontal wellbores.

Innovation Solution

A downhole pumping apparatus featuring a positive displacement rotary gear pump driven by a rotating rod string or submersible electric motor, capable of operating within a wide temperature range and equipped with a flex coupling and monitoring system for real-time data collection and control, allowing efficient fluid extraction from horizontal wellbores.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If progressive cavity pumps are used, then they can operate at lower temperatures, but they fail to operate well at high temperatures above 180 F (80 C)

Engineering Contradiction:

Improvemaximum operating temperatureVSAvoidoperational reliability at high temperature

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent changes the material parameters of the pump components, specifically using high-temperature resistant materials for the rotor and stator. The rotor is made of heat-treated steel or ceramic matrix composite, and the stator uses high-temperature elastomer or rubber compound, enabling operation at temperatures up to 350°F (177°C) or higher while maintaining reliability.

Inventive Principle:

Principle #35Parameter changes

2Speed

If electric submersible pumps are used, then they can operate at high rotational speeds, but they are adversely affected by inflow viscosity limitations and are not suitable for heavy oil applications

Engineering Contradiction:

Improverotational speedVSAvoidsuitability for heavy oil and viscous fluid

Core Design Contradiction:

SpeedVSAdaptability or versatility

Solution Approach 1:

The patent replaces the dynamic impeller-based mechanical system of ESPs with a positive displacement gear pump mechanism. The intermeshing gears create discrete pumping chambers that mechanically displace fluid, providing consistent flow independent of viscosity and eliminating the speed-viscosity limitations of impeller-based systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If jet pumps are used, then they can provide fluid transmission, but they have lower efficiency than positive displacement pumps and require higher intake pressures to avoid cavitation

Engineering Contradiction:

Improvefluid transmission capabilityVSAvoidpumping efficiency

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The patent extracts the fluid transmission function from the high-pressure jet stream and replaces it with a positive displacement gear pumping mechanism. This eliminates the energy losses associated with jet pump cavitation and high-pressure requirements, achieving superior efficiency while maintaining fluid transmission capability.

Inventive Principle:

Principle #2Taking out (Extraction)

4Stress or pressure

If gas lift systems are used, then they can reduce hydrostatic pressure, but they have lower efficiencies than positive displacement pumps and are uncontrollable under varying well conditions

Engineering Contradiction:

Improvehydrostatic pressure reductionVSAvoidcontrollability under varying conditions

Core Design Contradiction:

Stress or pressureVSEase of operation

Solution Approach 1:

The patent incorporates a monitoring system with sensors that detect flow rate, pressure, temperature, and motor performance parameters. This feedback enables real-time control adjustments, allowing the gear pump system to adapt to varying well conditions and maintain optimal performance, unlike uncontrollable gas lift systems.

Inventive Principle:

Principle #23Feedback

5Ease of operation

If pump jack systems are used, then they can provide reciprocating pumping action, but they have number of well-known disadvantages including complexity and suitability for horizontal wells

Engineering Contradiction:

Improvereciprocating pumping capabilityVSAvoidsurface unit complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent replaces the complex surface reciprocating mechanical system of pump jacks with a downhole electric motor-driven gear pump. This substitution eliminates the lengthy surface mechanical linkage (beam, horsehead, rods) and achieves reciprocating-equivalent positive displacement pumping through compact intermeshing gears, greatly reducing surface complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 provides efficient and reliable fluid extraction across a broad range of production conditions, including high temperatures and viscous fluids, with improved control and reduced susceptibility to contamination and wear, enhancing operational efficiency and longevity.

Implementation Method 1

a positive displacement rotary gear pump (RGP)

Methodology Applied

Scientific EffectPositive displacement:

Data Source

PatentUS11208999B2Electric motor and rod-driven rotary gear pumps

Publication Date: 2021.12.28 ADVANCING PUMP TECH CORP

AI summary

A downhole pumping apparatus comprising a positive displacement rotary gear pump (RGP), driven by a rotating rod string or a submersible electric motor.