Gel Canister Design to Prevent Solids Fallback in ESP-Lifted Wells
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Solution Overview
Problem
The challenge of solids fallback in wells using electrical submersible pumps (ESPs) leads to blockages and unretrievable components, reducing well production efficiency and necessitating costly retrieval of entire completions.
Innovation Solution
A system and method involving a gel canister and pressure release conduit are used to suspend and lift solids, preventing fallback by injecting a low-density gel to capture and carry solids upward using buoyancy when the ESP stops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If electrical submersible pumps (ESPs) are used to lift fluids from subterranean reservoirs, then productivity is improved, but solids fallback occurs causing blockages and reducing reliability
Solution Approach 1:
A gel canister containing gel is introduced as an intermediary substance between the ESP pump and the solids in the fluid stream. The gel acts as a mediator that captures solids through adhesion and suspension, preventing them from falling back to the pump while allowing continuous fluid production. This intermediary gel substance resolves the contradiction by enabling high productivity without the reliability issues caused by solids fallback.
Solution Approach 2:
The invention changes the physical parameters of the fluid stream by introducing gel, which alters the viscosity, density, and suspension characteristics of the well fluid. This parameter change enables solids to remain suspended in the upward-flowing fluid rather than settling and falling back to the pump, thereby maintaining both high productivity and reliability.
2Device complexity
If solids fallback is allowed to occur naturally, then device complexity is reduced, but blockages occur requiring costly retrieval operations
Solution Approach 1:
The gel canister system provides self-service protection against solids fallback without requiring complex external monitoring or control systems. The gel is continuously dispensed through the pressure release conduit based on automatic pressure differential, creating a self-regulating system that prevents blockages naturally and eliminates the need for frequent maintenance interventions.
Solution Approach 2:
The gel is continuously introduced into the fluid stream in advance to preemptively capture and suspend solids before they can fall back to the pump or create blockages. This preliminary action of gel dispersion prevents the need for costly retrieval operations later, effectively trading minimal continuous system complexity for major maintenance cost reduction.
3Reliability
If gel is continuously delivered to suspend solids, then reliability is improved, but device complexity increases due to additional components
Solution Approach 1:
The gel delivery system utilizes hydraulic principles by employing a pressure release conduit that operates based on pressure differentials between the canister interior and the well fluid stream. This hydraulic mechanism automatically regulates gel dispensing without requiring complex mechanical or electronic control systems, thereby achieving high reliability with minimal device complexity.
Solution Approach 2:
The gel canister and pressure release conduit system performs multiple functions: it stores gel, regulates its dispensing based on pressure conditions, suspends solids, and maintains continuous fluid flow. This multi-functionality consolidates what would otherwise require separate systems into a single integrated component, improving reliability while minimizing the increase in device complexity.
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 mitigates solids fallback, enhancing well production by maintaining flow paths and reducing the risk of blockages, thus optimizing ESP performance and minimizing maintenance.
Implementation Method 1
injecting a low-density gel to capture and carry solids upward using buoyancy when the ESP stops
Implementation Method 2
A gel canister and pressure release conduit are used to suspend and lift solids, preventing fallback by injecting a low-density gel
Data Source
AI summary
A method includes providing an electrical submersible pump assembly (ESP) with a pump, an intake, a gel canister, a protector, and a motor disposed in a casing. The method includes providing fluid communication between a production tubing and the ESP, the production tubing delivering well fluid containing solid particles and liquids from the ESP into a wellhead assembly through an inner bore of the production tubing. The method includes locating a pressure release conduit configured in a closed state, between a canister exterior in a hydraulic communication with a canister inner chamber of the gel canister and the inner bore. The closed state prevents the hydraulic communication between the canister inner chamber and the inner bore. The method includes delivering a canister contents to the well fluid.