Integral Gas Separator and Pump for ESP Gas Lock
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Solution Overview
Problem
Gas presence in electric submersible pumps (ESPs) leads to reduced pump performance, gas lock conditions, and increased operational costs due to interrupted fluid flow, which limits hydrocarbon production rates and shortens pump lifespan.
Innovation Solution
An integral gas separator and pump assembly is introduced, featuring centrifugal pump stages downstream of a crossover to separate gas and liquid phases, eliminating the need for a traditional centrifugal pump assembly downstream, thereby maintaining higher flow rates and avoiding flow path restrictions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gas separation is implemented before pump entry, then pump performance is improved and gas lock is reduced, but device complexity increases due to additional separation components
Solution Approach 1:
The patent combines the gas separator and pump into a single integrated assembly where the pump is positioned downstream of the crossover within the same housing structure. This merging eliminates the need for separate gas separation equipment while maintaining effective gas-liquid separation before pumping, thus improving pump performance without proportionally increasing device complexity.
Solution Approach 2:
The integrated assembly serves multiple functions: the upper chamber acts as a gas separator, the crossover provides phase separation, and the downstream pump delivers liquid flow. This multi-functional design achieves gas separation and pumping in one unit, resolving the contradiction between reliability improvement and complexity increase.
2Productivity
If traditional centrifugal pump assembly is used downstream, then pump performance is maintained, but flow path restrictions occur reducing hydrocarbon production rates
Solution Approach 1:
The pump assembly is segmented into multiple stages with each stage having its own impeller and diffuser arranged in series downstream of the crossover. This segmentation allows progressive pressure build-up while maintaining smooth flow paths, avoiding the flow restrictions that would occur in a single-stage traditional pump configuration.
Solution Approach 2:
The patent transitions from a horizontal flow path configuration to a vertical arrangement where fluid moves upward through multiple pump stages. This dimensional change optimizes the flow path to eliminate restrictions while maintaining pumping efficiency, thereby increasing hydrocarbon production rates.
3Duration of action of moving object
If gas is present in the pump, then pressure creation is reduced, but continuous operation is interrupted due to gas lock conditions
Solution Approach 1:
The gas separator is positioned upstream of the pump within the integrated assembly, performing gas-liquid separation before the fluid enters the pump. This preliminary action removes gas that would otherwise cause pressure reduction and gas lock, enabling continuous operation and extending pump life while maintaining pressure creation capability.
Solution Approach 2:
The crossover acts as an intermediary component between the gas separator and pump, providing a transition zone that directs liquid phase flow to the pump while allowing gas phase to be vented. This intermediary structure prevents gas from entering the pump, eliminating gas lock conditions and ensuring continuous operation.
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 configuration enhances hydrocarbon production rates by ensuring continuous fluid flow, reducing the risk of gas lock, and extending pump operational life by maintaining efficient pump performance.
Implementation Method 1
a gas flow path and liquid flow path separator located downstream of the separation chamber and having an inlet fluidically coupled to the annulus, having a gas phase discharge port open to an exterior of the assembly, and having a liquid phase discharge port
Implementation Method 2
centrifugal pump stages upstream of the inlet of the centrifugal pump assembly, wherein the plurality of centrifugal pump stages produces the fluid lift needed to lift the liquid phase fluid to a surface location
Data Source
AI summary
A downhole integral gas separator and pump assembly, The assembly comprises a drive shaft; a separation chamber concentrically disposed around the drive shaft; a gas flow path and liquid flow path separator having a gas phase discharge port open to an exterior of the assembly, and having a liquid phase discharge port; a fluid mover mechanically coupled to the drive shaft having an inlet fluidically coupled to the liquid phase discharge port of the gas flow path and liquid flow path separator, and having an outlet; a housing that retains the drive shaft, the gas flow path and liquid flow path separator, and the fluid mover; and a pump discharge coupled to a downstream end of the housing, wherein the pump discharge is fluidically coupled to the outlet of the fluid mover and is configured to connect to a production tubing.