Inverted ESP Bypass System for Motor Overheating Prevention
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Solution Overview
Problem
Current systems with inverted electrical submersible pump (ESP) systems face issues with fluid recirculation between the pump intake and discharge, leading to motor overheating and premature failure, when trying to access the reservoir downhole of the ESP for interventions like logging or stimulation.
Innovation Solution
The implementation of a y-tool configuration with a seal assembly and packers allows for reservoir access by diverting fluid flow through a bypass tubular, preventing recirculation and enabling interventions without removing the ESP, with a motor located uphole of the pump to reduce cable length and enhance reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a y-tool is used with an inverted ESP system to access the reservoir downhole, then reservoir access for interventions is enabled, but fluid recirculation between pump intake and discharge occurs causing motor overheating
Solution Approach 1:
The flow path is segmented into separate channels: a primary flow path through the pump and a secondary bypass flow path. The bypass flow path includes a bypass inlet, bypass passage, and bypass outlet that allows fluid to bypass the pump intake/discharge recirculation loop, preventing motor overheating while maintaining reservoir access capability through the y-tool
Solution Approach 2:
A bypass flow path acts as an intermediary channel between the pump discharge and the bypass inlet, providing an alternative fluid pathway that prevents direct recirculation through the motor. This intermediary bypass passage allows fluid to flow around the motor area without causing overheating, while still enabling the y-tool to access the reservoir downhole
2Ease of operation
If the ESP is retrieved from the well to access the reservoir, then reservoir interventions can be performed, but well time is lost and production is interrupted
Solution Approach 1:
The bypass flow path and y-tool configuration are installed and prepared in advance within the wellbore before interventions are needed. This preliminary setup allows rapid access to the reservoir through the bypass inlet and y-tool without requiring ESP retrieval, minimizing well time loss and maintaining continuous production capability
Solution Approach 2:
The bypass flow path serves as an intermediary access route that allows intervention tools to reach the reservoir through the bypass inlet and y-tool without removing the ESP. This intermediary pathway provides a permanent access channel that eliminates the need for time-consuming ESP retrieval operations while enabling necessary reservoir interventions
3Ease of manufacture
If the motor is located downhole of the pump in a conventional ESP, then the pump can be directly driven, but cable length is increased and reliability is reduced
Solution Approach 1:
The motor and pump positions are inverted compared to conventional ESP configuration. The motor is located uphole of the pump rather than downhole, which shortens the cable length and reduces cable damage risks while maintaining direct drive capability through the inverted arrangement. This inversion resolves the contradiction by sacrificing conventional positioning for improved reliability
Data Source
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AI summary
A system for providing artificial lift to wellbore fluids has a pump (18) located within a wellbore (12) and a motor (22) located within the wellbore uphole of the pump. A seal assembly (24) has a first side connected to the motor and a second side connected to the pump. The pump (18), motor (22), and seal assembly (24) together form a submersible pump string (16). An uphole packer (28) circumscribes the production tubular (20) uphole of the motor. A downhole packer (30) is located downhole of the pump. An uphole y-tool (34) has an uphole y-tool first end (36) in fluid communication with the production tubular and an uphole y-tool second end (38) with a first uphole y-tool branch (38A) that is mechanically connected to the submersible pump string and a second uphole y-tool branch (38B) in fluid communication with a bypass tubular (32). The bypass tubular is positioned adjacent to the submersible pump string and extends between the uphole y- tool and the downhole packer.