Inverted ESP Shroud Assembly for Gas Pocket Mixing
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Solution Overview
Problem
Existing electrical submersible pump assemblies (ESPs) face challenges in managing gas accumulation at the intake, leading to reduced performance and increased maintenance costs due to gas pockets forming at the packer assembly, which can degrade mechanical and electrical components.
Innovation Solution
The implementation of an inverted shroud system that circumscribes the production tubing downstream of the ESP, using fasteners and bolt holes to couple the shroud to the intake and protector, allowing for a mixing zone with the packer assembly to prevent gas accumulation and ensure a combined gas-liquid mixture is directed towards the intake, thereby enhancing ESP performance and reducing maintenance costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gas accumulates at the packer assembly, then gas pockets form that can degrade mechanical and electrical components, but the pump assembly continues to operate
Solution Approach 1:
The patent inverts the conventional shroud configuration by positioning the shroud base flanges at the top of the pump assembly and the shroud base at the bottom, creating an inverted arrangement that directs gas toward the intake rather than allowing accumulation at the packer assembly. This inversion of the traditional configuration fundamentally changes gas flow patterns and eliminates gas pocket formation.
Solution Approach 2:
The inverted shroud acts as an intermediary structure between the pump assembly and the production tubing, creating a mixing zone that facilitates gas-liquid interaction. The shroud base flanges and shroud base configuration serve as mediators that direct and mix gases with liquids before they enter the pump, preventing harmful gas accumulation while maintaining pump operation.
2Productivity
If gas pockets form at the packer assembly, then component degradation occurs, but the pump can continue to pump fluid
Solution Approach 1:
By inverting the shroud configuration and directing gas flow toward the intake rather than allowing gas to accumulate at the packer assembly, the system maintains continuous pump operation while protecting components from gas-induced degradation. The inverted arrangement ensures gases are mixed with liquids and directed through the pump inlet where they can be properly handled.
Solution Approach 2:
The patent converts the potentially harmful effect of gas accumulation into a beneficial mixing process. By directing gases toward the intake through the inverted shroud configuration, gases are mixed with liquids in a controlled manner, transforming what would be harmful gas pockets into a mixed fluid that protects pump components while maintaining productivity.
3Device complexity
If conventional shroud configuration is used, then gas accumulates at the packer assembly, but the structure is simpler
Solution Approach 1:
The patent employs an inverted shroud configuration where the shroud base flanges are positioned at the top and the shroud base at the bottom, opposite to conventional arrangements. This inversion creates a mixing zone that prevents gas pocket formation at the packer assembly, though it does increase structural complexity slightly through the additional fastening requirements.
Solution Approach 2:
The shroud assembly is segmented into distinct components including shroud base flanges, shroud base, and fasteners that can be independently positioned and assembled. This segmentation allows for precise positioning of the inverted configuration while maintaining ease of installation through modular assembly, balancing complexity with installability.
4Ease of operation
If the packer assembly is positioned closer to the ESP, then the mixing zone is reduced, but installation is easier
Solution Approach 1:
The inverted shroud configuration creates an effective mixing zone even when the packer assembly is positioned relatively close to the ESP by directing gas flow upward through the shroud base flanges and mixing zone. This inversion of the traditional configuration ensures adequate mixing without requiring large distances, maintaining both installation simplicity and gas mixing effectiveness.
Solution Approach 2:
The system utilizes fluid dynamics and gas-liquid interaction principles to create effective mixing in a compact zone. The inverted shroud configuration leverages natural fluid flow patterns and gas-liquid mixing mechanisms to achieve reliable gas dispersion without requiring excessive space between the packer assembly and ESP, balancing installation ease with mixing effectiveness.
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 inverted shroud system effectively mixes gases and liquids, preventing gas accumulation at the packer assembly, improving ESP reliability and reducing overall life cycle costs by minimizing degradation of electrical and mechanical components.
Implementation Method 1
The packer assembly is located uphole of the opposite open end at a distance causing a mixing of a gas pocket with the well fluid to form a combined gas and liquid mixture
Data Source
AI summary
A method includes providing an electrical submersible pump assembly with a pump, an intake, shroud base flanges, a protector, and a motor. The method includes coupling the shroud base flanges to an intake downhole end using fasteners and a set of protector top bolt holes. The method includes locating a closed end of an inverted shroud between the intake and the protector. The inverted shroud includes a shroud base on the closed end, and an opposite open end that is open toward the packer. The method includes coupling the inverted shroud to the shroud base flanges. The packer is located uphole of the opposite open end at a distance causing a mixing of a gas pocket with the well fluid to form a combined gas and liquid mixture and directing the combined gas and liquid mixture in a direction toward the intake.