Inverted Shroud ESP Gas Separator Recirculation
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Solution Overview
Problem
Electric submersible pumps (ESPs) face operational challenges due to gas accumulation, which can lead to gas lock and disrupt the continuous flow of reservoir liquid, causing bearing overheating and reduced pump life.
Innovation Solution
The implementation of an inverted shroud system around the gas separator assembly and centrifugal pump, which recirculates gas-rich fluid back into the intake after gas bubbles off, reducing the gas-to-liquid ratio and mitigating the effects of gas slugs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional ESP system operates without an inverted shroud, then the structure is simpler and easier to manufacture, but gas accumulation occurs leading to gas lock and disrupted fluid flow
Solution Approach 1:
The inverted shroud system segments the pump intake area into a protected zone where gas-rich fluid is recirculated separately from the main fluid flow path. This segmentation allows gas to be managed in a dedicated circulation loop rather than mixing with the production fluid, preventing gas lock while maintaining reliable continuous flow.
Solution Approach 2:
The inverted shroud acts as an intermediary structure between the gas separator and the pump intake. It creates a controlled interface where gas-rich fluid can be recirculated through the shroud and discharged at the periphery, mediating the interaction between gas and liquid phases to prevent gas accumulation in the pump while maintaining system reliability.
2Duration of action of moving object
If gas accumulates in the ESP suction side, then the device complexity remains low, but bearing overheating occurs and pump life is reduced
Solution Approach 1:
The inverted shroud system performs preliminary action by recirculating gas-rich fluid through the shroud before it can enter the pump and cause gas lock. This preliminary circulation allows gas to bubble off in a controlled environment, preventing the harmful effect of gas accumulation from reaching the pump bearings and causing overheating, thereby extending pump life.
Solution Approach 2:
The system converts the harmful effect of gas accumulation into a beneficial recirculation process. Gas-rich fluid that would normally cause gas lock is instead directed through the inverted shroud where the gas can separate and bubble off harmlessly. The recirculated fluid, now with reduced gas content, is discharged at the periphery, transforming a harmful factor into a protective mechanism that prevents bearing overheating and extends pump operational life.
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 reduces the gas-to-liquid ratio of the fluid entering the ESP, preventing gas lock and extending the operational life of the pump by maintaining continuous fluid flow and reducing bearing wear.
Implementation Method 1
The inverted shroud system recirculates gas-rich fluid back into the intake after gas bubbles off
Data Source
AI summary
An electric submersible pump (ESP) assembly. The ESP assembly comprises an electric motor; a seal section coupled to the electric motor; a fluid intake coupled to an uphole end of the seal section, wherein the fluid intake defines a plurality of inlet ports; a gas separator comprising a plurality of gas phase discharge ports, and at least one liquid phase discharge port, wherein the gas separator is located uphole of the fluid intake; a centrifugal pump comprising a fluid inlet at a downhole end, wherein the at least one liquid phase discharge port of the gas separator is fluidically coupled to the fluid inlet of the centrifugal pump; and an inverted shroud assembly, wherein a downhole end of the inverted shroud assembly is coupled to an outside of the gas separator downhole of the gas phase discharge ports of the gas separator and uphole of the fluid intake.