Multiphase ESP Production With Gas Separation and Dual Tubing
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Solution Overview
Problem
Electric submersible pumps struggle with gas locking in high gas/oil ratio formations, leading to reduced production and potential damage, and traditional casings are prone to corrosion when used to produce the gaseous phase.
Innovation Solution
A system with a gas separator on the ESP inlet and dual tubing strings is used to separate and produce the liquid and gaseous phases separately, avoiding the wellbore annulus and reducing corrosion risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If an electric submersible pump is used to produce multiphase formation fluids in high gas/oil ratio formations, then production efficiency is improved, but gas locking occurs causing reduced production and potential pump damage
Solution Approach 1:
The system divides the production stream into separate gas and liquid phases using a gas separator positioned above the ESP. The separator creates distinct flow paths where gas is routed through the annulus and liquid enters the pump, preventing gas accumulation that would cause locking while maintaining efficient liquid production
Solution Approach 2:
The gas separator extracts the gaseous phase from the multiphase formation fluid before it reaches the ESP. By removing gas from the liquid stream at the separator, the pump receives predominantly liquid, eliminating the gas locking problem while preserving the pump's high productivity capability
2Reliability
If the wellbore annulus is used to produce the gaseous phase, then gas locking is prevented, but corrosion damage to the casing occurs
Solution Approach 1:
The system introduces a second tubing string as an intermediary flow path for gas production. Instead of allowing corrosive gas to contact the casing directly in the annulus, the gas travels through the protected interior of the second tubing string, which can be replaced or maintained without compromising wellbore integrity
Solution Approach 2:
The system segments the flow paths by creating separate conduits for gas and liquid phases. The second tubing string provides a dedicated, isolated pathway for corrosive gas, physically separating it from the casing and preventing direct corrosive interaction while maintaining reliable gas production
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 approach prevents gas locking and minimizes corrosion, ensuring efficient multiphase fluid production without compromising wellbore integrity.
Implementation Method 1
a gas separator comprising a multiphase formation fluid inlet, a gaseous phase outlet, and a liquid phase outlet
Data Source
AI summary
A system for producing a multiphase formation fluid from a subsurface formation may comprise a surface collection point; a power source positioned at the surface collection point; a wellbore extending from the surface collection point to the subsurface formation; a packer positioned within the wellbore, the packer defining a first cavity and a second cavity; an electric submersible pump (ESP) comprising an ESP inlet end and an ESP outlet end; a gas separator coupled to the ESP inlet end; a first tubing string coupled to the top surface of the packer at the first cavity; a second tubing string coupled to the top surface of the packer at the second cavity; and one or more power cables extending from the power source through the second tubing string and second cavity to the ESP, the one or more power cables electrically coupled to the ESP and the power source.