Multi-Pump Wellbore System for Variable Flow Adaptation
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Solution Overview
Problem
Conventional pumping systems for wells face challenges in efficiently managing varying fluid flow rates over the life of a well, leading to high initial production followed by decreased rates, requiring costly system replacements and increased operational and maintenance costs, especially when dealing with shale formations where production drops significantly over time. Additionally, managing fluid from multiple reservoirs with separate pumping systems is difficult due to space constraints and higher costs.
Innovation Solution
A pumping system with multiple pumps of different flow capacities, selectively operated by a single motor based on fluid flow rates within the well casing, allowing for efficient operation across varying production phases and reducing the need for frequent system replacements by axially aligning the pumps and motor for efficient installation and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single high flow rate pumping system is installed to meet initial production requirements, then high rate production is achieved in early phase, but the system becomes oversized and costly for later phases when production rate decreases
Solution Approach 1:
The pumping system is segmented into multiple independent pump units (first pump, second pump) with different flow capacities. Each pump can operate independently or in combination, allowing the system to be divided into functional modules that can be selectively activated based on production requirements.
Solution Approach 2:
The pumping system transitions from a static single-pump configuration to a dynamic multi-pump configuration where pumps can be selectively engaged or disengaged. The motor can selectively operate different pumps based on real-time production rate requirements, making the system adaptable to changing well conditions throughout its life cycle.
2Adaptability or versatility
If separate pumping systems are installed for multiple reservoirs to accommodate different flow rates, then each reservoir can be optimized, but space constraints in the wellbore and increased installation complexity arise
Solution Approach 1:
Multiple pump units that would traditionally require separate pumping systems are merged into a single integrated assembly. The first pump and second pump are coupled to the same housing and can be selectively operated by a single motor, combining the functionality of multiple systems into one compact unit that fits within wellbore space constraints.
Solution Approach 2:
The single motor assembly is designed to universally operate multiple pump types with different flow capacities. The motor can selectively engage either the first pump, the second pump, or both simultaneously, providing multi-functional capability that replaces the need for separate dedicated pumping systems for different reservoirs.
3Productivity
If pumping systems are replaced over time to match decreasing production rates, then optimal production efficiency is maintained, but design, operational, and maintenance costs increase significantly
Solution Approach 1:
The system is pre-configured with multiple pump units of different flow capacities during initial installation, anticipating future production rate decreases. This preliminary preparation eliminates the need for later system replacements, as the appropriate pump capacity is already available within the installed assembly.
Solution Approach 2:
Instead of replacing entire pumping systems when production rates change, the system recovers and utilizes the existing multi-pump assembly by selectively engaging different pumps. The original high-capacity pump remains in place and can be reused when high production is needed, while lower-capacity pumps handle reduced production rates, avoiding disposal and replacement costs.
Data Source
AI summary
A pumping system for use in moving a fluid present within a well casing and through a production tubing is provided. The pumping system includes a housing coupled to the production tubing. The pumping system further includes a first pump coupled to the housing and having a first flow capacity and a second pump coupled to the housing and having a second flow capacity. The second flow capacity is different than the first flow capacity. A motor is coupled to the first pump and the second pump, wherein the motor is configured to selectively operate at least one of the first pump and the second pump based on a flow capacity of the fluid present within the well casing.