Radial Inflow Port Geometry for Solids-Laden ESP Intakes
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Solution Overview
Problem
Existing ESP systems face issues with erosion and pressure drop due to high flowrates of production fluids containing solids, particularly in high flow and high heat applications like SAGD wells, leading to reduced system run life.
Innovation Solution
The ESP system incorporates a proportional pattern of intake ports with varying density, size, and angle along the intake housing to balance flow, minimize pressure drops, and screen solids, using a filter media to exclude specific particle sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high flowrate intake ports are used to maintain productivity, then production fluid flow is improved, but erosion and pressure drop increase
Solution Approach 1:
The patent applies local quality by varying the density, size, and angle of intake ports at different locations along the intake housing. The port density is highest at the bottom and decreases toward the top, with each row having ports of different diameters and angles. This localized variation optimizes flow distribution while reducing erosion and pressure drop in specific high-stress areas, thereby maintaining productivity without sacrificing reliability.
2Ease of manufacture
If uniform intake ports are used, then manufacturing is simplified, but flow distribution becomes unbalanced
Solution Approach 1:
The patent implements asymmetry by deliberately creating non-uniform patterns in the intake ports. Each row contains ports with different diameters, angles, and spacing, breaking the symmetry that would result from uniform ports. This asymmetric design ensures balanced flow distribution across the intake housing while remaining manufacturable through standardized drilling and machining processes.
3Productivity
If high density intake ports are used throughout, then flow intake is maximized, but pressure drop and erosion increase
Solution Approach 1:
The patent applies parameter changes by systematically varying multiple parameters of the intake ports: density (ports per unit area), size (diameter), and angle (inclination relative to the housing surface). The port density decreases from bottom to top, diameters vary within each row, and angles are optimized for flow direction. These parameter variations maximize fluid intake while minimizing pressure drop and erosion by distributing flow more efficiently across the intake surface.
Data Source
AI summary
An intake section for an electric submersible pump (ESP) assembly comprising an outer housing with a plurality of inflow ports distributed across an outer surface of the intake housing in a proportional pattern. The size and shape of the plurality of inflow ports within the proportional pattern are configured to distribute the inflow flowrate of fluids across the outer surface of the intake housing.