Downhole Sand Catcher Layout for Unobstructed Pump Restart
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Downhole pumps in hydrocarbon production systems are prone to plugging due to sand and abrasive solids settling on the pump during shutdown, leading to costly and time-consuming failures requiring work-over operations.
Innovation Solution
A downhole apparatus with strategically positioned baskets and filters that collect and prevent sand and solids from settling on the pump, allowing unobstructed flow and self-cleaning upon restart, compatible with ESPs, PCPs, and rod lift systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pump shutdown occurs, then fluid levels equalise and flow ceases, but sand particles settle on the pump causing plugging
Solution Approach 1:
A sand catcher device is introduced as an intermediary component between the pump and the production bore. This device collects sand particles that fall during shutdown, preventing them from settling on the pump. The sand catcher acts as a mediator that intercepts the harmful sand particles before they can reach and plug the pump inlet.
Solution Approach 2:
The sand catcher is positioned to collect sand particles during the shutdown period before the pump is restarted. By performing the collection action in advance (during shutdown), the device prevents sand accumulation on the pump, ensuring the pump is ready for immediate restart without plugging issues.
2Productivity
If pump restart is attempted with sand plug, then higher load is required, but motor burnout or shaft breakage occurs
Solution Approach 1:
The sand catcher serves as a protective intermediary that removes sand particles from the fluid column before they can form a plug on the pump. This prevents the harmful high-load condition during restart by ensuring the pump inlet remains clear of sand accumulation.
Solution Approach 2:
The sand catcher provides beforehand protection by collecting sand during shutdown, cushioning the pump against the harmful effect of sand plugs. This preliminary protective action prevents the need for excessive startup load and eliminates the risk of motor burnout or shaft breakage.
3Reliability
If sand is collected in the production bore, then pump plugging is prevented, but work-over operations are still required
Solution Approach 1:
The sand catcher is a permanently installed intermediary device that continuously collects sand during shutdown periods. By providing ongoing protection against sand plugging, it prevents pump failures that would otherwise require costly and time-consuming work-over operations, thereby maintaining continuous pump operation.
Solution Approach 2:
The sand catcher performs self-service by automatically collecting sand particles during shutdown periods without requiring external intervention. The device passively intercepts falling sand through gravity, eliminating the need for active monitoring or manual intervention, and prevents pump plugging without requiring work-overs.
4Quantity of substance
If baskets cover entire borehole section, then solids collection is maximised, but flow path becomes obstructed
Solution Approach 1:
The sand catcher is divided into multiple separate baskets or collection chambers arranged within the device. Each basket can be positioned at different angular locations around the central flow path. This segmentation allows solids to be collected in distributed locations while maintaining an open central channel for fluid flow, thus maximizing collection capacity without obstructing the flow path.
Solution Approach 2:
Different regions of the sand catcher have different functions: the peripheral baskets are designed for solids collection, while the central region maintains an unobstructed flow path. This local differentiation of quality ensures that solids collection is maximized in the basket areas while the central flow area remains open for fluid passage.
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
Prevents pump plugging by collecting solids, reducing the risk of motor burnout and shaft breakage, and enabling efficient pump restart without the need for rig-based interventions.
Implementation Method 1
the remaining flow path having a container to collect the solids fall back being partially make of a filter material
Implementation Method 2
Gravity acting on the sand particles present in the column of fluid above the pump causes the sand and any other solids to fall back towards the pump
Data Source
AI summary
A downhole apparatus for collecting solids fallback in the tubing of an oil producing borehole comprises two or more baskets to collect the solids fall back, each basket partially occupying a portion of the inner cross section of the tubing, leaving a portion of the inner cross section of the tubing having an unrestricted flow path. The baskets when considered in plan view along longitudinal axis of the tubing are distributed such that together they cover substantially the whole area of the tubing while leaving an unobstructed non-straight flowpath around the baskets.