Sand Diverter for Inverted ESP Preventing Sand Accumulation
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Solution Overview
Problem
In hydrocarbon development, inverted electric submersible pumps (ESPs) often get stuck due to sand accumulation during shutdowns, which blocks production and complicates retrieval, leading to operational inefficiencies and increased costs.
Innovation Solution
A sand diverter is installed downhole to redirect sand and solid particles away from the ESP, preventing accumulation and ensuring fluid flow paths are clear, even when the pump is shut down, by using a moveable inner sleeve with biasing and counter-pressure mechanisms to manage flow positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pump is shut down to allow sand to settle, then sand can be separated from fluid, but sand accumulates at the bottom of the completion causing the pump to get stuck
Solution Approach 1:
The sand diverter extracts sand and solid particles from the main fluid flow path by providing a separate downhole discharge path. During pump shutdown, sand-laden fluid is diverted through the sand diverter's inner bore to the downhole packer, separating sand from the production stream before it can accumulate at the bottom of the completion and cause sticking issues.
Solution Approach 2:
The sand diverter acts as an intermediary component between the pump discharge and the downhole packer. It mediates the flow of sand-laden fluid by providing an alternative path that bypasses the bottom of the completion, allowing sand to be discharged downhole of the packer while maintaining separation from the production tubular flow path.
2Quantity of substance
If frequent shutdowns are performed for sand settling, then sand separation occurs, but sand accumulation increases making retrieval difficult
Solution Approach 1:
The sand diverter performs preliminary sand separation action during each pump shutdown by immediately diverting sand-laden fluid through its inner bore to the downhole packer. This preliminary action prevents sand from reaching the bottom of the completion where it would accumulate over time, thereby eliminating the need for extended retrieval operations and reducing loss of time.
3Loss of substance
If sand accumulation is allowed to occur, then sand can be trapped for later removal, but pump discharge becomes blocked preventing production
Solution Approach 1:
The system segments the flow path into two distinct channels: the production tubular for hydrocarbon flow and the sand diverter inner bore for sand discharge. This segmentation allows sand to be separated and discharged through the downhole packer without blocking the production discharge path, maintaining productivity while still managing sand accumulation.
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 solution enhances ESP operational reliability by preventing sand accumulation, reducing the risk of equipment sticking and production blockages, thereby improving economic returns and extending ESP system life.
Implementation Method 1
When the pump is shut down, fluid that contains entrained sand will follow a path of least resistance. Because there is a tortuous flow path through the ESP, the fluid that contains entrained sand will preferentially flow through the sand diverter.
Implementation Method 2
A sand diverter is installed at the downhole region of the ESP string that creates an access for the sand and other solid particles to drain downhole of the downhole packer when the pump is shut down.
Implementation Method 3
The sand diverter has a diverter inner bore in fluid communication with the wellbore downhole of the downhole packer, where the flow port assembly has an inner sleeve that is moveable between an open position where an inner sleeve port assembly is aligned with an outer sleeve port assembly of an outer sleeve, and a closed position where the inner sleeve port assembly is unaligned with the outer sleeve port assembly.
Data Source
AI summary
Systems and methods for providing artificial lift to wellbore fluids include a pump located within a wellbore. A motor is located uphole of the pump and a protector assembly is located between the pump and the motor. A downhole packer is located within the wellbore downhole of the pump. A sand diverter is located downhole of the pump and has a flow port assembly located uphole of the downhole packer, the sand diverter having a diverter inner bore in fluid communication with the wellbore downhole of the downhole packer. The flow port assembly has an inner sleeve that is moveable between an open position where an inner sleeve port assembly is aligned with an outer sleeve port assembly of an outer sleeve, and a closed position where the inner sleeve port assembly is unaligned with the outer sleeve port assembly.