SMA Intake Screen Control for ESP Phase Inversion Flow
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Solution Overview
Problem
The phase inversion phenomenon in multiphase formation fluids, which causes a significant increase in viscosity, leads to reduced efficiency and potential failure of electric submersible pumps (ESPs) due to unaddressed changes in fluid properties during production.
Innovation Solution
A flow control system utilizing a shape memory alloy (SMA) mesh in the ESP intake screen that adjusts its shape in response to temperature changes, controlled by a sensor and heating component, to manage fluid flow based on fluid properties measured at or near the ESP intake.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the intake screen maintains a fixed mesh configuration, then the device structure is simple and reliable, but the ESP efficiency decreases significantly when phase inversion occurs due to inability to adapt to changing fluid properties
Solution Approach 1:
The intake screen transitions from a static fixed mesh configuration to a dynamic adjustable configuration using shape memory alloy (SMA) wires that can change mesh aperture size in response to temperature changes. This allows the screen to adapt its opening size dynamically based on fluid viscosity conditions, resolving the contradiction between structural simplicity and adaptability.
Solution Approach 2:
The invention changes the physical parameter of the intake screen by using SMA wires that alter their shape and the resulting mesh aperture size in response to temperature changes. When temperature increases (indicating phase inversion), the SMA wires transform to increase mesh openings, allowing the screen to adapt to changing fluid properties without requiring complex mechanical adjustment mechanisms.
2Productivity
If the mesh aperture size is increased to maintain flow rate during phase inversion, then the fluid flow rate is maintained, but the intake screen cannot effectively filter formation fluids when in normal operating conditions
Solution Approach 1:
The intake screen uses dynamically adjustable mesh apertures via SMA wires that respond to temperature changes. During normal operation at lower temperatures, the SMA wires maintain smaller mesh openings for effective filtration. When phase inversion occurs and temperature increases, the SMA wires automatically transform to enlarge the openings, maintaining flow rate. This dynamic adjustment resolves the contradiction between maintaining flow rate and ensuring filtration effectiveness.
3Ease of operation
If a traditional fixed intake screen is used, then the system is simple to operate, but the ESP efficiency drops significantly during phase inversion due to high viscosity fluids
Solution Approach 1:
The intake screen incorporates temperature-sensitive SMA wires that automatically adjust mesh aperture size in response to temperature changes caused by phase inversion. The system self-regulates without requiring external control mechanisms or complex operation, maintaining ESP efficiency during fluid property changes while preserving operational simplicity. This resolves the contradiction between ease of operation and maintaining productivity.
4Reliability
If the mesh size is increased to prevent ESP failure during phase inversion, then the ESP reliability is improved, but the intake screen allows excessive fluid intake that can overload the pump during normal conditions
Solution Approach 1:
The intake screen uses SMA wires that change mesh aperture size based on temperature parameters. During normal operation, smaller openings control fluid intake to match pump capacity. During phase inversion, temperature-induced transformation of SMA wires enlarges openings to prevent clogging and ESP failure. This parameter-based adaptive control resolves the contradiction between preventing ESP failure and controlling fluid intake.
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
The system effectively controls fluid flow by adjusting the SMA mesh shape to maintain optimal intake conditions, preventing ESP failure and ensuring efficient operation despite changes in fluid characteristics.
Implementation Method 1
the intake screen comprises a shape memory alloy (SMA) mesh, wherein the SMA mesh is configured to perform a reversible modification between a first shape and a second shape
Implementation Method 2
the changing of the temperature of the SMA mesh may be accomplished by the actuation of a heating component configured to modify the SMA mesh to a transformation temperature at which the reversible modification occurs
Data Source
AI summary
A flow control system for controlling multiphase formation fluid flow in a wellbore may comprise an electric submersible pump, an intake screen, a controller, a sensor, and a heating component, wherein: the intake screen comprises a shape memory alloy (SMA) mesh configured to perform a reversible modification between a first shape and a second shape; the sensor is configured to measure one or more fluid properties; the controller is communicably coupled to the sensor and the heating component and is configured to: determine whether the one or more fluid properties fall outside a predetermined tolerance at the controller, and actuate the heating component upon determining the one or more fluid properties fall outside the predetermined tolerance; and the heating component is configured to modify the SMA mesh from the first shape to the second shape when actuated, and thereby to control the multiphase formation fluid flow through the intake screen.