Submersible Pump Intake Module with Tangential Ports
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Solution Overview
Problem
Existing submersible pumping systems struggle with efficiently separating gas and liquid phases in high gas-to-liquid ratio fluids, leading to gas interference and vapor lock, particularly in high flow rate applications, which complicates recovery and processing of hydrocarbons.
Innovation Solution
A submersible pumping system with a tangential fluid intake module featuring a housing with two-stage chambers and tangential fluid intake ports that induce swirling motion, combined with gas discharge ports, utilizes centrifugal and gravity separation mechanisms to separate gases and liquids efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gravity-based separation mechanism is used in intake chamber, then gas and liquid separation is achieved, but in high flow rate applications the multi-phase fluid moves too fast to permit effective gravity separation
Solution Approach 1:
The intake chamber is divided into multiple stages with different separation mechanisms. The first stage uses gravity-based separation for low flow rates, while the second stage uses centrifugal separation for high flow rates, allowing the system to adapt to varying productivity levels effectively
Solution Approach 2:
The system dynamically switches between gravity-based and centrifugal separation mechanisms based on flow conditions. The centrifugal separation mechanism is activated when high flow rates require faster separation, while gravity-based separation handles lower flow rates, optimizing performance across different operating conditions
2Reliability
If centrifugal forces are exerted by downhole turbomachinery, then gas and liquid separation is increased, but gas interference and vapor lock occur
Solution Approach 1:
The intake module performs gas-liquid separation before the fluid enters the pump assembly. By separating gas from liquid in advance using gravity-based and centrifugal mechanisms, the pump receives mostly liquid with minimal gas, preventing gas interference and vapor lock during pumping operations
Solution Approach 2:
The intake module acts as an intermediary component between the wellbore and the pump assembly. It receives multi-phase fluid from the wellbore, separates gas and liquid through its chambers, and delivers separated liquid to the pump, thereby protecting the pump from gas-related problems
3Productivity
If multistage centrifugal pumps are used, then liquid production is achieved, but high gas-to-liquid ratio fluids cause pumping problems
Solution Approach 1:
The intake module performs preliminary gas removal before fluid reaches the pump. By separating gas in the intake chamber using gravity and centrifugal forces, the pump receives fluid with reduced gas content, maintaining stable pumping operations even when the well produces high gas-to-liquid ratio fluids
Solution Approach 2:
The intake module serves as a protective intermediary between the wellbore and the pump. It handles the harsh condition of high gas-to-liquid ratio fluids, separates the gas, and delivers suitable liquid to the pump, allowing the pump to operate reliably without direct exposure to problematic multi-phase flow
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 reduces gas content in the fluid before it reaches the production pump, enhancing the recovery of liquid hydrocarbons by minimizing gas interference and vapor lock, thus improving the efficiency and reliability of pumping operations.
Implementation Method 1
The tangential fluid intake ports are configured to induce a swirling motion of multi-phase fluid in the first stage chamber
Implementation Method 2
a second stage chamber inside the first stage chamber... in which gases are allowed to escape from the top of the chamber and liquids are drawn downward
Data Source
AI summary
A submersible pumping system for producing two-phase fluids from a well includes an intake module between a production pump and a motor. The intake module includes a housing, a first stage chamber inside the housing, and a second stage chamber inside the first stage chamber. The second stage chamber is in fluid communication with the production pump. The intake module further includes a plurality of tangential fluid intake ports that extend from the wellbore through the housing into the first stage chamber. The plurality of tangential fluid intake ports are configured to induce a swirling motion of two-phase fluid in the first stage chamber that encourages separation of liquids and gases. The intake module also includes a plurality of gas discharge ports that extend from the wellbore to the first stage chamber, where the plurality of gas discharge ports are located above the plurality of tangential fluid intake.