Teardrop Crossover for ESP Gas Separators
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Solution Overview
Problem
Conventional gas separators in electric submersible pumps face inefficiencies due to turbulence and pre-rotation issues, leading to decreased performance and potential gas lock when handling gas-laden fluids, as they rely on rotational inertia for separation, causing disruptive fluid flow and abrasive damage.
Innovation Solution
A teardrop-shaped crossover system with helical passageways and a spider bearing to guide fluids with gentle angles and remove rotational momentum, reducing turbulence and pre-rotation, and ensuring efficient separation and delivery of fluids to the pump.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional crossovers are used in gas separators, then gas separation can be achieved, but turbulence and pre-rotation occur causing decreased pump efficiency and potential gas lock
Solution Approach 1:
The crossover passage is designed with curved walls and smooth transitions instead of sharp angles. The passage includes a curved upper surface and rounded corners that guide fluid flow smoothly from the separator chamber into the pump inlet, eliminating abrupt directional changes that cause turbulence and pre-rotation.
Solution Approach 2:
The crossover passage geometry is specifically designed to counteract the rotational momentum generated in the separator chamber. By using curved surfaces and strategic passage routing, the design preemptively neutralizes pre-rotation before fluid enters the pump, preventing the harmful effects of rotational flow on pump performance.
2Reliability
If rotational inertia is used for gas separation, then gas and fluid can be separated, but disruptive turbulence occurs causing gas accumulation and coalescence
Solution Approach 1:
The crossover passage uses curved walls and smooth transitions to guide fluid flow away from abrupt directional changes. The curved upper surface and rounded corners create laminar flow conditions that prevent gas bubbles from coalescing and accumulating, while still allowing effective gas separation to occur in the separator chamber.
3Reliability
If higher density fluid circumnavigates vent ports, then gas rich fluid can be vented, but sharp turns cause erosive damage and scale blocking
Solution Approach 1:
The passage routing around vent ports is designed with curved walls and smooth transitions instead of sharp corners. This eliminates abrupt turns that cause high-velocity impacts and abrasive wear on the passage walls, while still allowing effective circumnavigation of vent ports for gas-rich fluid removal.
4Reliability
If pre-rotation of fluid occurs at pump entrance, then gas separation can be maintained, but pump impeller cannot effectively cut through fluid reducing production rate
Solution Approach 1:
The crossover passage geometry is specifically designed to counteract and eliminate rotational momentum before fluid enters the pump inlet. The curved surfaces and strategic passage routing preemptively neutralize pre-rotation, ensuring that fluid enters the pump with minimal rotational component, allowing the impeller to effectively cut through and move the fluid at optimal production rates.
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 teardrop-shaped crossover system and spider bearing enhance the efficiency of gas separation by minimizing turbulence and pre-rotation, reducing the likelihood of gas lock and abrasive damage, thereby improving the overall performance and longevity of the electric submersible pump.
Implementation Method 1
Both vortex and rotary type separators separate gas from the well fluid by inertia of rotation before fluid enters the pump. Such centrifugal separation forces higher density, gas poor fluid outward, while lower density, gas rich fluid remains inward near the shaft.
Implementation Method 2
Such centrifugal separation forces higher density, gas poor fluid outward, while lower density, gas rich fluid remains inward near the shaft.
Data Source
AI summary
A crossover system, method and apparatus for an electric submersible pump (ESP) gas separators. A crossover of an ESP gas separator includes a first helical pathway for higher density fluid that extends at an angle of 10° to 40° from a horizontal plane through the crossover, the first helical pathway fluidly coupled to a spider bearing including crescent shaped vanes that remove rotational momentum from the higher density fluid, a second helical pathway for lower density fluid that tangentially intersects a crossover jacket, the first helical pathway and the second helical pathway defined by a channel having teardrop shaped openings in the crossover jacket that define channel exit ports venting to a casing annulus, and teardrop shaped openings in a crossover skirt that define a channel entrance, where the first helical pathway is around the channel and the second helical pathway is through an inside of the channel.