Variable Flow Regulator for Downhole Motor Cooling and Cavitation Control
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Solution Overview
Problem
Submersible pumping systems face issues with excessive gas flow from upper formations interfering with liquid production and cooling of the pump motor, leading to potential cavitation and reduced efficiency in hydrocarbon extraction.
Innovation Solution
A downhole submersible pumping system with a variable flow regulator responsive to motor temperature, energy consumption, and gas flow, which includes a control system to monitor and regulate fluid flow between the pump and the wellbore casing, using a packer or controllable valve to manage flow rates and prevent excessive gas and water from reaching the pump inlet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the pump operates in a wellbore with gas and liquid flow from upper formations, then liquid production is achieved, but excessive gas flow causes cavitation and reduces pump efficiency
Solution Approach 1:
The patent extracts and removes gas from the fluid stream before it reaches the pump inlet. A gas removal device is positioned in the wellbore to separate gas bubbles from liquid, allowing only liquid to enter the pump. This extraction of the harmful gas component resolves the cavitation issue while maintaining liquid production capability.
Solution Approach 2:
The patent introduces an intermediary substance or mechanism between the wellbore environment and the pump. A flow regulator or choke device acts as an intermediary to control and optimize fluid flow characteristics, filtering out excessive gas while maintaining adequate liquid flow to the pump inlet.
2Productivity
If flow from upper formations is not restricted, then liquid production is maintained, but excessive water flow restricts liquid flow across the pump motor reducing cooling effect
Solution Approach 1:
The patent applies local quality control by restricting flow in specific zones around the pump motor while maintaining overall liquid production. Flow regulators are positioned to create localized flow patterns that ensure adequate cooling water passes over the motor while still allowing sufficient liquid to reach the pump inlet for production.
Solution Approach 2:
The patent uses dynamic flow control mechanisms that can adjust flow rates in real-time. Flow regulators or variable orifices modify the flow characteristics dynamically to optimize both cooling and production requirements, allowing the system to adapt to changing wellbore conditions.
3Reliability
If a flow regulator is added to control gas and water flow, then pump performance is improved, but device complexity increases
Solution Approach 1:
The patent employs simple, readily available flow control components such as adjustable orifices, packers, or basic valve mechanisms that can be easily installed and adjusted. These straightforward devices provide effective flow control without requiring complex systems, minimizing the increase in device complexity while improving pump performance.
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 restricts unwanted gas and water flow, preventing cavitation and ensuring efficient liquid production by optimizing fluid flow rates, thereby enhancing pump performance and extending motor lifespan.
Implementation Method 1
a variable flow regulator disposed in the annulus between the wellbore casing and the pumping system
Implementation Method 2
the flowing fluid contacts the housing of the motor 24 and draws heat from the motor 24
Implementation Method 3
excessive gas from the upper formation can become entrained with the downflowing water and potentially cause pump cavitation
Data Source
AI summary
A submersible pumping system for use downhole, wherein the system includes a pump, an inlet section for receiving fluid, a pump motor, and an actively controlled flow restriction device for controlling flow to the submersible pump from an upper fluid producing zone. Active flow control proximate to the submersible pump motor protects the pump motor from overheating.