US20190003296A1 - Apparatus and method for preventing particle interference of downhole devices - Google Patents
Apparatus and method for preventing particle interference of downhole devices Download PDFInfo
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- US20190003296A1 US20190003296A1 US16/124,547 US201816124547A US2019003296A1 US 20190003296 A1 US20190003296 A1 US 20190003296A1 US 201816124547 A US201816124547 A US 201816124547A US 2019003296 A1 US2019003296 A1 US 2019003296A1
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- tube
- ports
- check valve
- esp
- annulus
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- 239000002245 particle Substances 0.000 title claims abstract description 38
- 238000000034 method Methods 0.000 title abstract description 7
- 239000012530 fluid Substances 0.000 claims abstract description 60
- 238000004519 manufacturing process Methods 0.000 claims abstract description 55
- 238000004891 communication Methods 0.000 claims abstract description 6
- 239000004576 sand Substances 0.000 abstract description 30
- 238000009825 accumulation Methods 0.000 abstract description 4
- 230000015556 catabolic process Effects 0.000 abstract 1
- 230000002401 inhibitory effect Effects 0.000 abstract 1
- 238000009987 spinning Methods 0.000 description 4
- 230000007423 decrease Effects 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000005755 formation reaction Methods 0.000 description 1
- 230000002706 hydrostatic effect Effects 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000010926 purge Methods 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/34—Arrangements for separating materials produced by the well
- E21B43/35—Arrangements for separating materials produced by the well specially adapted for separating solids
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/34—Arrangements for separating materials produced by the well
- E21B43/38—Arrangements for separating materials produced by the well in the well
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B27/00—Containers for collecting or depositing substances in boreholes or wells, e.g. bailers, baskets or buckets for collecting mud or sand; Drill bits with means for collecting substances, e.g. valve drill bits
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B34/00—Valve arrangements for boreholes or wells
- E21B34/06—Valve arrangements for boreholes or wells in wells
- E21B34/08—Valve arrangements for boreholes or wells in wells responsive to flow or pressure of the fluid obtained
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/12—Methods or apparatus for controlling the flow of the obtained fluid to or in wells
- E21B43/121—Lifting well fluids
- E21B43/128—Adaptation of pump systems with down-hole electric drives
-
- E21B2034/002—
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B2200/00—Special features related to earth drilling for obtaining oil, gas or water
- E21B2200/04—Ball valves
Definitions
- This invention relates to systems and methods to prevent particle interference with downhole equipment, such as an electrical submersible pump (ESP).
- ESP electrical submersible pump
- the device prevents particle interference with lifting equipment, such as an ESP, in a well bore having a production tubing string using a tube positioned between the lifting equipment and the surface and in fluid communication with the lifting equipment and the production tubing string.
- An annulus portion is defined around the tube, e.g. with a cylinder spaced from and surrounding the tube.
- the device includes a check valve proximate at least one end of the tube which operates to permit fluid flow from the lifting equipment to the surface, but prevents fluid flow from the tube to the lifting equipment.
- the device has a plurality of ports positioned in the wall of the tube which operate to permit fluid flow from the tube into the annulus during operation of the lifting equipment and operable to inhibit particles from entering the tube when the lifting equipment is not operating.
- the ports are angled in the direction of the lifting equipment and can be more dense closest to the lifting equipment.
- One method of the present invention operates to inhibit particle impediment to lifting equipment, such as an ESP, when not in use.
- the lifting equipment is positioned in the well bore downhole from the surface and operable to pump fluid through a production tubing string to the surface.
- a particle-excluding device is connected to the production tubing string between the lifting equipment and the surface, the device having a central tubular portion, a surrounding annulus portion, a plurality of spaced ports communicating between the tube and the annulus and a check valve between the ports and the lifting equipment.
- the lifting equipment is operated so that fluid flows through the check valve, ports, tubular portion and at least some of the annulus portion and into the production tubing.
- the method inhibits particles in the fluid from accumulating on the lifting equipment when the lifting equipment is not in use by trapping a substantial portion of particles in the annulus, whereby the ports inhibit particle flow into the tubing portion.
- the check valve prevents reverse fluid flow to the lifting equipment when not in use, and thus prevents the ESP from spinning backwards due to a reversal of the fluid flow.
- FIG. 1 is a schematic, sectional view of a first embodiment of a device in accordance with the present invention with the production fluid flowing normally.
- FIG. 2 is a sectional view of the device of FIG. 1 with the flow of the production fluid stopped.
- FIG. 3 is a sectional view of the device of FIG. 1 with the production fluid starting flow after having stopped.
- FIG. 4 is a sectional view of a detail of a port in the device of FIGS. 1-3 and FIGS. 6-9 showing normal production fluid flow.
- FIG. 5 is a sectional view of a detail of a port in the device of FIGS. 1-3 and FIGS. 6-9 showing production fluid flow stopped.
- FIG. 6 is a schematic, sectional view of a second embodiment of a device in accordance with the present invention with the production fluid flowing normally from an ESP to the surface.
- FIG. 7 is a sectional view of the device in FIG. 6 with the flow of the production fluid stopped.
- FIG. 8 is a sectional view of the device in FIG. 6 with the production fluid starting flow after having stopped.
- FIG. 9 is a cross section view of the device in FIG. 6 taken as shown.
- FIG. 10 is a side elevational view of an exemplary operational embodiment of a device in accordance with the present invention.
- FIGS. 1-5 a first embodiment of a device 10 in accordance with the present invention is illustrated in FIGS. 1-5 .
- the device 10 is inserted as part of the production tubing string with FIG. 1 showing production tubing 12 leading to the surface and ESP 14 located downhole adjacent to the device 10 .
- the device 10 can be spaced from the ESP and in fact, multiple devices 10 can be used in the production tubing string.
- FIG. 1 appears as a conventional vertical orientation, the device 10 can also be used in horizontal wells.
- the usefulness of the device 10 is illustrated in this embodiment as protecting an ESP, other downhole devices can be similarly protected from particles such as sand or fracking proppants.
- the device 10 includes a central production tube 16 surrounded by an enlarged cylinder housing 18 .
- the area between the tube 16 and the inner walls of the cylinder 18 define an annulus 20 .
- a check valve 21 , 22 At each end of the tube 16 is a check valve 21 , 22 .
- FIGS. 1-3 illustrate a ball check valve, but other types of check valves known in the art can be used, such as diaphragm check valve, swing check valve or tilting disc check valve, stop-check valve, lift-check valve, in-line check valve, duckbill valve, or pneumatic non-return valve.
- the check valve 21 , 22 illustrated has a pre-tensioned spring to bias a ball into a seat in a closed position and designed to open at a particular pressure.
- the check valves 21 , 22 of FIG. 1 are open.
- a number of ports 24 are arranged along the length of the tube 16 providing fluid communication between the production tube 16 and the annulus 20 .
- An end packer 26 is illustrated in FIG. 1 as defining the terminus for the cylinder. It should be understood, however, that any seals are acceptable, such as an O-ring bore seal. While the device 10 is illustrated as a discrete device inserted as part of the production tubing string, it can be appreciated that the cylinder 18 and annulus 20 could be defined by setting a packer at each end of a casing section to encompass the tube 16 and valves 21 , 22 .
- FIGS. 2-5 the same components as FIG. 1 are generally illustrated at various stages of the well operation.
- the ESP is off and production fluid flow has ceased. Therefore, particles such as sand 30 settles downward in the annulus 20 .
- the check valves 21 (if utilized), 22 are closed and movement of the sand entrained in the fluid is illustrated by the down arrows.
- Check valve 21 prevents particle flow into the tube 16 .
- Particles 30 tends to build up in the annulus 20 near the lower check valve 22 , but does not appreciably flow into the tube 16 through the ports 24 ; the design and orientation of the ports 24 prevent sand to flow into the tube 16 .
- the ESP 14 is turned on and there are no are no significant buildup of particles 30 on top of the ESP discharge, i.e. in the tube 16 .
- Both check valves 21 , 22 immediately open and production fluid flow through the tube 16 up the production tubing to the surface begins almost immediately.
- a number of the uppermost ports 24 are not covered by particles 30 and some of the fluid in the tube 16 flows through the ports 24 into the annulus 20 .
- the particles 30 cover some of the lower ports 24 (e.g., ports 24 near the lower check valve 22 ) and little fluid flow occurs through these lower ports 24 .
- the density of the particles 30 in the fluid in the annulus decreases towards the surface, allowing some fluid flow through the ports 24 into the annulus. This allows the annulus to be self-clearing over time. That is, as the upper ports 24 become partially uncovered with sand, fluid flows from the tube 16 through the ports 24 into the annulus helping to clear the remaining sand.
- FIGS. 4 and 5 are cross sections of a port 24 through the wall of the tube 16 .
- the ESP 14 is operating (e.g., as in FIG. 1 ) and fluid is flowing from the tube 16 through the port 24 into the annulus 20 .
- the arrow in FIG. 4 illustrates the fluid flow direction.
- Each port 24 is downwardly angled (relative to the fluid flow directions in FIG. 1 ) so that fluid will flow from the tube to the annulus 20 , but particles 30 will not easily flow from the annulus 20 into the tube 16 .
- FIG. 5 illustrates this tendency of particles 30 to not flow from the annulus 20 into the tube 16 when the ESP is not operating, such as FIG. 2 .
- the “downward” angle of the port 24 is greater than perpendicular, but the optimum angle is dependent on the orientation of the device 10 (vertical vs. horizontal), the density of the sand 30 and the composition of the fluid. It is believed that about a 45′ angle will work for most vertical applications, and preferably between 30-60′.
- the use of the angled ports 24 is believed advantageous over resistive mesh screens to prevent sand from entering the tube and hindering operation of the ESP 14 .
- the design of ports 24 includes consideration not only of the angle, but also the diameter of the port 24 .
- the design of the ports 24 also takes into consideration the wall thickness (weight) of the tube 16 . In FIG.
- port 24 includes an angle in the direction opposite fluid flow and diameter of the port ( 24 ) such that particles cannot flow into the tube ( 16 ) as shown.
- the size of the ports can be much larger than mesh screens thus allowing more flow area to be achieved.
- the size of the ports may also be non-uniform and vary in size depending on desired flow characteristics. While the port cross-section is circular, other geometries are acceptable such as elongated slots or square cross-sections.
- the ports may be variable in size, variable spacing and variable densities.
- While the device 10 is illustrated in the context of a vertical well bore in the figures, it will be understood that horizontal wells can benefit from the use of the device 10 .
- horizontal wells make extensive use of proppants for fracking which is a prime contributor to particles in the production tubing which can settle onto an ESP and hinder operation.
- protection of ESP's is a prime use of the device 10
- other downhole equipment can be protected from particle interference as well.
- FIGS. 6-9 A second embodiment of a device 50 in accordance with the present invention is illustrated in FIGS. 6-9 .
- the device 50 is inserted as part of the production tubing string with FIG. 6 showing production tubing 12 leading to the surface and ESP 14 located downhole adjacent to the device 50 .
- the device 50 can be spaced from the ESP and in fact, multiple devices 50 can be used in the production tubing string.
- FIG. 6 appears as a conventional vertical orientation, the device 50 can also be used in horizontal wells.
- the usefulness of the device 50 is illustrated in this embodiment as protecting ESP 14 , other downhole devices can be similarly protected from particles such as sand or fracking proppants.
- the device 50 includes a central cylindrical tube 56 surrounded by an enlarged cylinder housing 58 .
- the area between the tube 56 and the inner walls of the cylinder 18 define an annulus 60 .
- a check valve 62 At the distal end 72 of the tube 56 , nearest the ESP 14 , is a check valve 62 .
- a cap 66 At the proximal end 74 of the tube 56 , nearest the surface, is a cap 66 .
- check valves known in the art can be used, such as ball type check valves, diaphragm check valve, swing check valve or tilting disc check valve, stop-check valve, lift-check valve, in-line check valve, duckbill valve, or pneumatic non-return valve.
- the cap 66 is fixed to prevent fluid flow to or from the tube 56 in the region of the cap 66 .
- the check valve 62 of FIG. 6 is open.
- a number of ports 24 are arranged along the distal end 72 of the tube 56 providing fluid communication between the tube 56 and the annulus 60 .
- a few ports 24 are provided near the proximal end 74 as seen in FIGS. 6-9 . That is, the density of the ports 24 is greatest near the distal end 72 .
- An end packer 68 is illustrated in FIG. 6 as defining the terminus for the cylinder 18 near the distal end 72 . It should be understood, however, that any seals are acceptable, such as an O-ring bore seal.
- One or more centralizers 70 are shown for maintaining the tube 56 central in the cylindrical housing 58 . While the device 50 is illustrated as a discrete device inserted as part of the production tubing string, it can be appreciated that the cylinder 58 and annulus 60 could be defined by setting a packer at each end of a casing section to encompass the tube 56 , cap 66 and valve 62 .
- FIGS. 7-9 the same components as FIG. 6 are generally illustrated at various stages of the well operation.
- the ESP is off and production fluid flow has ceased. Therefore, particles such as sand 30 settle downward in the annulus 60 .
- the check valve 62 is closed and movement of the sand entrained in the fluid is illustrated by the down arrows.
- Cap 66 prevents particle flow into the tube 56 .
- Particles 30 tends to build up in the annulus 60 near the lower check valve 62 , but does not appreciably flow into the tube 56 through the ports 24 ; the design and orientation of the ports 24 prevent sand to flow into the tube 16 (see FIGS. 4-5 ).
- the fluid in the production tubing is retained while the ESP is off in FIG. 7 .
- This allows an almost immediate restart of the ESP and quick return to normal operation ( FIG. 6 ) and production rates.
- Refilling the production tubing with fluid upon restart of the ESP requires fluid equalization in the tubing and annulus and operation of the ESP in downthrust mode. Repeated startup of the ESP and operation in downthrust mode contributes to shortened ESP runlife.
- the check valve 62 is largely free from impingement by sand 30 during all phases of operation of the device 50 .
- the check valve 62 in FIG. 7 prevents reverse flow of fluids. Such reverse flow would occur through the ESP 14 until hydrostatic equilibrium is achieved between the production tubing and the wellbore. This reverse flow is undesirable because it can cause the ESP 14 to turn in the reverse direction compared to normal operation.
- the ESP cannot be restarted when it is ‘back spinning’ (turning in a reverse direction)—a period that can sometimes extend for a number of hours. This back spinning causes the operator to wait until he is reasonably assured that the ESP 14 is stationary before attempting to restart the ESP 14 .
- the distal check valve 62 stops reverse flow, and therefore alleviates this “back spinning” problem.
- the ESP 14 is turned on (restarted) and there are no significant buildup of particles 30 on top of the ESP discharge, i.e. ports 24 in the tube 56 .
- the check valve 62 immediately opens upon restart of ESP 14 and production fluid flow through the tube 56 up the production tubing 12 to the surface begins almost immediately.
- a number of the ports 24 are not covered by particles 30 and the fluid in the tube 16 flows through the ports 24 into the annulus 60 .
- the particles 30 cover some of the lower ports 24 (e.g., ports 24 near the lower check valve 62 ) and little fluid flow occurs through these lower ports 24 .
- the density of the particles 30 in the fluid in the annulus decreases towards the surface, allowing some fluid flow through the ports 24 into the annulus 60 .
- FIG. 9 is a cross section of the device 50 as shown in FIG. 6 .
- the ESP 14 is operating (e.g., as in FIG. 6 ) and fluid has traversed from the tube 56 through ports 24 into the annulus 60 .
- Centralizers 70 end to maintain the position of the tube 56 central in the housing 58 .
- FIG. 10 illustrates an exemplary operational embodiment of the device 50 illustrated schematically in FIGS. 6-9 .
- end cap 66 is positioned at the proximal end 74 of tube 56 .
- a few ports 24 are arranged near the end cap 66 to permit fluid flow between the tube 56 and annulus 60 .
- Centralizers 70 maintain the position of tube 56 in the housing 58 .
- the check valve 62 is located near the distal end 72 .
- a large number of ports 24 are positioned through the tube 56 near the distal end 72 .
- While the devices 10 , 50 are illustrated in the context of a vertical well bore in the figures, it will be understood that horizontal wells can benefit from the use of the devices 10 , 50 .
- horizontal wells make extensive use of proppants for fracking which is a prime contributor to particles in the production tubing which can settle onto an ESP and hinder operation.
- protection and efficient operation of an ESP are prime uses of the devices 10 , 50 , other downhole equipment can be protected from particle interference as well.
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Abstract
Description
- This application is a continuation of U.S. patent application Ser. No. 15/589,115, filed on May 8, 2017, which claims priority to U.S. Provisional Patent Application Ser. No. 62/334,174, filed on May 10, 2016, the contents of each are herein incorporated by reference in their entirety.
- This invention relates to systems and methods to prevent particle interference with downhole equipment, such as an electrical submersible pump (ESP).
- Management of sand in the well bore has long been an issue. Many oil and gas wells are in sand-producing intervals, such as sandstones. There are several forms of artificial lift of the production fluids, with the most common being the electrical submersible pump (ESP). In recent years, unconventional wells have gained wide spread acceptance and often involve horizontal production tubing, ESP's for lift, and multiple, highly fractured production intervals, often in shale or other unconsolidated formations.
- In such highly fractured, horizontal wells, the use of proppants, such as sand, to maintain the frac efficiency has increased. That is, there is a trend to use even more proppant per lateral foot of wellbore. Many ESP pumps have been manufactured to operate on sand filled fluid without significant numbers of failure. However, ESP's are often stopped, both intentionally and unintentionally. For example, electric reliability and power fluctuations often stop ESP operation or the ESP is stopped for maintenance or production issues. “Sand, particles and proppants” are sometimes used interchangeably for simplicity herein.
- When an ESP stops operating, the sand in the production fluid tends to settle in the production tubing. The sand settles on the ESP which not only induces component failures in the ESP, but also makes restart of the ESP difficult because the ESP must first clear substantial amounts of sand from the production tubing. Failure and replacement of an ESP is not only expensive because of the rework required in the well, but also because of the lost production time.
- Several attempts have been made to prevent sand accumulation on ESP's particularly when the ESP is idle. See e.g., CN Pat. Pub. No. 1,955,438, PCT App. Pub. No. WO2007083192, U.S. Pat. No. 6,289,990, U.S. Pat. No. 7,048,057, U.S. Pat. No. 9,181,785 and U.S. Pat. No. 9,441,435 (incorporated by reference). However, each of these existing tool designs has limitations which lead to suboptimal performance, and many are unnecessarily complex and expensive. Thus, a need continues to exist for a tool design that will automatically and cost effectively prevent the accumulation of sand on an ESP, without redepositing the sand below the ESP, potentially preventing the restarting of the ESP or requiring other steps to purge the production tubing of accumulated sand.
- Problems with ESP operation are addressed by the device and methods of the present invention which tend to prevent particle accumulation on the ESP when not in use and provide for more efficient operation. Therefore the reliability, efficiency, timeliness and the likelihood of a successful restart of an ESP is greatly increased. Generally, the device prevents particle interference with lifting equipment, such as an ESP, in a well bore having a production tubing string using a tube positioned between the lifting equipment and the surface and in fluid communication with the lifting equipment and the production tubing string. An annulus portion is defined around the tube, e.g. with a cylinder spaced from and surrounding the tube. The device includes a check valve proximate at least one end of the tube which operates to permit fluid flow from the lifting equipment to the surface, but prevents fluid flow from the tube to the lifting equipment. The device has a plurality of ports positioned in the wall of the tube which operate to permit fluid flow from the tube into the annulus during operation of the lifting equipment and operable to inhibit particles from entering the tube when the lifting equipment is not operating. Preferably, the ports are angled in the direction of the lifting equipment and can be more dense closest to the lifting equipment.
- One method of the present invention operates to inhibit particle impediment to lifting equipment, such as an ESP, when not in use. Generally, the lifting equipment is positioned in the well bore downhole from the surface and operable to pump fluid through a production tubing string to the surface. A particle-excluding device is connected to the production tubing string between the lifting equipment and the surface, the device having a central tubular portion, a surrounding annulus portion, a plurality of spaced ports communicating between the tube and the annulus and a check valve between the ports and the lifting equipment. The lifting equipment is operated so that fluid flows through the check valve, ports, tubular portion and at least some of the annulus portion and into the production tubing. The method inhibits particles in the fluid from accumulating on the lifting equipment when the lifting equipment is not in use by trapping a substantial portion of particles in the annulus, whereby the ports inhibit particle flow into the tubing portion. The check valve prevents reverse fluid flow to the lifting equipment when not in use, and thus prevents the ESP from spinning backwards due to a reversal of the fluid flow.
- Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the accompanying drawings.
-
FIG. 1 is a schematic, sectional view of a first embodiment of a device in accordance with the present invention with the production fluid flowing normally. -
FIG. 2 is a sectional view of the device ofFIG. 1 with the flow of the production fluid stopped. -
FIG. 3 is a sectional view of the device ofFIG. 1 with the production fluid starting flow after having stopped. -
FIG. 4 is a sectional view of a detail of a port in the device ofFIGS. 1-3 andFIGS. 6-9 showing normal production fluid flow. -
FIG. 5 is a sectional view of a detail of a port in the device ofFIGS. 1-3 andFIGS. 6-9 showing production fluid flow stopped. -
FIG. 6 is a schematic, sectional view of a second embodiment of a device in accordance with the present invention with the production fluid flowing normally from an ESP to the surface. -
FIG. 7 is a sectional view of the device inFIG. 6 with the flow of the production fluid stopped. -
FIG. 8 is a sectional view of the device inFIG. 6 with the production fluid starting flow after having stopped. -
FIG. 9 is a cross section view of the device inFIG. 6 taken as shown; and -
FIG. 10 is a side elevational view of an exemplary operational embodiment of a device in accordance with the present invention. - Turning to the drawings, a first embodiment of a
device 10 in accordance with the present invention is illustrated inFIGS. 1-5 . Thedevice 10 is inserted as part of the production tubing string withFIG. 1 showingproduction tubing 12 leading to the surface andESP 14 located downhole adjacent to thedevice 10. It should be understood that thedevice 10 can be spaced from the ESP and in fact,multiple devices 10 can be used in the production tubing string. Further, whileFIG. 1 appears as a conventional vertical orientation, thedevice 10 can also be used in horizontal wells. Additionally, while the usefulness of thedevice 10 is illustrated in this embodiment as protecting an ESP, other downhole devices can be similarly protected from particles such as sand or fracking proppants. - Generally, the
device 10 includes acentral production tube 16 surrounded by anenlarged cylinder housing 18. Thus, the area between thetube 16 and the inner walls of thecylinder 18 define anannulus 20. At each end of thetube 16 is acheck valve FIGS. 1-3 illustrate a ball check valve, but other types of check valves known in the art can be used, such as diaphragm check valve, swing check valve or tilting disc check valve, stop-check valve, lift-check valve, in-line check valve, duckbill valve, or pneumatic non-return valve. Thecheck valve check valves FIG. 1 are open. A number ofports 24 are arranged along the length of thetube 16 providing fluid communication between theproduction tube 16 and theannulus 20. - An
end packer 26 is illustrated inFIG. 1 as defining the terminus for the cylinder. It should be understood, however, that any seals are acceptable, such as an O-ring bore seal. While thedevice 10 is illustrated as a discrete device inserted as part of the production tubing string, it can be appreciated that thecylinder 18 andannulus 20 could be defined by setting a packer at each end of a casing section to encompass thetube 16 andvalves - During normal operation (
FIG. 1 ) most of the production fluid flows from the ESP throughtube 16, but at least part of the fluid within thetube 16 exits thetube 16 through theports 24 into the annulus. The fluid streams from within thetube 16 andannulus 20 recombine in the region of the top of thetube 16proximate check valve 21 to flow up the production tubing. - In
FIGS. 2-5 the same components asFIG. 1 are generally illustrated at various stages of the well operation. InFIG. 2 , the ESP is off and production fluid flow has ceased. Therefore, particles such assand 30 settles downward in theannulus 20. The check valves 21 (if utilized), 22 are closed and movement of the sand entrained in the fluid is illustrated by the down arrows. Checkvalve 21 prevents particle flow into thetube 16.Particles 30 tends to build up in theannulus 20 near thelower check valve 22, but does not appreciably flow into thetube 16 through theports 24; the design and orientation of theports 24 prevent sand to flow into thetube 16. - In
FIG. 3 , theESP 14 is turned on and there are no are no significant buildup ofparticles 30 on top of the ESP discharge, i.e. in thetube 16. Bothcheck valves tube 16 up the production tubing to the surface begins almost immediately. As shown inFIG. 3 , a number of theuppermost ports 24 are not covered byparticles 30 and some of the fluid in thetube 16 flows through theports 24 into theannulus 20. Theparticles 30 cover some of the lower ports 24 (e.g.,ports 24 near the lower check valve 22) and little fluid flow occurs through theselower ports 24. However, the density of theparticles 30 in the fluid in the annulus decreases towards the surface, allowing some fluid flow through theports 24 into the annulus. This allows the annulus to be self-clearing over time. That is, as theupper ports 24 become partially uncovered with sand, fluid flows from thetube 16 through theports 24 into the annulus helping to clear the remaining sand. -
FIGS. 4 and 5 are cross sections of aport 24 through the wall of thetube 16. InFIG. 4 , theESP 14 is operating (e.g., as inFIG. 1 ) and fluid is flowing from thetube 16 through theport 24 into theannulus 20. The arrow inFIG. 4 illustrates the fluid flow direction. Eachport 24 is downwardly angled (relative to the fluid flow directions inFIG. 1 ) so that fluid will flow from the tube to theannulus 20, butparticles 30 will not easily flow from theannulus 20 into thetube 16.FIG. 5 illustrates this tendency ofparticles 30 to not flow from theannulus 20 into thetube 16 when the ESP is not operating, such asFIG. 2 . - The “downward” angle of the
port 24 is greater than perpendicular, but the optimum angle is dependent on the orientation of the device 10 (vertical vs. horizontal), the density of thesand 30 and the composition of the fluid. It is believed that about a 45′ angle will work for most vertical applications, and preferably between 30-60′. The use of theangled ports 24 is believed advantageous over resistive mesh screens to prevent sand from entering the tube and hindering operation of theESP 14. The design ofports 24 includes consideration not only of the angle, but also the diameter of theport 24. The design of theports 24 also takes into consideration the wall thickness (weight) of thetube 16. InFIG. 5 a vertical (or near vertical) well is illustrated and the design ofport 24 includes an angle in the direction opposite fluid flow and diameter of the port (24) such that particles cannot flow into the tube (16) as shown. The size of the ports can be much larger than mesh screens thus allowing more flow area to be achieved. The size of the ports may also be non-uniform and vary in size depending on desired flow characteristics. While the port cross-section is circular, other geometries are acceptable such as elongated slots or square cross-sections. The ports may be variable in size, variable spacing and variable densities. - While the
device 10 is illustrated in the context of a vertical well bore in the figures, it will be understood that horizontal wells can benefit from the use of thedevice 10. In fact, horizontal wells make extensive use of proppants for fracking which is a prime contributor to particles in the production tubing which can settle onto an ESP and hinder operation. Additionally, while protection of ESP's is a prime use of thedevice 10, other downhole equipment can be protected from particle interference as well. - A second embodiment of a
device 50 in accordance with the present invention is illustrated inFIGS. 6-9 . Thedevice 50 is inserted as part of the production tubing string withFIG. 6 showing production tubing 12 leading to the surface andESP 14 located downhole adjacent to thedevice 50. It should be understood that thedevice 50 can be spaced from the ESP and in fact,multiple devices 50 can be used in the production tubing string. Further, whileFIG. 6 appears as a conventional vertical orientation, thedevice 50 can also be used in horizontal wells. Additionally, while the usefulness of thedevice 50 is illustrated in this embodiment as protectingESP 14, other downhole devices can be similarly protected from particles such as sand or fracking proppants. - Generally, the
device 50 includes a centralcylindrical tube 56 surrounded by anenlarged cylinder housing 58. Thus, the area between thetube 56 and the inner walls of thecylinder 18 define anannulus 60. At thedistal end 72 of thetube 56, nearest theESP 14, is acheck valve 62. At theproximal end 74 of thetube 56, nearest the surface, is acap 66. As with the first embodiment check valves known in the art can be used, such as ball type check valves, diaphragm check valve, swing check valve or tilting disc check valve, stop-check valve, lift-check valve, in-line check valve, duckbill valve, or pneumatic non-return valve. Thecap 66 is fixed to prevent fluid flow to or from thetube 56 in the region of thecap 66. Thecheck valve 62 ofFIG. 6 is open. A number ofports 24 are arranged along thedistal end 72 of thetube 56 providing fluid communication between thetube 56 and theannulus 60. Afew ports 24 are provided near theproximal end 74 as seen inFIGS. 6-9 . That is, the density of theports 24 is greatest near thedistal end 72. - An end packer 68 is illustrated in
FIG. 6 as defining the terminus for thecylinder 18 near thedistal end 72. It should be understood, however, that any seals are acceptable, such as an O-ring bore seal. One ormore centralizers 70 are shown for maintaining thetube 56 central in thecylindrical housing 58. While thedevice 50 is illustrated as a discrete device inserted as part of the production tubing string, it can be appreciated that thecylinder 58 andannulus 60 could be defined by setting a packer at each end of a casing section to encompass thetube 56,cap 66 andvalve 62. - During normal operation (
FIG. 6 ) the production fluid flows from the ESP throughtube 56, but all of the fluid within thetube 56 exits thetube 56 through theports 24 into theannulus 60. The fluid stream from within theannulus 60 flows up theproduction tubing 12. - In
FIGS. 7-9 the same components asFIG. 6 are generally illustrated at various stages of the well operation. InFIG. 7 , the ESP is off and production fluid flow has ceased. Therefore, particles such assand 30 settle downward in theannulus 60. Thecheck valve 62 is closed and movement of the sand entrained in the fluid is illustrated by the down arrows.Cap 66 prevents particle flow into thetube 56.Particles 30 tends to build up in theannulus 60 near thelower check valve 62, but does not appreciably flow into thetube 56 through theports 24; the design and orientation of theports 24 prevent sand to flow into the tube 16 (seeFIGS. 4-5 ). - Advantageously, the fluid in the production tubing is retained while the ESP is off in
FIG. 7 . This allows an almost immediate restart of the ESP and quick return to normal operation (FIG. 6 ) and production rates. Refilling the production tubing with fluid upon restart of the ESP requires fluid equalization in the tubing and annulus and operation of the ESP in downthrust mode. Repeated startup of the ESP and operation in downthrust mode contributes to shortened ESP runlife. - The
check valve 62 is largely free from impingement bysand 30 during all phases of operation of thedevice 50. Thecheck valve 62 inFIG. 7 , with production ceased, prevents reverse flow of fluids. Such reverse flow would occur through theESP 14 until hydrostatic equilibrium is achieved between the production tubing and the wellbore. This reverse flow is undesirable because it can cause theESP 14 to turn in the reverse direction compared to normal operation. The ESP cannot be restarted when it is ‘back spinning’ (turning in a reverse direction)—a period that can sometimes extend for a number of hours. This back spinning causes the operator to wait until he is reasonably assured that theESP 14 is stationary before attempting to restart theESP 14. Thedistal check valve 62 stops reverse flow, and therefore alleviates this “back spinning” problem. - In
FIG. 8 , theESP 14 is turned on (restarted) and there are no significant buildup ofparticles 30 on top of the ESP discharge, i.e.ports 24 in thetube 56. Thecheck valve 62 immediately opens upon restart ofESP 14 and production fluid flow through thetube 56 up theproduction tubing 12 to the surface begins almost immediately. As shown inFIG. 8 , a number of theports 24 are not covered byparticles 30 and the fluid in thetube 16 flows through theports 24 into theannulus 60. Theparticles 30 cover some of the lower ports 24 (e.g.,ports 24 near the lower check valve 62) and little fluid flow occurs through theselower ports 24. However, the density of theparticles 30 in the fluid in the annulus decreases towards the surface, allowing some fluid flow through theports 24 into theannulus 60. This allows the annulus to be self-clearing. That is, with someports 24 in the region ofdistal end 72 uncovered or partially uncovered withparticles 30, fluid flows from thetube 56 through theports 24 into theannulus 60 helping to clear the remaining sand. - In the case where sand covers substantially all of the
ports 24 in the region of thedistal end 72, thefew ports 24 in the region of theproximal end 74 are substantially clear. Restart ofESP 14 in this case causes a pressure differential build-up between the distal and proximal ends 72, 74. In this case, the entire column ofsand 30 in theannulus 60 clears through theproduction tubing 12 almost immediately. In this case, having a large number ofports 24 near the distal end widely spaced from afew ports 24 at the proximal end is advantageous. -
FIG. 9 is a cross section of thedevice 50 as shown inFIG. 6 . InFIG. 9 , theESP 14 is operating (e.g., as inFIG. 6 ) and fluid has traversed from thetube 56 throughports 24 into theannulus 60.Centralizers 70 end to maintain the position of thetube 56 central in thehousing 58. -
FIG. 10 illustrates an exemplary operational embodiment of thedevice 50 illustrated schematically inFIGS. 6-9 . For comparison purposes, like numerals are applied to like components. Generally,end cap 66 is positioned at theproximal end 74 oftube 56. Afew ports 24 are arranged near theend cap 66 to permit fluid flow between thetube 56 andannulus 60.Centralizers 70 maintain the position oftube 56 in thehousing 58. Thecheck valve 62 is located near thedistal end 72. A large number ofports 24 are positioned through thetube 56 near thedistal end 72. - While the
devices devices devices
Claims (13)
Priority Applications (1)
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US16/124,547 US20190003296A1 (en) | 2016-05-10 | 2018-09-07 | Apparatus and method for preventing particle interference of downhole devices |
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US201662334174P | 2016-05-10 | 2016-05-10 | |
US15/589,115 US10082014B2 (en) | 2016-05-10 | 2017-05-08 | Apparatus and method for preventing particle interference of downhole devices |
US16/124,547 US20190003296A1 (en) | 2016-05-10 | 2018-09-07 | Apparatus and method for preventing particle interference of downhole devices |
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US15/589,115 Continuation US10082014B2 (en) | 2016-05-10 | 2017-05-08 | Apparatus and method for preventing particle interference of downhole devices |
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US20190003296A1 true US20190003296A1 (en) | 2019-01-03 |
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US15/589,115 Active US10082014B2 (en) | 2016-05-10 | 2017-05-08 | Apparatus and method for preventing particle interference of downhole devices |
US16/124,547 Abandoned US20190003296A1 (en) | 2016-05-10 | 2018-09-07 | Apparatus and method for preventing particle interference of downhole devices |
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WO2021108200A1 (en) * | 2019-11-25 | 2021-06-03 | The Cavins Corporation | Sand fallback submersible pump protection apparatus |
WO2021126358A1 (en) * | 2019-12-17 | 2021-06-24 | Halliburton Energy Services, Inc. | Modified sand fallback prevention tool |
WO2024073258A1 (en) * | 2022-09-28 | 2024-04-04 | Saudi Arabian Oil Company | Sand shield for protecting inverted electric submersible pump at shutdown |
WO2024129695A1 (en) * | 2022-12-13 | 2024-06-20 | Saudi Arabian Oil Company | Downhole sand trap |
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US10082014B2 (en) * | 2016-05-10 | 2018-09-25 | Forum Us, Inc. | Apparatus and method for preventing particle interference of downhole devices |
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US10947813B2 (en) | 2018-07-30 | 2021-03-16 | Saudi Arabian Oil Company | Systems and methods for preventing sand accumulation in inverted electric submersible pump |
US11434723B2 (en) * | 2020-01-24 | 2022-09-06 | Odessa Separator, Inc. | Sand lift tool, system and method |
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US11365619B2 (en) * | 2020-07-14 | 2022-06-21 | Halliburton Energy Services, Inc. | Variable width sand bridge inducer |
US20230057971A1 (en) * | 2020-12-03 | 2023-02-23 | Stoneview Solutions LLC | Downhole Pump Gas Eliminating Seating Nipple System |
US11879320B2 (en) | 2021-04-20 | 2024-01-23 | PetroQuip Energy Services, LLC | Particle trap apparatus and method |
US11852003B2 (en) | 2021-08-10 | 2023-12-26 | Daniel J. Snyder | Sand collector for sucker rod pump |
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US20170328190A1 (en) | 2017-11-16 |
US10082014B2 (en) | 2018-09-25 |
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