Bonded Cable Strength Members for Downhole Pump Deployment
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Solution Overview
Problem
Conventional submersible pumping systems face challenges with power cables that are not strong enough to support the weight of the equipment downhole, leading to labor-intensive and time-consuming deployment processes, safety hazards, and vulnerability to downhole stresses and fluid infiltration.
Innovation Solution
A continuously bonded cable system that integrates strength member layers with a cable core, capable of supporting and powering downhole pumps, providing a single-cable solution for deployment and retraction without additional support structures, and designed to withstand harsh downhole conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional power cables are used to provide power to downhole pumps, then the pump can be powered, but the cable is not strong enough to support the weight of the equipment downhole
Solution Approach 1:
The patent combines the power cable and support cable into a single integrated cable assembly. The cable assembly includes both electrical conductors for power transmission and strength members for mechanical support, eliminating the need for separate cables and reducing deployment complexity.
Solution Approach 2:
The cable assembly serves multiple functions simultaneously: it provides electrical power to the downhole pump, supports the weight of the pump and equipment, and enables retrieval of the equipment. This multi-functional design replaces multiple separate systems with a single universal cable solution.
2Duration of action of stationary object
If permanent cables are used for long-term deployment, then the pump can be powered continuously, but the deployment process becomes labor-intensive and time-consuming
Solution Approach 1:
The cable assembly is pre-configured with both power conductors and strength members integrated together before deployment. This preliminary preparation allows for faster deployment since the cable is ready-to-use as a complete assembly, eliminating the need for on-site assembly or attachment of separate components.
Solution Approach 2:
The patent changes the structural parameters of the cable by integrating strength members with the electrical conductors into a single assembly. This parameter change enables the cable to be deployed as one unit rather than multiple components, significantly reducing deployment time and labor requirements.
3Reliability
If conventional cables are used, then power can be transmitted, but the cable is vulnerable to downhole stresses and fluid infiltration
Solution Approach 1:
The cable assembly uses composite construction combining electrical conductors, strength members, and protective bonding. The integration of different materials (conductors for electricity, strength members for mechanical support, and protective layers for environmental resistance) creates a composite structure that withstands downhole stresses and prevents fluid infiltration.
Solution Approach 2:
The cable assembly includes protective measures built in before deployment, such as the integrated strength members that cushion against mechanical stresses and the protective layers that prevent fluid infiltration. These protective features are incorporated in advance to withstand the harsh downhole environment.
4Strength
If additional support structures are used to support the pump, then the equipment can be properly supported, but the deployment system becomes more complex
Solution Approach 1:
The patent merges the support function into the cable assembly itself by integrating strength members with the power conductors. This eliminates the need for separate support structures such as additional cables or mechanical support systems, simplifying the overall deployment system while maintaining adequate support capacity.
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
Enables faster, safer, and more cost-effective deployment and retrieval of downhole pumps, reducing labor and equipment needs, while withstanding extreme downhole environments and eliminating torque imbalance issues.
Implementation Method 1
a cable having at least one strength member layer bonded to a cable core, in which a first end is connected to a power source disposed at a surface of the well and a second end is connected to the downhole pump
Implementation Method 2
The cable is configured to support and power the downhole pump in the well
Data Source
AI summary
Embodiments disclosed herein relate to a method and a system to deploy a downhole pump within a well. The system includes the downhole pump disposed in a well, the downhole pump having a motor, and a cable having at least one strength member layer bonded to a cable core, in which a first end is connected to a power source disposed at a surface of the well and a second end is connected to the downhole pump. The cable is configured to support and power the downhole pump in the well.