Coiled-Tubing ESP Cable Structure for Weight Transfer
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Solution Overview
Problem
Traditional power cables for electric submersible pumping systems (ESP) in hydrocarbon wells cannot support their own weight or the weight of the ESP, requiring additional support from production tubing and often necessitating the use of a workover rig for deployment and retrieval.
Innovation Solution
The installation of a power cable within coiled tubing, where the cable includes a power cable core with conductors, insulation, and a jacket, and optionally features a corrugated armor layer, swelling elastomeric jacket, or wire armor to secure the cable within the coiled tubing and transfer weight to it.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional power cable is used for ESP systems, then the cable can supply power to the ESP, but the cable cannot support its own weight or the weight of the ESP
Solution Approach 1:
The power cable is constructed as a composite structure combining electrical conductors with coiled tubing made of steel or other strong materials. This composite design allows the cable to simultaneously perform electrical power transmission and mechanical weight support functions, resolving the contradiction between strength and structural complexity.
Solution Approach 2:
The cable system is designed to perform multiple functions: power transmission through the conductors and mechanical support through the coiled tubing structure. This multi-functional design eliminates the need for separate support structures, reducing overall system complexity while improving weight support capability.
2Ease of operation
If production tubing supports the ESP weight, then the ESP can be deployed, but a workover rig is required for deployment and retrieval
Solution Approach 1:
The coiled tubing is configured in a dynamic, flexible coil structure that can be easily deployed and retrieved through the wellbore. This dynamic configuration allows the tubing to navigate the wellbore geometry while supporting the ESP, enabling deployment and retrieval operations without requiring a workover rig, thus improving ease of operation.
3Strength
If the power cable extends alongside and is secured to the production tubing, then the cable is supported, but the system requires additional support structures
Solution Approach 1:
The power cable and support structure are merged into a single integrated coiled tubing assembly. The conductors are positioned within the coiled tubing structure, eliminating the need for separate support structures and reducing overall system complexity while maintaining adequate mechanical support for the ESP system.
4Ease of operation
If coiled tubing is used to support the power cable and ESP, then deployment without workover rig is enabled, but the cable installation complexity increases
Solution Approach 1:
The conductors are pre-positioned and secured within the coiled tubing structure during manufacturing. This preliminary action ensures proper cable placement and secure attachment before field installation, simplifying the overall installation process while enabling deployment without workover rig operations.
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
This configuration allows the coiled tubing to support the weight of the power cable and ESP, enabling deployment and retrieval without a workover rig, while also reducing the need for steel armor and potentially improving thermal expansion and corrosion resistance.
Implementation Method 1
The jacket can include a material configured to swell in response to an activating fluid. In some such embodiments, the cable can include a barrier jacket surrounding the insulation and disposed between the insulation and the jacket, the barrier jacket configured to anchor the jacket such that the jacket swells radially outwardly rather than longitudinally in response to the activating fluid.
Implementation Method 2
The jacket can have a cross-sectional geometry comprising two or more portions having an outer diameter that exceeds an inner diameter of the coiled tubing and that contact an inner surface of the coiled tubing to create an interference fit with the coiled tubing and secure the power cable core in the coiled tubing.
Data Source
AI summary
Various cables for cable deployed electric submersible pumping systems and methods of manufacturing such cables are provided. The cable includes a power cable core and coiled tubing formed around the power cable core. The power cable core includes one or more conductors, insulation surrounding each conductor, and an elastomeric jacket extruded around the insulated conductors. Various mechanisms, systems, and methods are described to anchor the power cable core in the coiled tubing and to transfer weight from the power cable core to the coiled tubing.