Coiled Tubing Splice Assembly for Electrical Insulation Testing
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Solution Overview
Problem
The existing methods for retrieving and re-running electrical submersible well pumps supported by coiled tubing are complex and require additional equipment, as they lack efficient electrical insulation testing capabilities during the process, which can lead to potential damage and increased operational complexity.
Innovation Solution
A splice assembly that connects the lower and upper coiled tubing segments with a load supporting member and intermediate connector, allowing for electrical continuity and insulation testing, reducing the complexity and diameter of the splice while enabling weight support and parallel connection of power conductors for efficient retrieval and re-running.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional retrieval methods are used for ESP supported by coiled tubing, then the pump can be retrieved, but additional equipment and complex procedures are required without electrical insulation testing capability
Solution Approach 1:
The patent combines the electrical insulation testing function with the coiled tubing splice assembly by integrating terminals and conductors directly into the splice structure. The lower and upper splice assemblies include electrical terminals that connect to power cable conductors, enabling insulation resistance measurements to be performed during the retrieval operation without requiring separate testing equipment or procedures.
Solution Approach 2:
The splice assembly serves multiple functions simultaneously: it provides mechanical connection between coiled tubing segments, maintains electrical continuity through power cable conductors, and enables electrical insulation testing of the ESP motor windings. This multi-functionality eliminates the need for separate retrieval and testing procedures, reducing overall operational complexity.
2Reliability
If a complex splice assembly is used to enable electrical testing, then insulation testing is possible, but the splice diameter and complexity increase
Solution Approach 1:
The electrical terminals and power cable conductors are nested within the coiled tubing splice assembly structure. The terminals are positioned inside the splice body, and the conductors run through the assembly, allowing the electrical testing components to be contained within the existing splice diameter rather than adding external bulk.
Solution Approach 2:
The power cable conductors use flexible insulation layers and jackets that can be routed through the splice assembly without requiring large clearances. The elastomeric jacket and insulation layers allow the conductors to bend and fit within the constrained space of the splice assembly while maintaining electrical integrity.
3Productivity
If coiled tubing is spliced for retrieval and re-running, then the pump can be recovered, but electrical insulation testing during the process is not possible with existing methods
Solution Approach 1:
The splice assembly is self-sufficient for both mechanical connection and electrical testing functions. The integrated terminals and conductors allow the assembly to perform insulation resistance measurements on its own during the retrieval operation, without requiring external testing equipment or interrupting the retrieval process.
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 splice assembly facilitates efficient retrieval and re-running of coiled tubing by ensuring electrical continuity and insulation testing, reducing the need for additional equipment and minimizing potential damage during the process, thereby simplifying the operation and ensuring reliable pump performance.
Implementation Method 1
An intermediate connector electrically joins together the lower and upper terminals
Implementation Method 2
A load supporting member surrounds the intermediate connector and is joined to upper and lower ends, respectively, of the lower coiled tubing segment and the upper coiled tubing segment
Implementation Method 3
A lower power cable segment has three insulated lower power conductors and is installed within the lower coiled tubing segment
Data Source
AI summary
A splice connects a lower coiled tubing segment containing a lower power cable segment to an upper coiled tubing segment containing an upper power cable segment. The splice has a lower terminal electrically connecting together upper ends of lower power conductors. An upper terminal electrically connects together lower ends of upper power conductors. An electrical intermediate connector has an upper end that stabs into engagement with the upper electrical terminal and a lower end that stabs into engagement with the lower electrical terminal. A load supporting member surrounds the intermediate connector and joins to upper and lower ends, respectively, of the lower coiled tubing segment and the upper coiled tubing segment.