Flowable Conductive Slurry for Deep ESP Powering
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Solution Overview
Problem
Conventional methods for deploying and powering electric submersible pumps (ESPs) are limited by the need for a full rig, which is costly and economically prohibitive, especially at depths greater than 10,000 feet, due to heavy cable reels and thermal expansion issues.
Innovation Solution
A system utilizing a tubing string with a hollow interior filled with a flowable conductive material, forming a first conductive path, and a second conductive path, such as production tubing, to create a circuit for powering the ESP, allowing for deeper deployments without the need for a rig, using materials like lead shot, graphite, or copper, and incorporating features like filters and annulus-to-tubing injection valves for reverse circulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional coiled-tubing deployment with internally-installed cable is used, then the system can be deployed without a full rig, but the deployment depth is limited to about 10,000 feet due to cable length and weight constraints
Solution Approach 1:
The patent uses hydraulic pumping to inject conductive slurry through the tubing string to form the conductive path. This eliminates the need for long, heavy cables by using fluid injection to create electrical conductivity in situ, allowing deployment beyond 10,000 feet without proportionally increasing cable weight and complexity
Solution Approach 2:
The patent changes the physical state and properties of the conductive material from solid cable to fluid slurry that can be pumped and then set. This allows the conductive path to be formed after deployment, enabling greater depths without the constraints of pre-installed cable length and weight
2Power
If heavy cable reels are used for power transmission, then sufficient power can be delivered to the pump, but lifting operations challenge offshore cranes and may require support barges
Solution Approach 1:
The system uses hydraulic slurry injection instead of mechanical cable lifting. The conductive slurry is pumped through the tubing string using hydraulic pressure, eliminating the need to lift and handle heavy cable reels, thereby avoiding crane capacity challenges and the need for support barges
Solution Approach 2:
The patent replaces the mechanical cable-lifting system with a hydraulic slurry-injection system. Instead of mechanically lifting heavy cables into position, the system uses fluid dynamics to inject and distribute the conductive material, significantly reducing the mechanical lifting requirements
3Reliability
If the entire cable string is used for power transmission, then power can be delivered to deep ESPs, but the system cannot easily be spliced and the entire string must be lost if there is an issue
Solution Approach 1:
The system allows for localized repair by injecting additional conductive slurry at specific depths through injection valves. If a section of the conductive path fails, the system can self-repair by pumping more slurry through the existing tubing string to re-establish conductivity, eliminating the need to retrieve and replace the entire string
Solution Approach 2:
The conductive path is effectively segmented into controllable sections through the use of injection valves at different depths. This allows independent treatment and repair of specific zones without affecting the entire system, enabling localized maintenance and reducing material loss
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 the deployment and powering of ESPs at greater depths without the need for a full rig, reducing costs and operational challenges, while maintaining the integrity of the system through reverse circulation and secure power transmission.
Implementation Method 1
a flowable conductive material at least partially filling the hollow interior of the tubing string, the flowable conductive material forming a first conductive path
Implementation Method 2
the first conductive path and the second conductive path form a circuit for supplying power to the electric submersible pump
Implementation Method 3
annulus-to-tubing injection valves for reverse circulation
Data Source
AI summary
A system for deploying and powering an electric submersible pump within a subterranean well. The system includes a tubing string having a wall forming a hollow interior, one end of the tubing string connected to the electric submersible pump; a flowable conductive material at least partially filling the hollow interior of the tubing string, the flowable conductive material forming a first conductive path; and a second conductive path, wherein the first conductive path and the second conductive path form a circuit for supplying power to the electric submersible pump. A method for deploying and powering an electric submersible pump within a subterranean well is also provided.