Downhole Electrical Coupler for Pump Maintenance Access
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Solution Overview
Problem
Current downhole electrical pump systems require the entire production tubing to be retrieved from the wellbore for maintenance or repair, which is costly and logistically challenging.
Innovation Solution
An electrical coupling system that allows for the insertion and removal of electrically operated devices within the wellbore without pulling the tubing, utilizing a wet mateable electrical coupler and receptacle system with a bypass conduit and seal arrangements to maintain fluid isolation and power transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pump system is installed as an integrated part of the production tubing, then the electrical connection is reliable and stable, but the entire tubing must be retrieved for pump maintenance or repair
Solution Approach 1:
The system is divided into separate segments: the production tubing remains in the wellbore while the pump system can be independently retrieved through the tubing using wireline or coiled tubing methods. The electrical coupler is segmented into a receptacle portion attached to the tubing and a coupler portion attached to the pump, allowing independent access to each component.
Solution Approach 2:
An electrical coupler acts as an intermediary device between the production tubing and the pump system. It provides electrical connection while allowing the pump to be accessed independently through the tubing, serving as a mediator that enables both reliable connection and easy maintenance.
2Ease of repair
If the entire production tubing is retrieved for pump repair, then the pump can be maintained or replaced, but the operation becomes costly and logistically challenging
Solution Approach 1:
The system separates the pump retrieval operation from the production tubing retrieval. The pump can be independently accessed through the tubing using standard wireline or coiled tubing equipment, eliminating the need for complex workover rig operations to retrieve the entire tubing string.
Solution Approach 2:
The pump system is designed to be self-serviceable through the existing tubing infrastructure. The electrical coupler enables the pump to be connected and disconnected electrically without moving the tubing, allowing maintenance operations to be performed using simpler, more cost-effective methods.
3Reliability
If the pump system is permanently installed in the tubing, then the electrical connection is stable, but the retrieval and reinstallation becomes difficult and expensive
Solution Approach 1:
The electrical connection system transitions from a static permanent installation to a dynamic reusable configuration. The electrical coupler allows the pump to be connected and disconnected multiple times while maintaining electrical connectivity, enabling rapid retrieval and reinstallation without the time-consuming process of tubing retrieval.
Solution Approach 2:
The pump system can be easily retrieved, maintained, and reinstalled using the electrical coupler. The coupler itself remains in place on the tubing while the pump portion can be discarded (retrieved for maintenance) and recovered (reinstalled) independently, significantly reducing the time and effort required for maintenance cycles.
Data Source
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AI summary
An electrical coupling system for use in a wellbore that enables insertion and removal of an electrically operated device in a wellbore includes an electrical receptacle mounted at a selected axial position along a tubing disposed in the wellbore. The receptacle includes at least one insulated electrical conductor coupled to an electrical contact inside the receptacle and extending to the well surface. An electrical coupler is disposed on an exterior of the electrically operated device. The coupler includes at least one electrical contact disposed proximate the receptacle contact when the coupler is mated to the receptacle. The coupler including at least one flow passage enabling wellbore fluid flow from below the coupler to an annular space between the electrically operated device and an interior of the tubing.