Encapsulated ESP Layout for Fluid-Isolated Power Transmission
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Solution Overview
Problem
Deep set packers in ESP systems require packer penetrator systems, which introduce a weak point leading to high ESP failure rates due to reservoir fluid contact with the electric transmission system.
Innovation Solution
An encapsulated apparatus is used to isolate the electric transmission system from reservoir fluid contact by placing the ESP above the packer, eliminating the need for packer penetrator systems and using an external housing with a motor head, motor, and pump intake to direct reservoir fluid while keeping the internal housing with the electric transmission system fluidly isolated.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the ESP is placed below the packer with deep set packers, then the packer penetrator system can be used to pass the electrical power cable through the packer, but this introduces a weak point with high percentage of ESP failure occurrence due to reservoir fluid contact with the electric transmission system
Solution Approach 1:
The invention extracts the electric transmission system from the external environment by placing it inside a sealed internal housing. This eliminates the need for packer penetrator systems while maintaining the ability to pass power, as the entire electric transmission system is self-contained within the fluid-isolated housing.
Solution Approach 2:
The internal housing acts as an intermediary barrier between the electric transmission system and the reservoir fluid. This sealed enclosure allows the power cable to be connected to the motor without direct exposure to harmful fluids, thereby eliminating the weak point caused by packer penetrators.
2Adaptability or versatility
If the electric transmission system is exposed to reservoir fluid in the annulus, then the ESP can be installed below the packer, but reservoir fluid contact causes ESP failures
Solution Approach 1:
The electric transmission system is nested within the internal housing, which is itself contained within the external housing. This nested structure allows the ESP to be installed in various positions while maintaining fluid isolation of the electric components, thus improving reliability without limiting installation flexibility.
Solution Approach 2:
The internal housing serves as a protective intermediary that shields the electric transmission system from reservoir fluid contact. This allows the ESP to be positioned below the packer with full adaptability while the intermediary housing prevents fluid ingress that would cause failures.
3Reliability
If an encapsulated apparatus is used to isolate the electric transmission system from reservoir fluid, then ESP reliability increases, but the device complexity increases with internal and external housing structures
Solution Approach 1:
The invention merges the protection function with the structural housing by integrating the internal housing (for fluid isolation) and external housing (for mechanical support) into a unified encapsulated apparatus. This combined structure provides both protection and structural integrity without requiring separate complex systems.
Solution Approach 2:
The encapsulated housing structure serves multiple functions simultaneously: it provides mechanical support, seals against reservoir fluid, protects the electric transmission system, and enables flexible installation positions. This multi-functionality reduces the need for additional separate components, thereby managing complexity while maintaining high reliability.
Data Source
AI summary
An encapsulated apparatus includes an external housing and an internal housing. The external housing includes a plurality of components including a motor head, a motor, and a pump intake. The motor head has a fluid outlet configured to direct reservoir fluid out of the motor head. The motor head includes a power inlet configured to connect a power cable to an electric transmission system. The motor is connected to the motor head in contact with the reservoir fluid. The motor is powered by the electric transmission system. The pump intake is connected to the motor having a fluid inlet configured to direct the reservoir fluid from the fluid outlet into the fluid inlet. The internal housing is disposed in the external housing configured to be fluidly isolated from the reservoir fluid. The internal housing includes the electric transmission system.