Encapsulated ESP Motor Shroud Isolates Cables from Packer Penetration

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Solution Overview

Problem

Existing ESP systems face high failure rates due to the weak point of the packer penetration system, where the power cable must pass through the packer, leading to inefficiencies and reliability issues in hydrocarbon fluid extraction from deep well reservoirs.

Innovation Solution

The design of an ESP system that encapsulates the motor and allows electrical connections between the power cable and motor to occur outside the packer, using a motor head and shroud to isolate the motor from produced fluids, preventing fluid exposure and potential damage during energy transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If the power cable passes through the packer to power the ESP motor, then electrical energy can be transferred to the motor, but the packer penetration system becomes a weak point leading to high failure rates

Engineering Contradiction:

Improveenergy transfer to motorVSAvoidreliability at packer penetration point

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The invention extracts the electrical connection point from the problematic packer penetration zone by using a motor head with electrical connections located outside the packer. The power cable connects to the motor head externally, eliminating the need for the cable to pass through the packer, thus removing the weak point while maintaining energy transfer functionality.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The motor head acts as an intermediary component that receives electrical energy from the power cable outside the packer and transfers it to the motor. This intermediary structure allows energy transfer without requiring the power cable to penetrate the packer, thereby resolving the reliability issue at the penetration point.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If the motor is exposed to the external environment with produced fluids, then the motor can be positioned to power the pump, but fluid exposure causes potential damage and reduces system longevity

Engineering Contradiction:

Improvemotor positioning for pump operationVSAvoiddamage from produced fluids

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The invention uses a shroud, which is a protective enclosure shell, to encapsulate the motor. This shroud isolates the motor from produced fluids while allowing the motor to be positioned optimally for pump operation. The shroud acts as a physical barrier that prevents fluid damage without compromising the motor's operational positioning.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The invention extracts the motor from direct exposure to the harmful external environment by enclosing it within a shroud. This allows the motor to maintain its optimal positioning for powering the pump while being protected from produced fluids that would otherwise cause damage.

Inventive Principle:

Principle #2Taking out (Extraction)

3Length of moving object

If deep set packers are used to position the ESP downhole, then the pump can be set at the required depth, but the packer penetration system required to pass the power cable becomes a failure point

Engineering Contradiction:

Improvedepth positioning of ESPVSAvoidreliability of packer penetration system

Core Design Contradiction:

Length of moving objectVSReliability

Solution Approach 1:

The invention extracts the electrical connection functionality from the downhole packer penetration zone by positioning the motor head with its electrical connections outside the packer. This allows the ESP to be set at the required depth using deep set packers while eliminating the need for power cable penetration through the packer, thus maintaining depth positioning capability without the associated reliability issues.

Inventive Principle:

Principle #2Taking out (Extraction)

4Reliability

If the motor is isolated from produced fluids using a shroud, then the motor is protected from damage, but the system complexity increases with additional components

Engineering Contradiction:

Improvemotor protection from fluidsVSAvoidcomplexity of encapsulation system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The shroud serves multiple functions simultaneously: it protects the motor from produced fluids, provides structural support for the motor positioning, and facilitates the external electrical connection arrangement. By combining multiple functions into a single component, the invention reduces overall system complexity while maintaining reliable motor protection.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11802465B2Encapsulated electric submersible pump

Publication Date: 2023.10.31 SAUDI ARABIAN OIL CO

AI summary

A system includes production tubing, an electric submersible pump, a motor, a shroud, a motor head, and a cable. The production tubing traverses a packer and is disposed within the well. The electric submersible pump is connected to the production tubing and is located up hole from the packer. The motor is located up hole from the packer and is configured to power the electric submersible pump. The shroud encapsulates the motor, isolates the motor from an external environment, and contains a flow of produced fluids coming from the production tubing. The motor head is connected to the production tubing and extends from the external environment into the shroud. The power cable is connected to a section of the motor head that is located outside of the shroud and isolated from the produced fluids by the packer and the shroud.