Cable Deployment System for Electric Submersible Pumps
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Solution Overview
Problem
Existing systems for deploying and retrieving equipment like electric submersible pumps (ESPs) in oil and gas industries face inefficiencies due to cable failures at high stress points, fluid intrusion, and z-kinking caused by slack in cables, which limits their effectiveness.
Innovation Solution
A deployment and retrieval system using a single cable with modified tube injectors that grip and manage the cable, reducing stress points by distributing the weight vertically and employing sensors and spacers to prevent kinking, allowing precise cable length management and tension control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If cables are used to deploy and retrieve equipment in subsurface wells, then equipment deployment is enabled, but cable failures occur at high stress points such as drums and sheaves
Solution Approach 1:
The patent introduces an intermediary mechanism (the deployment system with controlled cable routing) between the cable and the high-stress elements (drums and sheaves). This system uses a series of guide wheels and tensioning mechanisms that distribute and redirect forces, preventing concentrated stress at any single point on the cable, thereby eliminating cable failures while maintaining deployment capability.
2Stability of the object's composition
If slack is present in electrical and telemetry conductors during equipment deployment, then cable flexibility is maintained, but z-kinking occurs causing conductor failure
Solution Approach 1:
The patent employs dynamic tensioning mechanisms that actively adjust cable tension during deployment and retrieval operations. The system continuously monitors cable state and applies appropriate tension forces to eliminate excessive slack that causes z-kinking, while maintaining enough flexibility for proper cable routing. This dynamic control prevents conductor failure while preserving necessary cable flexibility.
3Reliability
If cable tension is increased to prevent z-kinking, then conductor integrity is maintained, but stress on cables at high stress points increases
Solution Approach 1:
The patent segments the cable routing system into multiple controlled sections with individual tensioning and guiding points. Instead of applying single-point high tension, the system distributes tension control across multiple segments, allowing each section to maintain appropriate tension levels for preventing z-kinking without creating excessive stress concentrations at any single high-stress point on the cable.
4Ease of operation
If traditional cable systems are used for ESP deployment, then equipment can be lowered into the well, but fluid intrusion into cables causes failure
Solution Approach 1:
The patent employs a flexible protective sheath or coating system that envelops the electrical and telemetry conductors throughout the deployment process. This flexible shell protects the conductors from fluid intrusion while allowing the cable to maintain its flexibility and routing capabilities during deployment and retrieval operations, preventing fluid-related failures.
Data Source
AI summary
Representative implementations of devices and techniques provide a system arranged to deploy and retrieve a device such as an electric submersible pump with respect to a well or other like formation. An injection device for coiled tubing is modified to grip and inject a cable in order to lower a pump or like device into a wellbore. Modification to the tube injection device may include addition of cable-gripping blocks to the injection components. Multiple injection devices can be utilized to open and close in coordination in order to let a large connector or termination on the cable pass through an open injector while a closed injector maintains a grip on the cable.