ESP Power Cable Reel Coating System for Rust Inhibitor Application
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Solution Overview
Problem
Current methods for protecting electric submersible pump (ESP) power cables from rust degradation are inefficient, costly, and difficult to implement, leading to short shelf life and high waste of rust inhibitors.
Innovation Solution
A system and method involving a dip tank with a rotatable reel that submerges and rotates the ESP power cable in a treatment fluid, allowing for efficient coating of both inner and outer layers with rust remover or inhibitor, reducing the volume of treatment fluid needed and eliminating the need for overhead cranes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cable is unspooled and pulled through rust inhibitor, then the cable can be coated with rust inhibitor, but the process is labor intensive and requires large space
Solution Approach 1:
The system uses a rotatable reel mechanism that dynamically changes the cable's position from static storage to rotational motion during treatment. The reel rotates to submerge different portions of the cable in the rust inhibitor bath, eliminating the need for manual unspooling and respooling operations.
Solution Approach 2:
The manual mechanical process of unspooling, pulling, and respooling is replaced by a automated rotational system. The reel's rotation mechanism substitutes for human labor in handling the cable, reducing operational complexity and space requirements.
2Reliability
If a crane is used to submerge the cable in rust inhibitor, then the cable can be treated, but large quantities of rust inhibitor are wasted and overhead cranes are expensive
Solution Approach 1:
Instead of submerging the entire cable in a large volume of rust inhibitor, the system applies the inhibitor locally and efficiently. The rotatable reel ensures complete coverage of the cable surface with minimal fluid, reducing waste of the treatment substance.
Solution Approach 2:
The system uses partial submersion rather than complete immersion. By rotating the reel partially in the rust inhibitor bath, the cable receives adequate protection without requiring excessive amounts of inhibitor that would be wasted in full submersion methods.
3Productivity
If the cable is stored without treatment, then it is ready for immediate reuse, but the zinc coating deteriorates and the cable rusts quickly
Solution Approach 1:
The system applies rust inhibitor treatment in advance during the cable's storage period. This preliminary protective action prevents rust formation before it can compromise the cable's reusability, extending the storage life from 3-6 months to potentially a year or more.
Solution Approach 2:
The rust inhibitor is applied preliminarily to counteract the natural deterioration process. By establishing protective coverage before rust can form, the system prevents the harmful effects of oxidation and maintains cable integrity for extended storage periods.
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
Extends the shelf life of ESP power cables from three to six months to one year or more, reduces treatment fluid usage by 85%, and prevents air pocket issues, making the process more feasible and cost-effective.
Implementation Method 1
the aperture and openings define a treatment fluid pathway that flows from the tank into one of the openings, along the inner surface of the tubular drum and through the aperture to reach an inner layer of the ESP power cable
Implementation Method 2
A system and method involving a dip tank with a rotatable reel that submerges and rotates the ESP power cable in a treatment fluid
Implementation Method 3
the pair of support members actuatable between: a lowered position, wherein a lower portion of the cable-wrapped reel extends into and cycles through the treatment fluid when in the lowered position
Data Source
AI summary
An apparatus, system and method for treatment of an electric submersible pump (ESP) power cable is described. A method of treating an ESP power cable includes wrapping an ESP power cable around a reel as the cable is removed from a production well to form cable layers, supporting the cable-wrapped reel horizontally above a tank, the reel supported on a shaft extending between actuatable support members, pumping treatment fluid into the tank, lowering the cable-wrapped reel partially into the tank by activating the actuatable support members such that a lower portion of the reel is submerged in the treatment fluid and an inner diameter of the cable-wrapped reel is fluidly coupled to the treatment fluid, rotating the reel around its central axis such that each portion of an outermost layer of the cable is submerged in the treatment fluid at least once to coat the ESP power cable.