ESP Power Cable Connector for Rigless Well Replacement
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Solution Overview
Problem
Existing ESP systems face challenges in installation and replacement, particularly in high-cost environments like offshore and remote locations, due to their short run life and the need for costly rig-based operations, while existing rigless systems are limited by depth, power, and reliability issues.
Innovation Solution
A novel ESP system with a fixed power cable section and a connector receptacle, combined with an electrical kick-over tool, allows for reliable and cost-effective deployment and replacement without a rig, reducing dependency on permanent connections and enabling flexible installation and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ESP systems are installed using traditional rig-based operations, then installation reliability is ensured, but installation costs increase significantly
Solution Approach 1:
The system divides the power cable into two separate sections: a fixed power cable section permanently installed in the wellbore and a removable power cable that can be detached and replaced. This segmentation allows the expensive fixed infrastructure to remain while enabling low-cost replacement of the removable cable section, thus reducing overall installation costs while maintaining reliability through the robust fixed section.
Solution Approach 2:
The system transitions from a static, permanent power cable connection to a dynamic configuration where the removable power cable can be easily connected and disconnected. This dynamic design allows for quick replacement of the removable cable section without requiring expensive rig-based operations, thereby reducing installation costs while maintaining system reliability through the secure connection to the fixed power cable section.
2Reliability
If ESP systems are deployed with permanent power cable connections, then power transmission reliability is improved, but system flexibility and ease of replacement decrease
Solution Approach 1:
The power cable is segmented into a fixed section that ensures reliable power transmission and a removable section that provides flexibility. The fixed power cable section maintains stable electrical connection and power transmission reliability, while the removable power cable section can be easily detached and replaced, providing system flexibility and adaptability for maintenance and upgrades.
Solution Approach 2:
The system introduces a connector as an intermediary component between the fixed power cable section and the removable power cable section. This connector enables reliable electrical connection while allowing for easy disconnection and replacement, thus bridging the need for both power transmission reliability and system flexibility.
3Adaptability or versatility
If ESP systems are installed in offshore and remote locations, then access to difficult environments is enabled, but installation and replacement costs increase
Solution Approach 1:
The segmented power cable system allows the expensive fixed infrastructure to be installed once in challenging offshore environments, while subsequent replacements only require the removable power cable section to be changed. This significantly reduces the cost of maintenance and replacement operations in remote locations where rig-based operations would be particularly expensive.
Solution Approach 2:
The removable power cable section functions as a consumable component that can be easily replaced when needed. Instead of requiring expensive rig-based operations for any cable replacement, the system allows for economical replacement of the removable section, making offshore and remote operations more cost-effective.
Data Source
AI summary
An electric submersible pump (ESP) system is described herein. The ESP system includes a pump and a motor connected to drive the pump. The pump and motor are disposed to pump fluid into production tubing in a wellbore. A connector is in fluid communication with the production tubing and the connector contains a receptacle to receive a plug. A fixed power cable section is connected at a first end to power the motor. The fixed power cable section is fixedly connected at a second end to the receptacle of the connector. Also included in the ESP system is an ESP power cable that extends through the production tubing to an ESP surface unit. The ESP power cable includes a removable plug to engage the receptacle of the connector.