Coiled-Tubing ESP Power Cable With Swelling Jacket Anchoring
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Solution Overview
Problem
Traditional power cables for electric submersible pumping systems in hydrocarbon wells lack the structural support to carry their own weight and that of the ESP, necessitating additional equipment like workover rigs for deployment and retrieval, and existing solutions either require large coiled tubing or increase the cable's weight and cost.
Innovation Solution
A power cable system where the power cable is installed within coiled tubing, utilizing a corrugated armor layer and a swelling elastomeric jacket to create an interference fit, allowing the coiled tubing to support the weight of the ESP without a workover rig, and optionally incorporating internal strength members and corrosion-resistant claddings for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional power cable is used for ESP systems, then the cable can supply power to the ESP, but the cable cannot support its own weight or the weight of the ESP, requiring additional equipment like workover rigs for deployment and retrieval
Solution Approach 1:
The patent combines the power cable with coiled tubing into a single integrated structure. The coiled tubing is formed around the power cable core, creating a composite cable assembly that can support its own weight and the ESP weight, eliminating the need for separate workover rig equipment for deployment and retrieval.
Solution Approach 2:
The patent uses a composite structure consisting of the power cable core (with conductors, insulation, and jacket) combined with the coiled tubing (metallic structure). This composite design allows the cable to leverage the mechanical strength of the coiled tubing while maintaining its electrical function, enabling self-support without additional deployment equipment.
2Weight of moving object
If the coiled tubing inner diameter is reduced to decrease cable weight and cost, then the cable weight and cost are reduced, but the cable cannot be properly installed or supported within the tubing
Solution Approach 1:
The patent changes the geometric parameters of the jacket by adding protrusions that extend radially outward. This allows the jacket's outer diameter in certain regions to exceed the coiled tubing's inner diameter, creating an interference fit that secures the cable within the tubing while enabling the use of smaller diameter tubing overall, thus reducing cable weight and cost.
Solution Approach 2:
The patent applies local quality by adding protrusions only in specific regions of the jacket rather than uniformly increasing the entire jacket diameter. This localized geometric modification creates interference fit points that secure the cable to the coiled tubing while maintaining a compact overall cable profile, enabling proper installation feasibility.
3Strength
If an interference fit is created between the jacket and coiled tubing to secure the cable, then the cable is securely anchored, but thermal expansion may compromise mechanical integrity
Solution Approach 1:
The patent segments the jacket structure by adding discrete protrusions rather than creating a continuous tight fit. This segmentation allows localized anchoring points that secure the cable while leaving gaps and voids between the protrusions that accommodate thermal expansion of the cable components, preventing stress buildup that would compromise mechanical integrity.
Solution Approach 2:
The patent incorporates voids between the jacket protrusions and coiled tubing as a preliminary design feature before thermal expansion occurs. These pre-designed voids provide expansion space that absorbs thermal growth, preventing the interference fit from generating excessive stress during temperature changes while maintaining secure anchoring through the protrusions.
4Strength
If the jacket is designed with protrusions to create interference fit, then the cable is secured in the coiled tubing, but voids may allow pressure transmission through pinholes or breaches
Solution Approach 1:
The patent introduces a barrier jacket as an intermediary layer between the insulation and the protrusion-containing jacket. This barrier jacket is configured to anchor the protrusions and restrict their swelling, preventing pressure transmission through the voids and pinholes while allowing the protrusions to maintain their interference fit for secure cable anchoring.
Solution Approach 2:
The patent extracts the pressure containment function from the main jacket structure by introducing a separate barrier jacket layer. This dedicated barrier layer specifically addresses pressure transmission through pinholes and breaches, while the main jacket with protrusions focuses on providing mechanical anchoring, thereby resolving the conflict between securing strength and pressure containment reliability.
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
Enables the deployment and retrieval of ESP systems without a workover rig, reduces the weight and cost of the cable, and allows for thermal expansion without compromising mechanical integrity, while preventing pressure transmission through pinholes or breaches.
Implementation Method 1
The jacket can include a material configured to swell in response to an activating fluid
Implementation Method 2
The corrosion resistant cladding can be applied to the coiled tubing via flame spray or high velocity oxygen fuel spray
Implementation Method 3
The corrosion resistant cladding can be applied to the coiled tubing via flame spray or high velocity oxygen fuel spray
Data Source
AI summary
Various cables for cable deployed electric submersible pumping systems and methods of manufacturing such cables are provided. The cable includes a power cable core and coiled tubing formed around the power cable core. The power cable core includes one or more conductors, insulation surrounding each conductor, and an elastomeric jacket extruded around the insulated conductors. Various mechanisms, systems, and methods are described to anchor the power cable core in the coiled tubing and to transfer weight from the power cable core to the coiled tubing.