Electric Submersible Pump Control Valve Using Magnetic Coupling
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Solution Overview
Problem
The integration of cable-deployed electric submersible pumps (CDESP) with subsurface safety valves (SSSV) poses challenges, including the need for long control lines and reliability issues due to additional electrical connections, especially in deep-set configurations, and complications with sand accumulation in shallow-set SSSVs, which affect the operational efficiency and deployment of these systems in hydrocarbon reservoirs.
Innovation Solution
A system and method utilizing an electric submersible pump assembly with a control valve assembly that includes a movable core driven by an electromagnetic actuator, allowing for the operation of SSSVs without surface control lines, using a solenoid type actuator and magnetic coupling to manage fluid flow and prevent sand accumulation, ensuring proper functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a deep-set SSSV is used with CDESP, then the obstruction can pass through without blocking the valve, but long control lines are required and reliability decreases due to additional electrical connections
Solution Approach 1:
The patent extracts the SSSV from its traditional deep-set position and relocates it to a shallow-set configuration above the CDESP. This extraction eliminates the need for long control lines and reduces the number of electrical connections, thereby improving reliability while maintaining the ability to handle obstructions through the redesigned valve architecture
Solution Approach 2:
The patent introduces a magnetic coupling mechanism as an intermediary between the CDESP and the SSSV. This magnetic coupling enables communication and control without requiring direct electrical connections or long control lines, resolving the contradiction between deep-set obstruction handling and system reliability
2Reliability
If a shallow-set SSSV is used with CDESP, then control lines are shorter, but sand accumulation occurs in the valve affecting operational efficiency
Solution Approach 1:
The patent implements a magnetic coupling mechanism that enables dynamic control of the SSSV without physical contact. The magnetic field can be adjusted to open or close the valve as needed, preventing sand accumulation issues while maintaining short control lines, thus preserving both reliability and operational efficiency
Solution Approach 2:
The patent replaces the traditional mechanical control system with a magnetic coupling system. This substitution eliminates the need for physical connections that can accumulate sand, while maintaining the shallow-set configuration benefits of shorter control lines and improved reliability
3Ease of operation
If electromagnetic actuator is used to operate SSSV without surface control lines, then deployment is simplified and rig time is reduced, but electrical power generation and magnetic coupling complexity is introduced
Solution Approach 1:
The patent merges the CDESP motor shaft with the electromagnetic actuator system through magnetic coupling. This integration allows the actuator to be powered and controlled through the existing CDESP electrical connection, simplifying deployment by eliminating separate control lines while managing the complexity through unified system architecture
Solution Approach 2:
The electromagnetic actuator serves multiple functions: it operates the SSSV, is powered through the CDESP electrical system, and communicates via magnetic coupling. This multi-functionality reduces the need for separate systems and components, simplifying deployment while containing complexity through versatile design
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
This solution simplifies the deployment and retrieval of CDESP systems, reduces rig time and costs, and enhances operational reliability by eliminating long control lines and sand-related issues, ensuring effective fluid production from hydrocarbon reservoirs.
Implementation Method 1
A generator is coupled to the output shaft and converts rotational mechanical energy into electrical power
Implementation Method 2
An electromagnetic actuator is coupled to the flow tube and converts the electrical power into linear motion
Implementation Method 3
using a solenoid type actuator and magnetic coupling to manage fluid flow
Data Source
AI summary
A system includes an electric submersible pump (ESP) assembly configured to transport a fluid in a casing string of a well to a surface location. The ESP includes a pump configured to receive, upon activation, the fluid through a pump intake and vent the fluid through a pump discharge; an output shaft extending downhole from and fixed to the pump; and a control valve assembly. The control valve assembly includes a movable core of an electromagnet movable along a central axis of the system; a generator in electrical communication with the electromagnet, configured to generate electrical power to pull the movable core in an uphole direction upon activation of the pump of the electric submersible pump assembly; a shaft coupler coupling a generator input shaft and the output shaft; and a stinger having a conduit for the fluid to flow from the tubing string to the pump intake. The stinger includes at least one intake slot configured to receive the fluid; and an exit configured to vent the fluid to the pump intake of the electric submersible pump assembly. The control valve assembly also includes a flow tube connected to the movable core, the flow tube comprising an exterior surface creating fluid communication between the flow tube and the stinger before, when, or after the exterior surface uncovers the at least one intake slot of the stinger. The ESP also includes a spring configured to slide the movable core upon deactivation of the pump of the electric submersible pump assembly.