Quick Connection Interface for ESP Components
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Solution Overview
Problem
Existing methods for repairing or replacing downhole equipment, such as Electrical Submersible Pumps (ESPs), often require killing the well, which can cause damage and is costly, or using a lubricator that limits the length of equipment that can be used.
Innovation Solution
A system and method for connecting and disconnecting upper and lower sections of downhole equipment using a quick connection assembly that includes an upper connection with external splines and a lower connection with internal splines, allowing for assembly and disassembly beneath a lubricator without rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lubricator is used to control pressure during downhole equipment work, then well pressure control is achieved, but the length of equipment that may be used is limited
Solution Approach 1:
The downhole equipment is divided into multiple sections that can be connected together. The system includes an upper section with an upper connection and a lower section with a lower connection, allowing the equipment to be assembled in segments beneath the lubricator to achieve greater overall length while still passing through the lubricator during deployment
2Ease of operation
If conventional connection methods are used for downhole equipment, then equipment sections can be connected, but the well must be killed or a lubricator must be used
Solution Approach 1:
The upper and lower connections are pre-configured with mating splines and engagement features that allow the sections to be connected together beneath the lubricator before deployment. The shear pins are pre-installed to provide automatic disconnection capability, eliminating the need to kill the well or use complex connection procedures during field operations
3Reliability
If the entire downhole equipment must fit within lubricator sealing valves, then pressure control is maintained, but equipment length and configuration options are restricted
Solution Approach 1:
The equipment is segmented into multiple sections with standardized connections that can be assembled in various configurations beneath the lubricator. This allows different equipment lengths and arrangements to be created while all sections pass through the lubricator individually during deployment, maintaining pressure control while increasing versatility
Solution Approach 2:
The upper and lower connections use universal spline interfaces that can accommodate different equipment configurations. The same connection mechanism works for various equipment types and lengths, providing a standardized interface that increases adaptability while maintaining compatibility with lubricator deployment
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 of longer ESP assemblies into a live well, overcoming length limitations and reducing the risk of well damage, while allowing for efficient and reliable connection and disconnection of equipment sections.
Implementation Method 1
the snap ring expands and falls into the snap ring receptacle
Implementation Method 2
shear pins configured to shear when a pre-determined tension is applied to the system
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A system includes an upper connection (206) having a ring shape with an external surface, where upper splines (222) are formed on the external surface and the upper connection (206) is fixed to the upper section (200). The system also includes a lower connection (208) having a ring shape with an internal surface, where lower splines (232) are formed on the internal surface and the lower splines (232) are configured to mate with the upper splines (222) of the upper connection (206). Further, the system includes a fishing sub having a first lateral end (254) and a second lateral end (256), where the first lateral end (254) is fixed to the lower connection (208) by shear pins (250) configured to shear when a pre-determined tension is applied to the system, and the second lateral end (256) is fixed to the lower section (202). The upper connection (206) is inserted into the lower connection (208) to form an engagement between the upper section (200) and the lower section (202).