ESP Spool Installation for Subsea Wells
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Solution Overview
Problem
The installation of an electrically submersible pump (ESP) on a subsea well is expensive and requires costly vessels for workover operations, as existing methods necessitate replacing the well completion and using expensive rigs, even for ESP malfunctions.
Innovation Solution
A system that includes an ESP spool operatively coupled to a production tree, with the ESP positioned within the production tubing, where the electric motor is secured within the spool, allowing for hydraulic or electrical connection and minimizing the need for external pressure barriers, enabling installation without removing the well completion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional ESP installation methods are used on subsea wells, then the pump can be installed and function properly, but expensive Mobile Offshore Drilling Units and complex workover operations are required
Solution Approach 1:
The ESP motor is nested within the spool structure, allowing the motor to be housed inside the same component that guides and positions the pump assembly. This integration eliminates the need for separate motor housing and simplifies the installation process, enabling deployment from lighter vessels without requiring complex workover operations.
Solution Approach 2:
The system is divided into modular components: the spool with integrated motor, the pump assembly, and the production tree interface. This segmentation allows each component to be independently manufactured, tested, and installed, reducing overall installation complexity and cost while maintaining functional integrity.
2Ease of operation
If the well completion is replaced to install an ESP, then the pump can be installed, but the operation becomes expensive and time-consuming
Solution Approach 1:
The motor is pre-integrated into the spool structure during manufacturing, so that when installation is required, the complete assembly is already prepared and ready for deployment. This preliminary integration eliminates the need for time-consuming on-site assembly and completion replacement operations.
Solution Approach 2:
The spool serves multiple functions: it acts as a structural support, a guide for the pump assembly, a housing for the motor, and an interface with the production tree. This multi-functionality reduces the number of separate components and operations needed, thereby reducing installation time and complexity.
3Reliability
If external pressure barriers are used for ESP installation, then the installation can be performed, but the system becomes more complex and expensive
Solution Approach 1:
The pressure barrier function is merged with the spool structure itself. The spool is designed to provide both mechanical support and pressure containment, eliminating the need for separate external pressure barrier components. This integration maintains reliability while reducing system complexity.
Data Source
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AI summary
Disclosed is a system for installing an ESP on a well. In one example the system comprises a production tree (12, 50) that is operatively coupled to a well (14), an ESP spool (16) that is operatively coupled to the production tree and production tubing (60) that extends into the well. The system also comprises an ESP (22) positioned within an inside diameter of the production tubing (60), wherein the ESP (22) comprises an electric motor (22M) and a pump (22P), the electric motor (22M) being positioned above the pump (22P), and wherein the pump (22P) comprises a fluid inlet (22X) and a fluid outlet (22Y). The system is installed above the existing down hole safety valve, and requires no modification to the existing well's completion equipment.