ESP Wet-Mate Stinger Electrical Coupling for Maintenance

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Solution Overview

Problem

The existing ESP completion schemes require the removal and de-completion of a non-defective ESP string for repairs or replacements of the sub-surface safety valve and wellhead, leading to temporary defunctness of the ESP string and the need for a new installation, which is inefficient and costly.

Innovation Solution

A system and method that allow the ESP string to be connected and disconnected in two sections without damage, using a stinger assembly and stinger receptacle to create an electrical connection between the upper and lower sections, enabling the removal of one section for repairs while leaving the other downhole, and subsequent reconnection after repairs are completed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of repair

If the ESP string is removed and de-completed for repairs or replacements of the sub-surface safety valve and wellhead, then the SSSV and/or wellhead can be repaired or replaced, but the ESP string becomes temporarily defunct and requires a new installation, leading to loss of time and productivity

Engineering Contradiction:

Improveability to repair SSSV and wellheadVSAvoidESP string operational status

Core Design Contradiction:

Ease of repairVSProductivity

Solution Approach 1:

The ESP string is divided into two separate sections: an upper section containing the SSSV and wellhead connections, and a lower section containing the pump assembly. This segmentation allows the upper section to be removed for repairs while the lower section remains in place, eliminating the need to remove the entire ESP string and maintaining productivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The stinger assembly is inserted into the stinger receptacle to create a nested connection between the upper and lower sections. This nested configuration allows the sections to be connected and disconnected without damaging the ESP string components, enabling quick reassembly after repairs.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Ease of repair

If the entire ESP string is removed for maintenance, then all components can be accessed for repair, but the non-defective ESP string must be de-completed and a new installation required, increasing loss of time and operational costs

Engineering Contradiction:

Improveaccess to ESP string componentsVSAvoiddowntime for ESP string replacement

Core Design Contradiction:

Ease of repairVSLoss of time

Solution Approach 1:

The ESP string is segmented into upper and lower sections that can be independently handled. The upper section can be removed for maintenance while the lower section remains installed, allowing repairs to be performed without removing the entire ESP string and significantly reducing downtime.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of discarding the entire ESP string when maintenance is needed, the system allows recovery and reuse of the lower section (pump assembly) while only the upper section is replaced. This recovering approach reduces both time and costs associated with complete reinstallation.

Inventive Principle:

Principle #34Discarding and recovering

3Adaptability or versatility

If the ESP string is disconnected into two sections, then maintenance can be performed on one section while leaving the other downhole, but additional connection and disconnection mechanisms (stinger assembly and receptacle) are required

Engineering Contradiction:

Improveability to separate and maintain ESP string sectionsVSAvoidESP string structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The stinger assembly fits into the stinger receptacle in a nested configuration, creating a compact and integrated connection mechanism. This nested design adds minimal complexity while enabling the versatility of separating and reconnecting ESP string sections for maintenance.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The stinger assembly and receptacle act as intermediary components that facilitate the connection and disconnection between upper and lower sections. These intermediary elements enable maintenance operations without requiring complex disassembly of the entire ESP string.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11970926B2Electric submersible pump completion with wet-mate receptacle, electrical coupling (stinger), and hydraulic anchor

Publication Date: 2024.04.30 SAUDI ARABIAN OIL CO

AI summary

A system includes an upper section, having a first lateral end. The upper section has upper production tubing configured to be a conduit for production fluids, an upper electrical cable configured to transmit electricity, and a sub-surface safety valve fixed to the upper production tubing. The system further includes a lower section having a second lateral end, lower production tubing configured to be a conduit for the production fluids, a lower electrical cable configured to transmit electricity, an electric submersible pump assembly, and an anchor configured to hold the lower section within the casing string. A stinger assembly is fixed to the first lateral end of the upper section, and a stinger receptacle is fixed to the second lateral end of the lower section. The stinger receptacle is configured to receive the stinger assembly and create an electrical connection between the upper section and the lower section.