ESP Y-tool Dynamic Seal and Millable Ball Valve
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Solution Overview
Problem
Access to the reservoir downhole of an electrical submersible pump (ESP) is typically blocked, hindering intervention or workover operations, as existing bypass systems require frequent wireline operations to open and reset blanking plugs, which can be cumbersome, especially in deep horizontal wells.
Innovation Solution
A Y-tool apparatus with a dynamic seal and millable ball valve in the bypass branch allows for seamless passage of intervention tools without removing the ESP, using a control line to operate the closure valve and dynamic seal, eliminating the need for blanking plugs and reducing the complexity of slickline operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a blanking plug is used to seal the bypass branch, then the bypass branch is sealed to prevent recirculation, but frequent wireline operations are required to retrieve and reset the blanking plug
Solution Approach 1:
The patent replaces the static blanking plug with a dynamic seal system that includes an inflatable dynamic seal and a ball valve mechanism. The dynamic seal can be inflated or deflated via control lines to open or close the bypass passage, allowing the system to transition between states without requiring physical retrieval or resetting of sealing components.
Solution Approach 2:
The patent replaces the mechanical blanking plug retrieval system with a fluid-based control system using control lines that extend to the surface. The ball valve and dynamic seal are actuated by fluid pressure transmitted through these control lines, eliminating the need for mechanical wireline operations to retrieve and reset sealing components.
2Reliability
If the bypass branch is sealed with a blanking plug, then recirculation is prevented, but the system complexity increases due to frequent wireline operations
Solution Approach 1:
The control lines serve multiple functions: they control both the ball valve opening/closing and the dynamic seal inflation/deflation. This multi-functional control system reduces operational complexity by using a single control mechanism for what would otherwise require separate operations.
Solution Approach 2:
The ball valve and dynamic seal system is designed to be self-actuating through fluid pressure from the control lines. Once the control lines are activated, the valve and seal automatically open or close without requiring additional manual intervention or complex operational procedures.
3Adaptability or versatility
If intervention tools are passed through the bypass branch, then access to downhole reservoir is enabled, but the ESP must be removed or the bypass system becomes cumbersome
Solution Approach 1:
The Y-tool apparatus divides the flow path into separate segments: the production branch for ESP operation and the bypass branch for intervention tools. The ball valve and dynamic seal create distinct flow paths that can be independently controlled, allowing intervention tools to pass through the bypass branch while the ESP continues to operate in the production branch without removal.
Solution Approach 2:
The bypass branch acts as an intermediary pathway that allows intervention tools to access the downhole reservoir without interfering with the ESP operation in the production branch. The controlled opening of the ball valve and dynamic seal provides a dedicated route for tools while maintaining separation between production and intervention operations.
Data Source
AI summary
An Electric Submersible Pump (ESP) is installed in a production branch of a Y-tool apparatus. A bypass branch of the Y-tool apparatus permits an intervention tool on a coiled tubing string to bypass the ESP for intervention operations in the wellbore. A permanent dynamic seal in the bypass branch includes an inflatable elastomeric chamber that forms a seal around the coiled tubing string while the coiled tubing is run-in and pulled out. A ball valve is also provided in the bypass branch. The dynamic seal and ball valve eliminate the need for blanking plugs to be retrieved and reset with slickline operations.