Gradational ESP Deployment via Pressure Control Assembly
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Solution Overview
Problem
Current methods for deploying and retrieving electric submersible pumps (ESPs) in wellbores require costly and complex interventions, especially in offshore and remote locations, where the use of coiled tubing is limited due to high costs, reliability issues, and availability constraints, and existing methods involve heavy well control measures to manage pressure.
Innovation Solution
A gradational insertion method using a pressure control assembly (PCA) with clamps, preventers, isolation valves, and a driver to safely deploy and retrieve ESPs in live wellbores, allowing for incremental assembly and disassembly of components without requiring heavy well control fluids, utilizing a lubricator and running tools to manage pressure and secure the ESP within the wellbore.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional deployment methods using tubing string with mechanical cable protectors are used, then the system can survive longer periods without intervention, but well intervention requires costly servicing rigs and special spoolers especially in offshore locations
Solution Approach 1:
The deployment system is divided into separate functional components: a deployment basket for holding the ESP, a coiled tubing string for delivery, and a deployment tool for insertion. This segmentation allows the ESP to be deployed independently without requiring complete tubing string intervention, reducing the complexity and cost of servicing operations.
2Ease of operation
If coiled tubing is used to support weight of equipment and cable, then deployment is improved over jointed tubing, but cost and availability prohibit broader use
Solution Approach 1:
A deployment basket acts as an intermediary device that attaches to the coiled tubing and holds the ESP. This intermediary allows the ESP to be deployed using coiled tubing's flexible delivery system while avoiding the need for expensive coiled tubing units to directly support the entire equipment weight, reducing overall system cost.
3Reliability
If heavy weight kill fluid is injected to neutralize flowing pressure, then well control is improved, but the process becomes more complex and costly
Solution Approach 1:
The deployment basket and ESP are prepared and assembled on the surface before deployment. The coiled tubing is pre-filled with deployment fluid rather than requiring kill fluid injection during the actual deployment process. This preliminary preparation eliminates the need for complex well control measures during insertion, simplifying the overall process while maintaining safety.
Data Source
AI summary
A method of inserting a downhole assembly into a live wellbore, includes: assembling a pressure control assembly (PCA) onto a production tree of the live wellbore; inserting a first deployment section of the downhole assembly into a lubricator; landing the lubricator onto the PCA; connecting the lubricator to the PCA; lowering the first deployment section into the PCA; engaging a clamp of the PCA with the first deployment section; after engaging the clamp, isolating an upper portion of the PCA from a lower portion of the PCA; and after isolating the PCA, removing the lubricator from the PCA.