Live-Well ESP Deployment Using Sealed Cable Hangers
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Solution Overview
Problem
Existing methods for deploying electric submersible pumps (ESPs) in wells require killing the well, which is costly, difficult, and can reduce reservoir productivity due to hydrostatic pressure and permeability issues.
Innovation Solution
A method involving installing a plug below the well tree, replacing valve closure elements with gate seats, and using a cable hanger with sealing elements to extend the ESP on an electrical cable without killing the well, maintaining pressure integrity and avoiding tree disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If well killing method is used to deploy ESP, then pump deployment is enabled, but well productivity is reduced and operational complexity increases
Solution Approach 1:
The well control system is segmented into functional zones: the kill fluid is confined to the annular space between the wellbore and the deployment cable, while the production tubing remains separate and accessible. This segmentation allows the kill fluid to perform its function of preventing uncontrolled flow during deployment without requiring the entire well to be killed, thus preserving production capability through the tubing.
Solution Approach 2:
The deployment cable acts as an intermediary element that enables ESP installation without direct well killing. The cable provides a controlled pathway through which the pump can be lowered into the well, and it serves as a barrier that contains the kill fluid in the annular space rather than requiring the entire wellbore to be pressurized with kill fluid.
2Ease of manufacture
If well killing method is used to deploy ESP, then pump deployment is enabled, but operational cost and complexity increase
Solution Approach 1:
The operational process is segmented into distinct phases: first, the well is equipped with a kill fluid injection system and deployment cable; second, the ESP is deployed through the cable; third, the cable is removed and the well is returned to production mode. This segmentation allows the complex kill fluid procedures to be isolated to specific operational windows rather than requiring continuous well killing, reducing overall operational complexity.
Solution Approach 2:
The well is preliminarily equipped with the deployment cable and kill fluid injection capability before ESP installation. This preliminary preparation allows the actual ESP deployment to proceed without requiring complex real-time well killing operations, as the infrastructure is already in place to contain and manage the kill fluid during the deployment process.
3Reliability
If kill fluid is used to deploy ESP, then well control is achieved, but reservoir permeability is reduced
Solution Approach 1:
The kill fluid is segmented to affect only the annular space between the wellbore and deployment cable, rather than flooding the entire wellbore and formation. This localized application minimizes the volume of kill fluid that can potentially invade the formation, thereby reducing the impact on reservoir permeability while still achieving the necessary well control during deployment.
Solution Approach 2:
The deployment cable is extracted from the wellbore after ESP installation, and the kill fluid is subsequently removed or diluted. This extraction and removal process minimizes the residual presence of kill fluid in the formation, helping to preserve reservoir permeability and productivity while still having achieved the necessary well control during the deployment operation.
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 ESP installation in a live well without killing it, preserving well productivity and avoiding costly disassembly of tree components or flow lines, thus reducing operational expenses and maintaining reservoir integrity.
Implementation Method 1
The cable hanger has sealing elements to engage the seat and an electrical connector
Implementation Method 2
installing at least one plug in the well below a well tree
Implementation Method 3
An upper master valve and a lower master valve in the well tree are closed
Data Source
AI summary
A method for installing an electric submersible pump (ESP) in a well includes installing a plug in the well below a well tree. An upper and lower master valve on the tree are closed. Closure elements are removed from the lower master valve and replaced with gate seats, and a replacement gate block. The replacement gate block has a seat for a cable hanger. The upper master valve is opened. The plug is removed and the ESP extended into the well on an electrical cable. A cable hanger is affixed to the cable and is seated in the seat. The cable hanger has sealing elements to engage the seat and an electrical connector. The electrical connector is oriented to enable access through a side opening in the replacement gate block.