Master Valve and Cable Hanger for Live Well ESP Deployment
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Solution Overview
Problem
Existing methods for deploying electric submersible pumps (ESPs) in subsurface wells often require 'killing' the well, which is costly, difficult, and can reduce well productivity due to high-density fluid displacement, and may still necessitate adjusting flowlines or removing surface control valves.
Innovation Solution
A valve and cable hanger system that allows for the deployment and electrical connection of ESPs in a 'live' well without killing it, using a valve body with a through bore, cable hanger with seals and electrical contacts, and orienting tools to bypass seal sections and make fluid and electrical connections without disrupting well operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high density kill fluid is used to kill the well, then the well is unable to move fluid to surface, but this reduces productivity and requires expensive equipment and storage
Solution Approach 1:
The master valve is divided into separate functional sections: a valve body with throughbore for fluid flow, a cable hanger section for tool deployment, and a seal area. This segmentation allows the well to remain active for fluid production while enabling cable and tool installation without requiring well killing.
Solution Approach 2:
A blanking plug is used as an intermediary element to seal the transverse bore during well operations. This allows the well to maintain productivity while the cable hanger and tools are deployed through the throughbore, eliminating the need for high-density kill fluid.
2Ease of manufacture
If the well is killed to deploy ESP, then pump deployment is enabled, but this requires transport of pumping equipment and storage of kill fluid
Solution Approach 1:
The master valve assembly serves multiple functions: it controls well flow through the valve closure element, accommodates cable deployment through the throughbore, and provides sealing for electrical connections. This multi-functionality eliminates the need for separate kill fluid storage and handling equipment.
Solution Approach 2:
The cable hanger and electrical connection components are extracted as separate modular elements that can be deployed through the throughbore without requiring the entire well system to be shut down or killed, reducing equipment and storage requirements.
3Reliability
If high density kill fluid is used to kill the well, then well control is achieved, but permeability in near-wellbore area is reduced
Solution Approach 1:
The blanking plug acts as a mediator to provide sealing in the transverse bore without introducing high-density fluid into the near-wellbore area, thus maintaining permeability while achieving well control during ESP deployment.
Solution Approach 2:
The harmful effect of high-density kill fluid is eliminated by extracting the well killing function and replacing it with a mechanical sealing approach using the blanking plug and valve closure element, which controls fluid flow without reducing near-wellbore permeability.
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 the installation of ESPs in live wells without killing the well, reducing costs and maintaining well productivity by avoiding fluid displacement and flowline adjustments, while facilitating electrical connections through existing well trees.
Implementation Method 1
The cable hanger has a seal section having longitudinally spaced apart seals engageable with an interior of the seal area
Implementation Method 2
A valve closure element is arranged to close the through bore
Implementation Method 3
A flow port is arranged to bypass the seal section, and penetrates at least one of the seal section and the seal area
Implementation Method 4
electrical contacts disposed between the seals
Data Source
AI summary
Master valve and cable hanger system for deploying and making electrical connection to an electric submersible pump. A landing for the cable hanger (50) is in the through bore below the valve closure element. The landing has a seal area and a bore transverse to the through bore penetrating into the seal area for allowing electric connection to the pump. The cable hanger has a seal section having longitudinally spaced apart seals engageable with an interior of the seal area, electrical contacts disposed between the seals, and a lockdown profile. Flow ports are arranged to bypass seal area and seal section. A blanking plug (58) is disposed in the transverse bore to seal the seal area prior to insertion of the cable hanger.