Modular Gauge Package for Wet-Connect ESP Systems

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Solution Overview

Problem

Conventional ESP systems with wet connections require expensive and time-consuming removal of tubing and equipment for maintenance or repair, as gauges cannot be conventionally attached to the bottom of the pump motor due to interference with the wet connection system.

Innovation Solution

A modular gauge package with complementary electrical connectors that allow gauges to be added to existing pump motors, enabling power and communication signals to be passed through the gauge package while maintaining the wet connection, allowing the ESP system to be lowered into the well without interfering with the existing connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If gauges are conventionally attached to the bottom of the pump motor, then gauge functionality is achieved, but the wet connection system cannot be properly configured

Engineering Contradiction:

Improvegauge compatibilityVSAvoidconnection system complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The gauge system is segmented into a separate modular gauge package that can be independently attached to the pump motor, rather than integrating the gauge into the motor assembly. This allows the gauge to be added as a separate component without interfering with the wet connection system configuration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A modular gauge package serves as an intermediary component between the pump motor and the wet connection system. The gauge package includes connectors that interface with both the motor and the production conduit, allowing it to function without requiring redesign of the motor or disruption of the wet connection system.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of repair

If the tubing and cable are pulled out of the well for maintenance, then equipment can be accessed and repaired, but expensive rig operations are required and production is impacted

Engineering Contradiction:

Improveequipment accessibilityVSAvoidproduction downtime

Core Design Contradiction:

Ease of repairVSLoss of time

Solution Approach 1:

The gauge is designed as a separate modular package that can be independently accessed and replaced without requiring removal of the entire tubing string or cable assembly. This segmentation allows for easier maintenance operations and reduced production impact.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The modular gauge package is pre-configured with all necessary connectors and components before being attached to the pump motor. This preliminary preparation allows for quick replacement and maintenance operations, reducing the time required for repair activities and minimizing production downtime.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If the pump motor is redesigned to incorporate gauge sensors and electronics, then gauge functionality is integrated, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvegauge integrationVSAvoidmotor manufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The gauge system is separated from the pump motor into an independent modular package. This segmentation allows the motor to be manufactured without incorporating gauge sensors and electronics, maintaining existing manufacturing processes and reducing complexity. The gauge package can be attached separately to existing motors.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The modular gauge package is designed to be universally compatible with existing pump motors that have wet connection systems. The standardized connectors and interface designs allow the same gauge package to be attached to various motor configurations without requiring motor redesign or customization.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 use of gauges in wet-connect ESP systems without redesigning the pump motor, facilitating easier maintenance and reducing the need for costly rig operations by allowing the ESP system to be lowered and operated within the well without disrupting the power connection.

Implementation Method 1

power is passed through the body from one connector to the other

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS8821137B2Modular down hole gauge for use in retrievable electric submersible pump systems with wet connect

Publication Date: 2014.09.02 BAKER HUGHES CO

AI summary

Systems and methods for employing gauge packages for use with a wet-connect ESPs. In one embodiment, a modular gauge package includes a body, a gauge electronics assembly housed within the body, and a pair of electrical connectors at the upper and lower ends of the body, where power is passed through the body from one connector to the other. The electrical connector at the top of the body engages a complementary electrical connector on the bottom of a pump motor. The electrical connector at the bottom of the body engages a complementary electrical connector at the end of a production conduit. The connector at the bottom of the body may be identically configured with the connector at the bottom of the pump motor, and the connector at the top of the body may be identically configured with the connector at the end of the production conduit.