Artificial Lift Power Cable Shielding for Downhole Stress
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Solution Overview
Problem
Current artificial lift equipment, such as electric submersible pumps (ESPs), face challenges in reliability and efficiency due to harsh downhole environments, including high temperatures, pressures, and corrosive conditions, which affect cable integrity and lead to increased non-productive time and costs, especially in deep installations.
Innovation Solution
The development of a power cable with multiple conductor assemblies, each comprising a copper conductor, conductor shield, insulation, insulation shield, metallic shield, and polymer barrier, surrounded by a jacket and armor, designed to withstand harsh conditions and enhance reliability through improved electrical stress management and mechanical protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional ESP cables are used in harsh downhole environments, then the cable structure is simple and cost is low, but reliability deteriorates due to corrosion, high pressure, and temperature affecting cable integrity
Solution Approach 1:
The cable is divided into multiple conductor assemblies (typically three), each independently shielded and insulated. Each assembly contains a conductor, conductor shield, insulation layer, and insulation shield, creating modular units that can be individually protected and replaced if needed.
Solution Approach 2:
The cable structure employs nested shielding layers where conductor shields surround individual conductors, insulation shields surround the insulation layers, and an outer metallic shield surrounds all conductor assemblies. This nested arrangement provides progressive electrical stress management and protection at each level.
Solution Approach 3:
The cable utilizes composite material construction combining copper conductors with semiconductive polymer shields, cross-linked polyethylene insulation, metallic armor layers, and protective jackets. This composite structure provides simultaneous electrical, mechanical, and environmental protection.
2Length of moving object
If cable length is increased for deep installations, then the ability to reach deepwell targets is improved, but failure risk increases and non-productive time increases
Solution Approach 1:
The cable is pre-assembled with all shielding, insulation, and protective layers in place before deployment. Motor lead extensions are pre-spliced to the cable during manufacturing, ensuring proper electrical connections and stress management are established before the cable enters the harsh downhole environment.
Solution Approach 2:
Multiple protective layers including conductor shields, insulation shields, and outer metallic shields are applied in advance to cushion against electrical stress, corrosion, and mechanical damage that will occur during long-term deepwell 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
The enhanced power cable improves the reliability and longevity of ESP operations by providing better resistance to corrosion, high pressures, and temperature fluctuations, reducing the risk of failure and associated costs in deepwater and high-temperature applications.
Implementation Method 1
a conductor shield with resistivity less than about 5000 ohm-m surrounding the conductor
Implementation Method 2
an insulation shield having a resistivity less than about 5000 ohm-m surrounding the insulation
Data Source
AI summary
A power cable for artificial lift equipment can include one or more conductor assemblies, each including a copper conductor, a conductor shield with resistivity less than about 5000 ohm-m surrounding the conductor, insulation, an insulation shield having a resistivity less than about 5000 ohm-m surrounding the insulation, a metallic shield surrounding the insulation shield, and a polymer barrier surrounding the metallic shield. Such a cable may include a jacket molded about the one or more conductor assemblies and optionally armor surrounding the jacket. Various other apparatuses, systems, methods, etc., are also disclosed.