Retrievable Artificial Lift System with Segmented Stator
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Solution Overview
Problem
Artificial lift systems in wells often fail due to electrical system failures, leading to costly workover procedures and lost production, as these systems are exposed to hostile downhole environments and have integrated electrical components with rotating and non-rotating parts, reducing reliability.
Innovation Solution
A retrievable string system with a stator and electromagnetic coil configuration that separates electrical components from rotating parts, using a magnetic bearing system and cooling circuit to enhance reliability and facilitate quick replacement, thereby reducing maintenance and production losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical components are integrated with rotating and non-rotating parts in artificial lift systems, then the system can function as a complete artificial lift solution, but the reliability deteriorates due to exposure to hostile downhole environments and potential failures
Solution Approach 1:
The system is divided into separate functional modules: a retrievable string containing the rotor and coupling part, and a stator containing the electromagnetic coil and electrical components. This segmentation allows the electrical components to be isolated in the stator while the rotor can be independently retrieved for maintenance, improving reliability by preventing cascade failures from integrated systems.
Solution Approach 2:
The rotor string is extracted as a separate retrievable component from the complete artificial lift system. The coupling part enables the rotor to be detached and retrieved independently through the completion string, separating the rotating mechanical components from the stationary electrical components in the stator, thereby improving maintenance access and system reliability.
2Reliability
If workover procedures are performed to maintain artificial lift equipment, then equipment reliability can be restored, but lost production occurs during the workover process
Solution Approach 1:
The rotor is segmented as a separate retrievable string that can be independently accessed and replaced. This allows maintenance to be performed on only the rotating components without requiring complete system shutdown or complex workover procedures, reducing production loss while restoring equipment reliability.
Solution Approach 2:
The rotor string is designed to be retrievable and replaceable as a separate component. When maintenance is needed, the rotor can be retrieved through the completion string and replaced with a new or refurbished unit, allowing quick restoration of reliability with minimal production interruption compared to traditional workover procedures.
3Loss of time
If the rotor is made retrievable through the completion string, then maintenance time and production loss are reduced, but the coupling mechanism becomes more complex
Solution Approach 1:
The coupling part serves multiple functions: it connects the rotor to the stator during operation, provides a retrieval mechanism for the rotor string, and enables reconnection after maintenance. This multi-functional coupling design reduces maintenance time while managing complexity through integrated rather than separate mechanisms.
Solution Approach 2:
The coupling part acts as an intermediary component between the rotor and the completion string. It provides a standardized interface that simplifies the retrieval and reconnection process, reducing maintenance time while the complexity is contained within the coupling mechanism itself rather than the overall system.
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 system improves the reliability of artificial lift systems, reduces the frequency of workover procedures, and minimizes lost production by isolating electrical components from hostile environments and allowing for quick replacement of retrievable strings, resulting in lower capital and maintenance costs over the well's life.
Implementation Method 1
The system can include an electromagnetic coil configured to generate a first magnetic field in response to the electromagnetic coil receiving power, to engage the motor permanent magnet and cause the rotor to rotate.
Implementation Method 2
The actuator can be configured to generate a second magnetic field to engage the magnetic bearing target and counteract a mechanical load of the retrievable string.
Data Source
AI summary
A system for use in a completion string of a well is described. The system includes a coupling part configured to detachably couple a retrievable string to the system. The system includes a stator configured to attach to a tubing of the completion string. While the retrievable string is coupled to the system, the stator is configured to drive a rotor of the retrievable string in response to receiving power.