Self-Supporting ESP Cable for Wireline Deployment and Retrieval
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Solution Overview
Problem
Conventional electric submersible pumping systems face challenges with rigid production tubing deployment, including high costs and difficulties in retrieval, and wireline deployment systems that suffer from wet connections and wireline corrosion due to unsupported power cables.
Innovation Solution
A self-supporting power cable system is deployed using a wireline, where the power cable is attached to the pumping system and supports its weight, allowing for retrieval of the wireline and preventing corrosion, with a landing assembly that supports the pumping system and includes a subsurface safety valve for fail-safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid production tubing is used to deploy electric submersible pumping systems, then the system can be deployed and retrieved, but the cost increases and workover rig availability becomes difficult
Solution Approach 1:
The patent removes the powered docking assembly from the production tubing, extracting the problematic wet connection component. The power cable is instead banded to the wireline, allowing the wireline to serve dual purposes: deploying the pump and providing power, while eliminating the need for a complex docking assembly in the production tubing.
Solution Approach 2:
The wireline is given multiple functions: it serves as both the deployment mechanism for the electric submersible pumping system and as the support structure for the power cable. This multi-functionality eliminates the need for separate powered docking assemblies and reduces overall system complexity.
2Ease of operation
If power cable is banded to wireline for support, then the pumping system can be deployed by wireline, but the wireline cannot be removed and may corrode over time
Solution Approach 1:
The power cable is banded to the wireline before deployment, preparing the system in advance. The band is designed to release automatically when the wireline is paid out, allowing the power cable to then support itself and the pumping system during operation, while the wireline can be retrieved without the power cable attached.
Solution Approach 2:
The connection between the power cable and wireline transitions from a static bonded state to a dynamic released state. The band holds them together during deployment, then releases to allow the power cable to function independently, enabling the wireline to be retrieved while the power cable remains in place.
3Reliability
If powered docking assembly is used at lower end of production tubing, then power cable can be banded to production tubing, but wet connection is subject to failure
Solution Approach 1:
The powered docking assembly is completely removed from the system. Instead of having a complex docking assembly at the lower end of the production tubing, the patent uses a simple band to attach the power cable to the wireline during deployment, then releases it to allow the power cable to function independently.
Solution Approach 2:
The wireline serves as an intermediary during deployment, temporarily supporting the power cable through a simple band connection. This intermediary role eliminates the need for a complex powered docking assembly while ensuring reliable power transmission during the deployment process.
4Ease of operation
If wireline is used to support power cable during deployment, then pumping system can be deployed, but wireline corrosion risk increases with prolonged exposure
Solution Approach 1:
The band is attached to the wireline in advance of deployment, preparing the power cable support structure beforehand. During deployment, the band provides temporary support, then automatically releases when the wireline is paid out, allowing the wireline to be retrieved without prolonged exposure to corrosive well fluids.
Solution Approach 2:
The wireline is discarded from the wellbore after deployment by releasing the band connection. This allows the wireline to be recovered before it can corrode from prolonged exposure to well fluids, while the power cable remains in place to continue supporting the pumping 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
This solution enables efficient and cost-effective deployment and retrieval of electric submersible pumping systems, preventing wet connections and corrosion, while ensuring reliable operation and safety through the use of a self-supporting power cable and landing assembly.
Implementation Method 1
the power cable is attached to the pumping system and supports its weight
Implementation Method 2
a landing assembly that supports the pumping system and includes a subsurface safety valve for fail-safe operation
Data Source
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AI summary
A submersible pumping system for use in producing wellbore fluids from a wellbore within a subterranean formation includes a motor and a pump driven by the motor to produce the wellbore fluids. The pumping system further includes a self-supporting power cable connected to the pump. The self-supporting power cable includes a plurality of conductors and a plurality of strength members. A method of deploying and retrieving a submersible pumping system in a wellbore includes the steps of connecting a wireline to the submersible pumping system, connecting a self-supporting power cable to the submersible pumping system, lowering the submersible pumping sy stem into the wellbore while the weight of the submersible pumping system is borne by the wireline. The method continues with the step of locating the submersible pumping system on a landing assembly, disconnecting the wireline from the submersible pumping system, and retrieving the wireline from the wellbore without removing the submersible pumping system from the wellbore.