Submersible Pump Control Valve for Continuous Well Access
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Solution Overview
Problem
Existing submersible pump systems face challenges in accessing the production zone of a well bore for maintenance or operations while the pumping device is in use, as they obstruct direct mechanical access and require costly and time-consuming procedures, such as using Y-tools with flappers that are prone to mechanical failure and require significant downtime for repair.
Innovation Solution
A submersible pump system incorporating a Y-tool, a control valve assembly, and a power conduit that allows selective access to the production zone by transmitting control signals through the power conduit, enabling the submersible pumping device to operate continuously and the control valve to open independently of the pumping device's operation, allowing tools to traverse through the system without interrupting fluid production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a Y-tool with flapper is used to access the production zone, then mechanical access is enabled, but the system experiences mechanical failure risk and requires pump shutdown
Solution Approach 1:
The patent replaces the mechanical flapper system with an electrically actuated valve assembly. The control valve receives electrical signals through the power conduit to open or close, eliminating the need for mechanical flappers that are prone to failure. This substitution of mechanical actuation with electrical control resolves the reliability issue while maintaining access capability.
Solution Approach 2:
The patent extracts the access control function from the pump mechanism itself and places it in a separate control valve assembly. This allows the pump to continue operating independently while the valve controls access to the production zone, eliminating the need to shut down the pump for access operations.
2Ease of operation
If a Y-tool with flapper is used to access the production zone, then mechanical access is enabled, but pump operation must be interrupted
Solution Approach 1:
The patent extracts the access control function from the pump mechanism and places it in a separate control valve assembly. This allows the pump to continue operating independently while the valve controls access to the production zone, enabling maintenance operations without interrupting fluid production.
Solution Approach 2:
The patent enables continuous pump operation by using an electrically actuated valve that can be opened or closed independently of the pump's mechanical operation. The pump maintains continuous fluid production while the valve provides intermittent access to the production zone, ensuring uninterrupted useful action.
3Ease of operation
If auto Y-tool is used to access the production zone, then access is enabled, but replacement requires work over rig and extensive downtime
Solution Approach 1:
The power conduit serves multiple functions: it provides electrical power to the submersible pump and simultaneously transmits control signals to the control valve assembly. This multi-functionality eliminates the need for separate control wiring and simplifies the system, reducing complexity and potential failure points while maintaining access capability.
Solution Approach 2:
The patent replaces the mechanical flapper system with an electrically actuated valve assembly controlled through the power conduit. This eliminates the need for mechanical replacement operations using work over rig, as the electrical valve can be replaced or repositioned more easily without requiring extensive downtime and specialized equipment.
4Adaptability or versatility
If repeated use of auto Y-tool is made to access the production zone, then access operations can be performed, but wear and tear on pump and flapper increases
Solution Approach 1:
The patent replaces the mechanical flapper system with an electrically actuated valve assembly. The valve is positioned in the bypass branch rather than directly in the pump's flow path, reducing mechanical wear on the pump. Electrical actuation eliminates the wear associated with repeated mechanical flapper operation, extending the operational life span of both the pump and access control mechanism.
Solution Approach 2:
The control valve assembly acts as an intermediary between the control system and the production zone access. By positioning the valve in the bypass branch and using it to control access, the system reduces direct mechanical interaction between the pump and access operations, minimizing wear and tear on the pump while maintaining adaptability for access operations.
Data Source
AI summary
A submersible pump system that is operable to permit selective access into a production zone of a well bore while a submersible pumping device is operating includes a Y-tool, a submersible pumping device, a control valve assembly and a power conduit. The control valve assembly is also operable to selectively permit access between the interior of the submersible pumping system and the exterior of the submersible pumping system. The valve is operable to form a dynamic seal. The power conduit is operable to convey both power and a pre-designated control signal simultaneously. A method for accessing the production zone of the well bore with a well bore tool uses the submersible pump system while the submersible pump system is producing production zone fluid. The submersible pumping device continues to operate without interruption after transmission of the pre-designated pump control signal.