Subsea Power Control Pod for Electric Submersible Pump Deployment
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Solution Overview
Problem
Current subsea artificial lift systems require costly and complex well intervention methods for deploying and retrieving electric submersible pumps, especially in offshore and remote locations, due to the need for heavy weight fluid injection to manage well pressure, which increases costs and reduces reliability.
Innovation Solution
A subsea power and control pod system that converts direct current power from a dry location to alternating current for electric submersible pumps, using a diplexer to separate power and command signals, and a motor controller to supply three-phase power, allowing for remote operation and maintenance of subsea ESPs without the need for heavy weight fluid injection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heavy weight fluid injection is used to manage well pressure during deployment and retrieval, then well control is improved, but operational cost and system complexity increase
Solution Approach 1:
The patent extracts the power conversion and control functions from the traditional ESP deployment system by introducing a separate control pod. This control pod contains a power converter that transforms single-phase power from the umbilical cable into three-phase power for the ESP motor, eliminating the need for heavy weight fluid injection and associated well control procedures during deployment and retrieval operations.
Solution Approach 2:
The control pod acts as an intermediary device between the umbilical cable and the ESP motor. It receives single-phase power through the umbilical, converts it to three-phase power, and supplies it to the ESP motor. This intermediary power conversion system enables direct electrical control of the ESP without requiring mechanical intervention or heavy weight fluid injection.
2Reliability
If heavy weight fluid injection is used to manage well pressure, then well control is improved, but operational cost increases
Solution Approach 1:
The patent replaces the mechanical well control system (heavy weight fluid injection) with an electrical power conversion system. The control pod's power converter electronically transforms single-phase power to three-phase power, enabling direct electrical actuation of the ESP motor and eliminating the need for mechanical fluid injection processes, thereby reducing operational costs associated with well intervention.
3Ease of manufacture
If traditional deployment methods with mechanical cable fastening are used, then equipment deployment is achieved, but intervention cost and time increase
Solution Approach 1:
The patent introduces dynamic control capabilities through the control pod, which can remotely adjust ESP motor parameters and operational characteristics in real-time. This dynamic electrical control system replaces static mechanical deployment methods, allowing for flexible adjustment of pump speed, power consumption, and operational parameters without requiring physical intervention or time-consuming well servicing operations.
4Ease of operation
If coiled tubing is used to support equipment weight, then deployment improvement is achieved, but reliability and availability decrease due to unit constraints
Solution Approach 1:
The patent segments the traditional integrated ESP deployment system into separate functional components: an umbilical cable for power transmission, a control pod for power conversion and control, and the ESP motor itself. This segmentation allows each component to be optimized independently, with the control pod providing reliable three-phase power conversion that enhances overall system availability and reduces dependence on specialized coiled tubing units.
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 efficient and cost-effective deployment and retrieval of subsea ESPs by reducing the need for heavy weight fluid injection, improving reliability and reducing operational costs in offshore and remote locations.
Implementation Method 1
converting the DC power signal to an alternating current (AC) power signal by the control pod
Implementation Method 2
a diplexer for separating a composite signal received by the umbilical into a DC power signal and a command signal
Implementation Method 3
a power supply for reducing voltage of the DC power signal from medium to low
Data Source
AI summary
Embodiments of the present invention generally relate to a power and control pod for subsea artificial lift system. In one embodiment, a method of operating a downhole tool in a subsea wellbore includes: supplying a direct current (DC) power signal from a dry location to a subsea control pod; converting the DC power signal to an alternating current (AC) power signal by the control pod; and supplying the AC power signal from the control pod, into the subsea wellbore, and to the downhole tool.