Wellhead Cable Cooling Layout for Downhole Connector Reliability

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Solution Overview

Problem

High failure rates in downhole electrical equipment, particularly in electric submersible pumps and heaters, due to electrical cable system failures, especially at connection points, which are exacerbated by extreme temperature and pressure conditions in hydrocarbon recovery processes like SAGD.

Innovation Solution

A system and process that includes a cooling section along the piping for downhole electrical cables and an electrical connector positioned outside the wellhead, where temperatures and pressures are lower, to reduce the risk of electrical shorting and failure, featuring a passageway through the wellhead sidewall and pipe spools with seals and a cooling radiator to maintain the electrical wires and connector at a cooler temperature.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If electrical cables are exposed to downhole conditions for powering submersible pumps and heaters, then the equipment can function at depth, but the cables suffer from high failure rates due to electrical shorting at connection points

Engineering Contradiction:

Improvecable system reliabilityVSAvoidelectrical shorting at connection points

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The electrical connector is extracted from the downhole environment and positioned outside the wellhead where temperatures and pressures are lower. This removes the connection point from the harsh thermal and pressure conditions that cause electrical shorting, thereby improving cable system reliability without sacrificing downhole equipment functionality

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

A cooling section is introduced as an intermediary component between the downhole environment and the electrical connector. This cooling section, which may include pipe spools with seals and a cooling radiator, maintains the electrical wires and connector at lower temperatures, preventing electrical shorting while still allowing power transmission to downhole equipment

Inventive Principle:

Principle #24Intermediary (Mediator)

2Power

If electrical cables extend from wellhead to downhole equipment, then power can be delivered to submersible pumps, but the cables are exposed to extreme temperatures causing failure

Engineering Contradiction:

Improvepower delivery to downhole equipmentVSAvoidextreme downhole temperatures

Core Design Contradiction:

PowerVSTemperature

Solution Approach 1:

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The electrical connector is repositioned from the traditional downhole location to an uphole location outside the wellhead. This spatial repositioning moves the connector out of the extreme temperature zone while maintaining the vertical power transmission path, thereby protecting the connection point from thermal damage

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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

Significantly reduces the failure rates of downhole electrical equipment by maintaining the electrical connector and wires at lower temperatures and pressures, thereby extending their lifespan and improving the reliability of hydrocarbon production systems.

Implementation Method 1

A cooling section is disposed along the piping through which the electrical wires pass

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS11851990B2System and process for installing a hydrocarbon production system

Publication Date: 2023.12.26 CENOVUS ENERGY INC

AI summary

A system for use in hydrocarbon production includes a well that has a wellhead and extends downhole into a reservoir. The wellhead has a passageway that extends through a sidewall thereof. The system includes piping extending from the wellhead at the passageway. A downhole electrical device is disposed downhole in the well. A cable is coupled to the downhole electrical device and includes electrical wires extending from the downhole electrical device, out of the wellhead, through the passageway in the sidewall, and along the piping. A cooling section is disposed along the piping through which the electrical wires pass, and an electrical connector is coupled to the electrical wires for electrical connection thereto such that the wires extend along the cooling section between electrical connector and the wellhead.