Wet Connect Tool for ESP Replacement Without Pulling Completion

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Solution Overview

Problem

The existing systems for replacing electric submersible pumps (ESPs) in wells are costly and time-consuming, as they require pulling the entire upper completion out of the well, which is not efficient due to the short lifespan of ESPs compared to other completion equipment.

Innovation Solution

A wet connect system is implemented, where a connector inside the production tubing allows the ESP to be electrically coupled and decoupled without removing the upper completion, enabling the ESP to be retrieved and replaced without disturbing the tubular structure or power cabling, using wireline, slickline, or coiled tubing for installation and removal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of repair

If the entire upper completion is pulled out to replace the ESP, then the ESP can be replaced, but the operation becomes costly and time-consuming

Engineering Contradiction:

ImproveESP replacement capabilityVSAvoidESP replacement time

Core Design Contradiction:

Ease of repairVSLoss of time

Solution Approach 1:

The system divides the upper completion into separable components: a permanent connector assembly that remains in the well and a removable ESP. The connector is segmented into a setting tool portion and a receptacle portion, allowing the ESP to be replaced independently without removing the entire upper completion, thereby reducing replacement time and cost.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A connector assembly serves as an intermediary between the ESP and the upper completion. This connector includes a setting tool with a piston that can be lowered to engage with a receptacle in the production tubing, creating a mechanical and electrical connection that allows ESP replacement without removing the completion.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of repair

If the entire upper completion is pulled out to replace the ESP, then the ESP can be replaced, but operational costs increase

Engineering Contradiction:

ImproveESP replacement capabilityVSAvoidOperational cost

Core Design Contradiction:

Ease of repairVSLoss of energy

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connector assembly is pre-installed in the production tubing before the ESP is deployed. The setting tool is lowered and engaged with the receptacle in advance, establishing the connection infrastructure beforehand. This preliminary action enables quick ESP replacement without costly completion removal.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11441363B2ESP tubing wet connect tool

Publication Date: 2022.09.13 BAKER HUGHES OILFIELD OPERATIONS LLC

AI summary

Systems and methods for installing and removing a downhole electric tool in a well, independent of an upper completion in the well. A connector on the interior of a tubular structure (e.g., production tubing or casing) serves as an electrical socket for the tool. This connector is coupled to electrical cables which run from the connector to the surface. The tool, which is raised and lowered on a wireline, slick line or coiled tubing, is plugged into this connector so the tool can be pulled from the socket using the wireline/slick line/coiled tubing and removed from the well without having to remove the tubular structure or other parts of the completion. A replacement tool can then be lowered into the tubular structure and, when the tool lands on the connector, it engages the connector and couples the tool through the cabling to the surface equipment.