Redundant Wet Connector System for ESP Power Supply
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Solution Overview
Problem
Fixed power supply systems in hydrocarbon wells are vulnerable to failures of fixed cabling and wet connectors, requiring surface recovery for repairs, which disrupts well operations and fluid flow.
Innovation Solution
A redundant wet connection system with an ESP that can be reconfigured to engage alternative fixed wet connectors, allowing for power supply redundancy and maintenance without affecting fluid flow, using a tubular spacer to adjust the position of the wet connector relative to the orientation element for alignment with either of two fixed connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a fixed power supply system with fixed cabling is used, then the central bore of production tubing remains clear for unobstructed flowpath and tool introduction, but the system becomes vulnerable to failures requiring surface recovery for repairs
Solution Approach 1:
The system is divided into modular components: fixed cabling segments, movable wet connectors, and the ESP pump. The wet connectors can be independently positioned and repositioned along the production tubing, allowing the system to maintain functionality even if one connector or cable segment fails, without requiring complete surface recovery.
Solution Approach 2:
The wet connectors are designed to be movable rather than fixed, allowing them to be repositioned along the production tubing. This dynamic capability enables the system to adapt to failures by moving connectors to alternative connection points, maintaining reliability while preserving the clear central bore for flow and tool access.
2Adaptability or versatility
If fixed cabling is used for power supply, then the ESP can be remotely connected via wet connector, but failures in fixed cabling or wet connector cannot be repaired without recovering tubing to surface
Solution Approach 1:
The movable wet connector acts as an intermediary between the fixed cabling and the ESP. It can be detached from the ESP and repositioned along the production tubing to connect to different cable segments, serving as a flexible interface that improves repair accessibility without compromising remote connection capability.
Solution Approach 2:
The system allows for discarding or replacing individual wet connectors or cable segments without requiring recovery of the entire production tubing. The modular design enables selective replacement of failed components, significantly improving ease of repair while maintaining remote operation capability.
3Device complexity
If the ESP is connected to a single fixed wet connector, then the connection is simple, but the system is critically dependent on the integrity of that single connection point
Solution Approach 1:
The wet connectors are designed with universal engagement capability, allowing a single connector type to engage with multiple fixed wet connectors positioned at different locations along the production tubing. This multi-functionality enables the ESP to connect to alternative points if one connection fails, improving reliability while maintaining relatively simple connection mechanics.
Solution Approach 2:
Multiple fixed wet connectors are installed at different locations along the production tubing before deployment, providing pre-positioned backup connection points. This beforehand cushioning ensures that if one connection point fails, alternative connections are already in place, reducing the impact of connection failures while maintaining system simplicity.
Data Source
AI summary
A wet connection system comprises a fixed tubing with an orientation profile and redundant, first and second fixed wet connectors, and an electrical submersible pump assembly (ESP) comprising a wet connector and an orientation element for engaging the orientation profile. The ESP can be reconfigured, for example, by interchanging its component modules so as to change the position of its wet connector with respect to the orientation element, whereby the wet connector on the ESP can be engaged alternatively with either one of the fixed wet connectors when the orientation element is engaged with the orientation profile in the same deployed position of the ESP.