US20170051593A1

US20170051593A1 - System and Method for Powering and Deploying an Electric Submersible Pump

Info

Publication number: US20170051593A1
Application number: US15/204,073
Authority: US
Inventors: Michael C. Romer; William A. Symington; Randy C. Tolman
Original assignee: Individual
Current assignee: Individual
Priority date: 2015-08-21
Filing date: 2016-07-07
Publication date: 2017-02-23
Also published as: US10132143B2; US20170051592A1

Abstract

A system for deploying and powering an electric submersible pump within a subterranean well. The system includes a tubing string having a wall forming a first conductive path, one end of which is connected to the electric submersible pump; and a second conductive path, wherein the first conductive path and the second conductive path form a circuit for supplying power to the electric submersible pump. A method for deploying and powering an electric submersible pump within a subterranean well is also provided.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 62/208,025, filed Aug. 21, 2015, entitled “System and Method for Powering and Deploying an Electric Submersible Pump,” the entirety of which is incorporated by reference herein. This application is also related to and claims the benefit of U.S. Provisional Application No. 62/209,596, filed Aug. 25, 2015 (Attorney Docket No. 2015EM137), entitled, “System and Method for Powering and Deploying an Electric Submersible Pump,” the disclosure of which is incorporated by reference in its entirety.

FIELD

The present disclosure relates to systems and methods for deploying and powering electric submersible pumps.

BACKGROUND

The utility of electric submersible pumps (ESPs) is sometimes limited by conventional deployment and retrieval methods. A conventional ESP may be installed with a tubing string, requiring a full rig to perform the work. Such installations can be costly, particularly in offshore and remote locations, frequently making ESP installations and retrievals economically prohibitive. As such, a desirable deployment method would avoid the need for a rig and allow the assembled ESP system to be “stripped” into the well through-tubing. Coiled-tubing and cable deployed ESPs have been developed that meet these requirements, but they still have limitations.
The most flexible commercially available coiled-tubing-deployed system employs an internally-installed cable. The cable used is pumped into the coiled tubing, with 10,000 feet the greatest length that vendors have been able to install. A three-phase, No. 2 AWG cable inside of 1¾″ coiled tubing represents a typical application. The cable may or may not be anchored inside the coiled tubing, and thermal expansion/contraction effects may be a concern. As may be appreciated, the cable-in-coiled-tubing reel is quite heavy, and lifting operations can challenge offshore cranes; certain platforms may require a support barge for installation. The system cannot easily be spliced, which means the entire string can be lost if there is an issue. Spooling and straightening of the reel can weaken or damage the cable and limit re-use.
Despite these advances, what is needed are improved systems and methods for deploying and powering an electric submersible pump within a subterranean well, which enable deployment at depths greater than about 10,000 feet.

SUMMARY

In one aspect, disclosed herein is a system for deploying and powering an electric submersible pump within a subterranean well. The system includes a tubing string having a wall forming a first conductive path, one end of which is connected to the electric submersible pump; and a second conductive path, wherein the first conductive path and the second conductive path form a circuit for supplying power to the electric submersible pump.
In some embodiments, the subterranean well comprises a casing and production tubing positioned within the casing, the interior surface of the casing and the exterior surface of the production tubing defining an annular space.
In some embodiments, the production tubing forms the second conductive path.
In some embodiments, the tubing string includes a conductive metallic material, the outer surface of which is coated with an insulating, non-conductive material.
In some embodiments, the subterranean well includes a casing which forms an annulus with the tubing string, the casing forming the second conductive path.
In some embodiments, the electric submersible pump includes an ESP motor, the ESP motor selected from a two-phase AC ESP motor or a DC ESP motor.
In some embodiments, the system further includes a downhole DC-to-AC inverter for powering a three-phase AC ESP motor.
In some embodiments, the system further includes a third conductive path to power a three-phase AC ESP motor.
In some embodiments, the electric submersible pump includes at least one sensor and power is transmitted through the system to power the electric submersible pump.
In some embodiments, a signal is impressed upon the power transmitted to provide a communications link between the electric submersible pump sensors and surface systems.
In another aspect, disclosed herein is a method for deploying and powering an electric submersible pump within a subterranean well. The method includes providing a tubing string having a wall forming a first conductive path, connecting the tubing string to the electric submersible pump; positioning the tubing string and electric submersible pump within the subterranean well; providing a second conductive path; and forming a circuit for supplying power to the electric submersible pump, the circuit comprising the first conductive path and the second conductive path.
In some embodiments, the subterranean well comprises a casing and production tubing positioned within the casing, the interior surface of the casing and the exterior surface of the production tubing defining an annular space.
In some embodiments, the production tubing forms the second conductive path.
In some embodiments, the tubing string includes a conductive metallic material, the outer surface of which is coated with an insulating, non-conductive material.
In some embodiments, the subterranean well includes a casing which forms an annulus with the tubing string, the casing forming the second conductive path.
In some embodiments, the electric submersible pump includes an ESP motor, the ESP motor selected from a two-phase AC ESP motor or a DC ESP motor.
In some embodiments, the method further includes a downhole DC-to-AC inverter for powering a three-phase AC ESP motor.
In some embodiments, the method further includes a third conductive path to power a three-phase AC ESP motor.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 presents a schematic view of a conventional system for deploying and powering an electric submersible pump within a subterranean well.

FIG. 2 presents a schematic view of yet another illustrative, nonexclusive example of a system for deploying and powering an electric submersible pump within a subterranean well, according to the present disclosure.

FIG. 3 presents another method for deploying and powering an electric submersible pump within a subterranean well, according to the present disclosure.

DETAILED DESCRIPTION

In FIGS. 1-3, like numerals denote like, or similar, structures and/or features; and each of the illustrated structures and/or features may not be discussed in detail herein with reference to the figures. Similarly, each structure and/or feature may not be explicitly labeled in the figures; and any structure and/or feature that is discussed herein with reference to the figures may be utilized with any other structure and/or feature without departing from the scope of the present disclosure.
In general, structures and/or features that are, or are likely to be, included in a given embodiment are indicated in solid lines in the figures, while optional structures and/or features are indicated in broken lines. However, a given embodiment is not required to include all structures and/or features that are illustrated in solid lines therein, and any suitable number of such structures and/or features may be omitted from a given embodiment without departing from the scope of the present disclosure.
FIGS. 2-3 provide illustrative, non-exclusive examples of methods and systems for deploying and powering electric submersible pumps within subterranean wells, according to the present disclosure, together with elements that may include, be associated with, be operatively attached to, and/or utilize such a method or system.
Although the approach disclosed herein can be applied to a variety of subterranean well designs and operations, the present description will primarily be directed to for deploying and powering electric submersible pumps within subterranean wells.
FIG. 1 presents, for illustrative purposes, a schematic view of a conventional system 10 for deploying and powering an electric submersible pump 12 within a subterranean well 14. As shown, the subterranean well 14 includes a casing 16 and production tubing 18 positioned within the casing 16. The interior surface 20 of the casing 16 and the exterior surface 22 of the production tubing 18 serve to define an annular space A.
The system 10 includes a tubing string 24, which may be formed from a coiled tubing 26. Tubing string 24 includes a wall 28 forming a hollow interior 30. One end 32 of the tubing string 24 is connected to the electric submersible pump 12.
To provide power to electric submersible pump 12, a conventional cable 34 is installed within the hollow interior 30 of tubing string 24. Cable 34 may be provided with three conductors to power a three phase ESP motor 13 of the electric submersible pump 12. Should a two phase ESP motor 13 be employed, cable 34 may be provided with two or three conductors for supplying power to the ESP motor 13.
Prior to installation of tubing string 24 within the well, the conventional cable 34 may be installed within the hollow interior 30 of tubing string 24 by pumping the conventional cable 34 into the tubing string 24, which may be in the form of a coiled tubing 26. This method of installation is limited to about 10,000 feet in length, the greatest length that suppliers have been able to install. As may be appreciated by those skilled in the art, an installation exceeding this limitation would then require a full rig. This can prove costly, particularly in offshore and remote locations, sometimes making electric submersible pump installations and retrievals economically prohibitive.
In operation, produced fluids enter the well 14 at perforations 36, pass through the production tubing 18, enter inlet 38 of electric submersible pump 12, and are discharged at outlet 40 into the annulus B formed by the inner surface 42 of production tubing 18 and the exterior surface 29 of wall 28 of tubing string 24, exiting at the surface. Seal 44 is installed to direct produced fluids to inlet 38 of electric submersible pump 12.
Referring now to FIG. 2, a schematic view of an illustrative, nonexclusive example of a system 300 for deploying and powering an electric submersible pump 312 within a subterranean well 314 is shown. Subterranean well 314 includes a casing 316 and production tubing 318 positioned within the casing 316. The interior surface 320 of the casing 316 and the exterior surface 322 of the production tubing 318 serve to define an annular space A′″. An annulus B′ is formed by the inner surface 342 of production tubing 318 and exterior surface 329 of wall 328 of tubing string 324.
The system 300 includes a tubing string 324, which may be formed from an externally insulated coiled tubing 326. In some embodiments, externally insulated coiled tubing 326 may be formed so as to have an insulated coating 327 applied to the external surface of coiled tubing 326. Tubing string 324 includes a wall 328, which forms a hollow interior 330. One end 332 of the tubing string 324 is connected to the electric submersible pump 312.
To provide power to the electric submersible pump 312, the tubing string 324 may form a first conductive path 352. In some embodiments, the production tubing 318 serves as a second conductive path 354, the first conductive path 352 and the second conductive path 354 forming a circuit for supplying power to the electric submersible pump 312.
In some embodiments, the electric submersible pump 312 has an intake 338 and an outlet or discharge 340. In some embodiments, the electric submersible pump 312 may be landed in the production tubing 318 to seal the intake 338 from the discharge 340 and provide a return electrical conduit.
In some embodiments, the ESP motor 313 is selected from a two-phase AC ESP motor or a DC ESP motor. In some embodiments, the system 300 includes a downhole DC-to-AC inverter 356 for powering a three-phase AC ESP motor. In some embodiments, the system 300 may also include a third conductive path to power a three-phase AC ESP motor.
In some embodiments, the electric submersible pump 312 includes at least one sensor 358 and power is transmitted through the system 300 to power the electric submersible pump 312. In some embodiments, a signal is impressed upon the power transmitted to provide a communications link between the electric submersible pump sensor(s) 358 and surface system(s) 360. In some embodiments, a wet-mate cable (not shown) is pumped to the electric submersible pump 312 through the tubing string 324 forming a dedicated communications link.
In operation, produced fluids enter the well 314 at perforations 336, pass through the production tubing 318, enters inlet 338 of electric submersible pump 312, and are discharged at outlet 340 into the annulus B′″ formed by the inner surface 342 of production tubing 318 and the exterior surface 329 of wall 328 of tubing string 324, exiting at the surface. Seal 344 is installed to direct produced fluids to inlet 338 of electric submersible pump 312.
As is known by those skilled in the art, electric submersible pump sensor data is typically communicated via a modulated signal layered upon an AC power transmission. As noted above, a similar scheme may be employed in the electrical arrangements disclosed herein. In some embodiments, a small umbilical may be pumped into the coiled tubing after landing and wet-mated to the electric submersible pump assembly. This line could serve as a dedicated sensing cable, as well as provide other benefits. The wet-mating operation can be performed with existing logging tools.
A deep-set surface-controlled subsurface safety valve (SCSSV) and/or fluid loss control valve could be placed in the lower completion to provide an additional well control barrier during equipment installation and retrieval. Permanent sensors may be placed in the completion to relay equipment operational parameters to facility personnel. This information would assist the operators in monitoring, optimizing, troubleshooting, and improving the operating lifetime of the equipment. Corrosion/scale inhibitor, demulsifier, and/or other chemicals could be injected through a mandrel below the pump to improve production performance.
Referring to FIG. 3, in another aspect, provided is another method for deploying and powering an electric submersible pump within a subterranean well 500. The method includes 502, providing a tubing string having a wall forming a first conductive path; 504 connecting the tubing string to the electric submersible pump; 506 positioning the tubing string and electric submersible pump within the subterranean well; 508, providing a second conductive path; and 510, forming a circuit for supplying power to the electric submersible pump, the circuit comprising the first conductive path and the second conductive path.
In some embodiments, the subterranean well comprises a casing and production tubing positioned within the casing, the interior surface of the casing and the exterior surface of the production tubing defining an annular space. In some embodiments, the production tubing forms the second conductive path. In some embodiments, the tubing string comprises a conductive metallic material, the outer surface of which is coated with an insulating, non-conductive material. In some embodiments, the subterranean well comprises a casing which forms an annulus with the tubing string, the casing forming the second conductive path. In some embodiments, the ESP motor is selected from a two-phase AC ESP motor or a DC ESP motor.
In some embodiments, the method 500 includes 512, providing a downhole DC-to-AC inverter for powering a three-phase AC ESP motor.
In some embodiments, the method 500 includes 514, providing a third conductive path to power a three-phase AC ESP motor.
As used herein, the term “and/or” placed between a first entity and a second entity means one of (1) the first entity, (2) the second entity, and (3) the first entity and the second entity. Multiple entities listed with “and/or” should be construed in the same manner, i.e., “one or more” of the entities so conjoined. Other entities may optionally be present other than the entities specifically identified by the “and/or” clause, whether related or unrelated to those entities specifically identified. Thus, as a non-limiting example, a reference to “A and/or B,” when used in conjunction with open-ended language such as “comprising” may refer, in one embodiment, to A only (optionally including entities other than B); in another embodiment, to B only (optionally including entities other than A); in yet another embodiment, to both A and B (optionally including other entities). These entities may refer to elements, actions, structures, steps, operations, values, and the like.
As used herein, the phrase “at least one,” in reference to a list of one or more entities should be understood to mean at least one entity selected from any one or more of the entity in the list of entities, but not necessarily including at least one of each and every entity specifically listed within the list of entities and not excluding any combinations of entities in the list of entities. This definition also allows that entities may optionally be present other than the entities specifically identified within the list of entities to which the phrase “at least one” refers, whether related or unrelated to those entities specifically identified. Thus, as a non-limiting example, “at least one of A and B” (or, equivalently, “at least one of A or B,” or, equivalently “at least one of A and/or B”) may refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including entities other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including entities other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other entities). In other words, the phrases “at least one,” “one or more,” and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C,” “at least one of A, B, or C,” “one or more of A, B, and C,” “one or more of A, B, or C” and “A, B, and/or C” may mean A alone, B alone, C alone, A and B together, A and C together, B and C together, A, B and C together, and optionally any of the above in combination with at least one other entity.
In the event that any patents, patent applications, or other references are incorporated by reference herein and define a term in a manner or are otherwise inconsistent with either the non-incorporated portion of the present disclosure or with any of the other incorporated references, the non-incorporated portion of the present disclosure shall control, and the term or incorporated disclosure therein shall only control with respect to the reference in which the term is defined and/or the incorporated disclosure was originally present.
As used herein the terms “adapted” and “configured” mean that the element, component, or other subject matter is designed and/or intended to perform a given function. Thus, the use of the terms “adapted” and “configured” should not be construed to mean that a given element, component, or other subject matter is simply “capable of” performing a given function but that the element, component, and/or other subject matter is specifically selected, created, implemented, utilized, programmed, and/or designed for the purpose of performing the function. It is also within the scope of the present disclosure that elements, components, and/or other recited subject matter that is recited as being adapted to perform a particular function may additionally or alternatively be described as being configured to perform that function, and vice versa.
It is within the scope of the present disclosure that an individual step of a method recited herein may additionally or alternatively be referred to as a “step for” performing the recited action.
Illustrative, non-exclusive examples of apparatus, systems and methods according to the present disclosure have been presented. It is within the scope of the present disclosure that an individual step of a method recited herein, may additionally or alternatively be referred to as a “step for” performing the recited action.

INDUSTRIAL APPLICABILITY

The apparatus and methods disclosed herein are applicable to the oil and gas industry.
It is believed that the disclosure set forth above encompasses multiple distinct inventions with independent utility. While each of these inventions has been disclosed in its preferred form, the specific embodiments thereof as disclosed and illustrated herein are not to be considered in a limiting sense as numerous variations are possible. The subject matter of the inventions includes all novel and non-obvious combinations and subcombinations of the various elements, features, functions and/or properties disclosed herein. Similarly, where the claims recite “a” or “a first” element or the equivalent thereof, such claims should be understood to include incorporation of one or more such elements, neither requiring nor excluding two or more such elements.
It is believed that the following claims particularly point out certain combinations and subcombinations that are directed to one of the disclosed inventions and are novel and non-obvious. Inventions embodied in other combinations and subcombinations of features, functions, elements and/or properties may be claimed through amendment of the present claims or presentation of new claims in this or a related application. Such amended or new claims, whether they are directed to a different invention or directed to the same invention, whether different, broader, narrower, or equal in scope to the original claims, are also regarded as included within the subject matter of the inventions of the present disclosure.

Claims

1. A system for deploying and powering an electric submersible pump within a subterranean well, the system comprising:

(a) a tubing string having a wall forming a first conductive path, one end of which is connected to the electric submersible pump; and

(b) a second conductive path,

wherein the first conductive path and the second conductive path form a circuit for supplying power to the electric submersible pump.

2. The system of claim 1, wherein the subterranean well comprises a casing and production tubing positioned within the casing, the interior surface of the casing and the exterior surface of the production tubing defining an annular space.

3. The system of claim 2, wherein the production tubing forms the second conductive path.

4. The system of claim 3, wherein the tubing string comprises a conductive metallic material, the outer surface of which is coated with an insulating, non-conductive material.

5. The system of claim 1, wherein the electric submersible pump includes an ESP motor, the ESP motor selected from a two-phase AC ESP motor or a DC ESP motor.

6. The system of claim 1, further comprising a downhole DC-to-AC inverter for powering a three-phase AC ESP motor.

7. The system of claim 1, further comprising a third conductive path to power a three-phase AC ESP motor.

8. The system of claim 1, wherein the electric submersible pump includes at least one sensor and power is transmitted through the system to power the electric submersible pump.

9. The system of claim 8, wherein a signal is impressed upon the power transmitted to provide a communications link between the electric submersible pump sensors and surface systems.

10. A method for deploying and powering an electric submersible pump within a subterranean well, the method comprising:

providing a tubing string having a wall forming a first conductive path;

connecting the tubing string to the electric submersible pump;

positioning the tubing string and electric submersible pump within the subterranean well;

providing a second conductive path; and

forming a circuit for supplying power to the electric submersible pump, the circuit comprising the first conductive path and the second conductive path.

11. The method of claim 10, wherein the subterranean well comprises a casing and production tubing positioned within the casing, the interior surface of the casing and the exterior surface of the production tubing defining an annular space.

12. The method of claim 11, wherein the production tubing forms the second conductive path.

13. The method of claim 12, wherein the tubing string comprises a conductive metallic material, the outer surface of which is coated with an insulating, non-conductive material.

14. The method of claim 10, wherein the electric submersible pump includes an ESP motor, the ESP motor selected from a two-phase AC ESP motor or a DC ESP motor.

15. The method of claim 10, further comprising providing a downhole DC-to-AC inverter for powering a three-phase AC ESP motor.

16. The method of claim 10, further comprising providing a third conductive path to power a three-phase AC ESP motor.