This disclosure is related to the field of electrically operated submersible well pumps (ESPs). More specifically, the disclosure relates to structures for ESP systems and methods for deploying, moving and redeploying an ESP through a wellbore tubing.
ESPs are known in the art for lifting liquid in a subsurface wellbore, as examples, in cases where energy in a subsurface reservoir penetrated by the wellbore is insufficient to lift the fluid to the surface, or where liquid produced from the formation such as water increases hydrostatic pressure in the wellbore so as to reduce productivity of the reservoir of desirable fluids such as oil or more particularly gas. The latter use is known as “dewatering.”
ESP systems known in the art may be deployed in the wellbore at the end of a section of conduit called “tubing” or a “velocity string”, which has a nominal diameter smaller than an internal diameter of a pipe or casing permanently emplaced in the wellbore. The casing serves to maintain mechanical integrity of the wellbore and to hydraulically isolate subsurface formations from each other. The tubing may serve the purpose of providing a smaller diameter conduit to increase the velocity of fluid moving to the surface, thus increasing capacity of wellbore fluid to lift higher density fluid components to the surface for a given amount of total energy (i.e., from the reservoir and from a pump if used).
Certain types of electrical cables may make practical the deployment of ESP systems through an emplaced tubing. Such capability may reduce the cost of deploying, servicing and/or replacing an ESP system as compared to those deployed at the end of a tubing.
In some cases it may be desired to be able to move the ESP after initial deployment and/or to repeatably seal the interior of the tubing after such movement without the need to completely remove the ESP system from the wellbore.
An aspect or embodiment according to the present disclosure relates to an electrical submersible pump (ESP) system comprising an electric motor operably coupled to a fluid pump having first and second ports selectively operable as a pump inlet and a pump discharge with reversal of a direction of rotation of the fluid pump. This ESP system includes an inflatable seal element. and controllable valves to selectively direct fluid discharge of the fluid pump to an inflation volume of the inflatable seal element and toward the surface in a wellbore.
The inflatable seal element when inflated may serve firstly to provide a seal against the bore of the tubing to support the pump differential pressure; secondly to provide a torque restraint for the pump unit; and thirdly, to support all or part of the weight of the pump assembly and cable weight in some embodiments.
The ESP system may comprise a torque converter disposed between the electric motor and the fluid pump in some embodiments.
The ESP system may comprise a protector disposed between the electric motor and the pump in some embodiments.
In some embodiments, the ESP system may further comprise one or more of the following: a cable head coupled to a longitudinal end of the electric motor, and which may be configured to couple the ESP system to an electrical cable. The electrical cable may be for use in moving the ESP system along an interior of a wellbore. The cable connection may include a swivel so that the pump unit can rotate without twisting the cable. In some embodiments other deployment medium may be utilized, such as coiled tubing, for example.
The electric motor may be operable to rotate the pump in a first direction in which the first fluid port functions as a pump discharge and the second fluid port functions as a pump inlet. In such an arrangement the valves may be controlled or operated to hydraulically connect the first fluid port to the inflation volume, whereby operation of the fluid pump introduces fluid under pressure to the inflation volume in the inflatable seal element.
The electric motor may be operable to rotate the pump in a second direction opposite to the first direction in which the first fluid port functions as a pump inlet and the second fluid port functions as a pump discharge. In such an arrangement the valves may be controlled to hydraulically connect the first fluid port to the wellbore on one side of the inflatable seal element and to hydraulically connect the second port to the wellbore on an opposite side of the inflatable packer.
In some embodiments, the ESP system may comprise a pressure relief valve in hydraulic communication between the second fluid port on the fluid pump and the wellbore.
In some embodiments, the ESP system may comprise a pressure relief valve in hydraulic communication between the inflation volume and the wellbore tubing.
In some embodiments, the ESP system may comprise a check valve operable to admit fluid to the first fluid port when the fluid pump is rotated such that the first fluid port operates as a pump inlet, the check valve operable to stop fluid flow therethrough when the fluid pump is rotated such that the first fluid port operates as a pump discharge.
In some embodiments, the controllable valves may be controllable to vent pressure in the inflation volume to deflate the packer.
In some embodiments, the ESP system may comprise a tubular core having a through bore in fluid communication with the first fluid port. The inflatable seal element may be mounted around the tubular core.
In some embodiments, the ESP system may comprise an inflate port in the tubular core to permit fluid communication between the through bore of the tubular core and the inflation volume of the inflatable seal element. One of the controllable valves may be operable to selectively permit fluid communication through the inflate port.
In some embodiments, the ESP system may comprise a torque anchor disposed at a selected axial position along an assembly formed by the electric motor and the pump.
An aspect or embodiment according to the present disclosure relates to a method for pumping fluid from a wellbore towards surface. Such method may include moving an electrical submersible pump (ESP) system to a selected position in a wellbore, wherein the ESP system includes a pump having first and second ports selectively operable as a pump inlet and a pump discharge with reversal of a direction of rotation of the fluid pump. The pump is rotated in a first direction and valves in the ESP system are operated to direct fluid discharge of the pump to an inflatable seal element in the ESP system. The pump is rotated in a second direction opposed to the first direction and the valves are operated to direct fluid discharge of the pump towards the surface in a wellbore.
The method may comprise, in some embodiments, operating the valves and rotating the pump in the first direction such that a second port in a pump in the ESP system withdraws fluid from the wellbore into the pump and a first port in the pump discharges fluid into the inflatable seal element in the ESP system.
The method may comprise, in some embodiments, operating the valves and rotating the pump in the second direction such that the first port withdraws fluid from the wellbore on one side of the inflatable seal element, for example below the seal element, and the second port discharges fluid into the wellbore on an opposite side of the inflatable seal element, for example above the seal element, toward the surface. The flow may flow or be pumped via a wellbore conduit.
In some embodiments, one or more of the following operations may be performed. Rotating the pump in the first and second directions may comprise operating an electric motor rotationally coupled to the pump in the first and second directions. The valves may be operated to at least partially vent fluid pressure from the inflatable seal element. The ESP system may be moved within the wellbore following at least partially venting fluid pressure from the inflatable seal element.
The method may comprise moving the ESP to a different position within the wellbore and repeating inflating the inflatable seal element at the different position in some embodiments.
The method may comprise repeating reversing pump direction of rotation and pumping fluid toward the surface at the different position in some embodiments.
The method may comprise retrieving the ESP system from the wellbore following at least partially venting fluid pressure from the inflatable seal element in some embodiments.
The method may comprise setting a torque anchor to rotationally lock the ESP system in the conduit in some embodiments.
Setting the torque anchor may comprise starting rotation of the pump to deploy locking arms by centripetal force in some embodiments.
The method may comprise releasing a set torque anchor prior to moving the ESP system by applying an upward axial force on the ESP system in some embodiments.
The method may comprise venting pressure above a preselected amount from the interior of the inflatable seal element in some embodiments.
The method may comprise venting pressure above a preselected amount from the pump when the pump is operated in the first direction in some embodiments.
Moving the ESP system may comprise extending and/or retracting an electrical cable coupled to a longitudinal end of the ESP system in some embodiments.
It is to be understood that both the foregoing summarized description and the following detailed description are only intended as examples of various aspects and embodiments according to the present disclosure. The accompanying drawings are included to provide a further understanding of the embodiments and are incorporated in and constitute a part of the present disclosure.
A flow bypass 4 may be disposed below the pump 116. The purpose for the flow bypass will be explained further below. A valve sub 118 may be disposed below the flow bypass 4 and may include valves to be further explained below that may be remotely operated to cause selective operation of various components of the ESP system 100 as required.
An inflatable packer 3 may be disposed below the valve sub 118. The inflatable packer may have an elastomer sealing element to seal an annular space between the exterior of the ESP system 100 and the interior of a wellbore tubing (2 in
The flow bypass 4 may be included in the ESP system 100 as previously explained with reference to
Circumscribing the core 12 may be a substantially cylindrical seal 13 which may be made from expandable elastomer. The seal 13 may be sealed to the core 12 at its connections at both ends 14, 15, making a pressure-tight annular volume 16 between the core 12 and the seal 13 when the seal 13 is inflated.
The seal 13 may be inflated by applying a higher hydraulic pressure to the annular volume 16 than the pressure which exists outside it. In an example system and method according to the present disclosure, such pressure may be provided by operating the pump (116 in
When the packer 3 is inflated, the seal 13 is pressed tightly against the internal surface 10 of the well tubing 2 which forms a pressure tight seal between the fluid 19 in the tubing 2 below the packer 3 and the fluid in the tubing above the packer 20. The seal provided by the packer 3 enables the pump (116 in
Inflation and deflation of the packer may be controlled by valves. Four valve functions may be implemented in some embodiments.
Although in the present example embodiment four separate valves are described, in other embodiments it may be possible to combine some of the functions of the foregoing individual valves, and reduce the number of valves in the ESP system. For example, the functions of the packer inflation valve and deflation valve may be included in a single two-way valve, with appropriate modifications to the ports. In some embodiments, it may be desirable to duplicate some valves in order to provide a backup in case of malfunction of one or more of the valves, in order to improve the reliability of the ESP system.
If the torque anchor 1 is used, to prepare the ESP system 100 for fluid pumping, the torque anchor 1 may be engaged with the internal surface of a wellbore tubing 2.
The torque anchor 1 in some embodiments may be a double acting type, or a combination of two single acting types arranged to resist torque in both directions. The torque anchor 1 may be released by applying tension to the electrical cable. The ESP system (100 in
An example method for deploying and operating an ESP system as described herein will be explained below.
The ESP system (100 in
A control signal may be sent from the surface, e.g., over the electrical cable (102 in
Valves in the valve sub (118 in
In some embodiments, a variable frequency AC motor drive may be configured to reverse the ordinary phase relationship of the electrical power output to the electric motor (108 in
The electric motor (108 in
When the packer is inflated to the required inflation pressure, inflation pressure is trapped in the packer such that the packer will maintain a seal in the wellbore tubing which will support the pressure differential generated by the pump and so allow fluid to be pumped from the wellbore upwardly in the tubing. By gripping in the wellbore tubing, the packer may also provide torsional restraint for the ESP system. Packer inflation pressure may be trapped in the annular volume (16 in
The pressure limiting valves as described above may prevent the packer being over-pressurized and the pump from being ‘dead headed’ which could result in damage to the system due to overloading.
The electric motor is then stopped.
A control signal may then be sent from the surface, e.g., over the electrical cable (102 in
The electric motor may then be restarted in a normal or forward direction of rotation to cause the pump to lift fluid from the wellbore to the surface. Flow direction through the ESP system may be suitably directed by setting the control parameters in a variable speed drive (e.g., as may be disposed in the signal decoding sub (106 in
When it is desired to retrieve the ESP system, or to move it to a different location in the wellbore, for example, deeper or shallower, the pump is stopped by control of the variable speed drive, a signal is sent to a valve in the setting sub which releases the inflation pressure from the packer to the wellbore, thereby releasing the packer from sealing in the wellbore. This may be the valve used to inflate the packer, or may be a separate valve as explained above.
The ESP system may then be moved to a different wellbore location or removed from the wellbore by winching on the electrical cable.
An example set of operations of setting the ESP system, pumping, and unsetting can be repeated as required. The example operating sequence may be summarized in TABLE 1.
An ESP system and method for operating according to the present disclosure may provide the capability of repeated setting, pumping fluid to surface and releasing the system for further movement or retrieval from the wellbore without the need for additional pumps to inflate and deflate an inflatable seal, and may provide such capabilities without the need to remove the wellbore tubing.
While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims.
Number | Name | Date | Kind |
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5404946 | Hess | Apr 1995 | A |
Number | Date | Country | |
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20160061010 A1 | Mar 2016 | US |