AU2021221405A1

AU2021221405A1 - Apparatus for deploying and removing a submersible pump to and from a borehole

Info

Publication number: AU2021221405A1
Application number: AU2021221405A
Authority: AU
Inventors: Arthur Grace; Lachlan Sharpe
Original assignee: Berkshire Renewable Energy Pty Ltd
Current assignee: Berkshire Renewable Energy Pty Ltd
Priority date: 2021-08-23
Filing date: 2021-08-23
Publication date: 2023-03-09

Abstract

An apparatus for deploying and removing a submersible pump in a borehole comprises a support structure and a hose reel for winding and unwinding a hose for connection to the pump. An actuable clamp assembly clamps the hose relative to the support structure when deploying and removing the pump. An electric cable reel is configured to wind and unwind an electric cable to supply electrical power to the pump. A drive means comprises a rotatable drive member to axially rotate the electric cable reel. The apparatus also comprises a mounting arrangement for releasably mounting the electric cable reel to the support structure. The mounting arrangement comprises an axle on the electric cable reel, mounting means provided on the support structure, wherein the mounting means rotatably receives and supports the axle releasably, and a coupling mechanism to connect the axle releasably to the drive member. 1/8 0 co 00 co co co N 00 N CD d N M Uco co co co co U-) CD U') co co U') Ir-

Description

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APPARATUS FOR DEPLOYING AND REMOVING A SUBMERSIBLE PUMP TO AND FROM A BOREHOLE

Field

[0001]The present invention relates to an apparatus for deploying and removing a submersible pump to and from a borehole.

Background

[0002] Electric submersible pumps are used to pump fluids from boreholes drilled into the ground for a variety of applications. For example, submersible pumps are used to control groundwater levels in the mining and construction industries and are used for artificial lift purposes in the oil and gas industry.

[0003] A submersible pump is typically deployed and removed to and from a borehole using a skid that is positioned on the ground next to the mouth of the borehole. The skid comprises a hose reel carrying a hose that is connected to the pump to receive borehole fluids pumped by the pump. The skid also comprises a cable reel that contains an electric cable to supply electrical power to the pump. To deploy the pump, the hose and cable are attached to the pump and the pump is then lowered down into the borehole over the end of the skid. The cable and hose reel may be driven by motors that are mounted on the skid, such as hydraulic motors, to lower the pump into the borehole in a controlled manner. The motors operate in reverse to remove the pump from the borehole.

[0004] The electric cable reel is typically fixedly connected to the skid and to its drive motor. When the submersible pump has finished pumping and has been removed from the borehole, the skid may be moved to a layby yard for storage. Various components on the skid may then be removed and stored separately from the skid so that they can be reinstalled and reused at a later date. The electric cable is typically unwound from the cable reel and arranged into a pile on the ground next to the skid until it needs to be used again. The cable is vulnerable to damage and deterioration when left in a pile and can present an inconvenient obstruction. If the cable subsequently needs to be reused for a submersible pump that is to be deployed using a skid, then winding the cable onto the skid's cable reel is time consuming and labor intensive.

[0005] In an effort to solve these problems, the electric cable reel may be mounted in a frame that is removably attached to the skid using a set of removable bolts. However, these bolts are time consuming and difficult to remove. Further, the drive axle of the cable reel must be connected to the reel's drive motor when the frame is being bolted onto the skid. This is a complicated mechanical process to perform that requires the expertise of a skilled technician.

[0006] The preceding discussion of the background art is intended to facilitate an understanding of the present invention only. The discussion is not an acknowledgement or admission that any of the material referred to is or was part of the common general knowledge as at the priority date of the application.

Summary

[0007] According to the present invention, there is provided an apparatus for deploying and removing a submersible pump to and from a borehole, the apparatus comprising: a support structure; a hose reel mounted on the support structure for winding and unwinding a hose for connection to the submersible pump; an actuable clamp assembly for clamping the hose relative to the support structure when deploying and removing the submersible pump; an electric cable reel for winding and unwinding an electric cable for supplying electrical power to the submersible pump; a drive means comprising a rotatable drive member for axially rotating the electric cable reel; and a mounting arrangement for releasably mounting the electric cable reel to the support structure, wherein the mounting arrangement comprises an axle extending axially through the electric cable reel, mounting means arranged on the support structure, wherein the mounting means rotatably receives and supports the axle releasably, and a coupling mechanism configured to connect the axle releasably to the rotatable drive member.

[0008] The coupling mechanism may comprise first and second coupling members that are provided on the axle and on the rotatable drive member respectively, wherein the coupling members are mutually dimensioned to engage one another in a mating arrangement.

[0009] The coupling members may comprise a tongue and groove arrangement.

[0010] A tongue of the tongue and groove arrangement may be provided on the axle, and a groove of the tongue and groove arrangement may be provided on the rotatable drive member.

[0011] The tongue and groove may each be mutually cuboidal in shape.

[0012] The coupling members may comprise a pair of cylindrical bodies axially aligned with the axle and rotatable drive member.

[0013] The drive means may comprise a hydraulic motor configured to rotate the rotatable drive member.

[0014] The mounting means may comprise a pair of brackets provided on the support structure, wherein the brackets are provided with locking means for releasably locking the axle into the brackets.

[0015] The actuable clamp assembly may comprise a static clamp member provided with a pair of jaws, wherein the jaws are pivotable about a pair of respective pivot axes at opposed ends of the static clamp member to clamp the hose against the static clamp member.

[0016] The clamp assembly may comprise a pair of linear actuators connected to the jaws for pivoting the jaws about the pivot axes.

[0017] The linear actuators may comprise hydraulic actuators.

[0018] The apparatus may comprise a hose guide assembly provided toward an end the support structure, wherein the hose guide assembly comprises a hose guide member to receive and guide the hose relative to a mouth of the borehole.

[0019] The hose guide assembly may be actuable such that a position of the hose guide member relative to the end of the support structure is adjustable.

[0020] The hose guide assembly may comprise an arm that is pivotably attached to the support structure, wherein the hose guide member is provided on the arm.

[0021] The hose guide assembly may comprise one or more linear actuators configured to pivot the arm relative to the support structure.

[0022] The actuable clamp assembly may be provided on the arm to move with the hose guide member.

[0023] The hose guide member may comprise an idler wheel.

[0024] The apparatus may comprise a cable guide assembly positioned relative to the electric cable reel, wherein the cable guide assembly comprises a cable guide member to receive and guide the electric cable relative to the electric cable reel.

[0025] The cable guide assembly may be actuable such that a position of the cable guide member is adjustable at least along an axis extending generally parallel to a rotational axis of the electric cable reel.

[0026] The cable guide assembly may include an arm that comprises the cable guide member, wherein the arm is pivotably attached to the support structure to pivot about an axis orientated generally orthogonal to the rotational axis.

Brief Description of Drawings

[0027] Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, in which: Figure 1 is an isometric view of an apparatus for deploying and removing a submersible pump to and from a borehole according to an example embodiment of the invention; Figure 2 is a further isometric view of the apparatus; Figure 3 is a plan view of the apparatus; Figure 4 is a front elevation view of the apparatus; Figure 5 is an enlarged isometric view of an electric cable reel of the apparatus; Figure 6 is a enlarged isometric view of a hose guide member of the apparatus;

Figure 7 is a further enlarged isometric view of the electric cable reel, wherein a mounting arrangement of the electric cable reel is shown in exploded form; and Figure 8 is a further enlarged isometric view of the electric cable reel, wherein the mounting arrangement is shown in exploded form.

Description of Embodiments

[0028] Referring to the Figures, an example embodiment of the present invention provides apparatus 10 for deploying and removing a submersible pump to and from a borehole. The apparatus 10 comprises a support structure 12 and a hose reel 14 mounted on the support structure 12 for winding and unwinding a hose for connection to the submersible pump. The apparatus 10 also comprises an actuable clamp assembly 16 for clamping the hose relative to the support structure 12 when deploying and removing the submersible pump, an electric cable reel 18 for winding and unwinding an electric cable for supplying electrical power to the submersible pump, and a drive means 20 comprising a rotatable drive member 22 for axially rotating the electric cable reel 18. The apparatus 10 also comprises a mounting arrangement for releasably mounting the electric cable reel 18 to the support structure 12. The mounting arrangement comprises an axle 24 extending axially through the electric cable reel 18, mounting means 26 arranged on the support structure 12, wherein the mounting means 26 rotatably receives and supports the axle 24 releasably, and a coupling mechanism 28 configured to connect the axle 24 releasably to the rotatable drive member 22 of the drive means 20.

[0029] More particularly, in the example depicted the support structure 12 comprises a skid that includes a rectangular platform 30 with four actuable legs 32 arranged at four respective corners of the platform 30. The legs 32 may comprise hydraulic linear actuators 34 that cause the legs 32 to expand and retract in length to raise and lower the platform 30 relative to the ground surface underneath the skid 12. In other examples, the support structure 12 may comprise a trailer, platform, deck, chassis, frame or other portable structure that can be positioned adjacent the mouth of a borehole.

[0030] The apparatus 10 may comprise an electrical power source 36, such as an engine-generator, mounted on the skid 12 for generating and supplying power to various electrical systems and devices included in the apparatus 10. For example, the drive means 20 of the electric cable reel 18 may comprise a hydraulic motor and the power source 36 may be used to supply power to a hydraulic power system 37 on the skid 12 that powers and controls the hydraulic motor 20. The hose reel 14 may also be driven by a drive means 38 that comprises a hydraulic motor powered and controlled by the hydraulic power system 37. In other examples, the drive means 20, 38 of the two reels 14, 18 may comprise electrical motors that receive power from the power source 36, and the power source 36 may comprise one or more batteries or solar panels in addition to, or instead of, an engine-generator.

[0031]The apparatus 10 may also comprise a wireline reel 40 mounted on the skid 12 that may also be driven by a hydraulic or electric motor. The wireline may be used to deploy and remove a dummy pump to and from the borehole to check the bore alignment prior to installation of the submersible pump. The apparatus 10 may also comprise a pair of free-wheeling, unpowered, reels 41 arranged below the electric cable reel 18. The reels 41 may be used to carry various instrument cables that may be attached to the submersible pump. For example, one of the reels 41 may carry a cable that carries power and signal information between the apparatus 10 and a pressure transducer sensor that is attached to the pump. The signal information received from the pressure transducer sensor may be used to monitor the level of fluid in the borehole during use. The power source 36 may also be used to power a master control system and panel 39 that is used to control the electric cable reel 18, hose reel 14, wireline reel 40 and the various other operative components of the apparatus 10.

[0032] The mounting arrangement is used to mount the electric cable reel 18 to the skid 12, and to connect the reel's axle 24 to the rotatable drive member 22, in a fast, easy-to-use and releasable manner. Referring to Figures 7 and 8, the coupling mechanism 28 of the mounting arrangement may comprise a first coupling member 42 and second coupling member 44. The first and second coupling members 42, 44 may be provided on, respectively, the axle 24 and the rotatable drive member 22. The coupling members 42, 44 may be mutually dimensioned to engage one another in a mating arrangement when pressed together during installation of the reel 18 onto the mounting means 26. In the example depicted, the cooperating coupling members 42, 44 are cylindrical bodies axially aligned with the axle 24 and rotatable drive member 22 respectively and comprise a tongue and groove arrangement. The first coupling member 42 may comprise a tongue that is generally cuboidal in shape and provided on a face of its cylindrical body 42 that faces the second coupling member 44. The second coupling member 44 may comprise a complementary cuboidal groove provided on a face of its cylindrical body 44 that faces the first coupling member 42 and is mutually dimensioned to receive the tongue.

[0033] It will be appreciated that the coupling mechanism 28 may comprise a different mechanism to the tongue and groove arrangement that is depicted for releasably connecting the axle 24 to the rotatable drive member 22. For example, the coupling mechanism 28 may comprise one or more clips, clasps, slidable connection rods or other releasable fastening means arranged between the axle 24 and drive member 22. The mounting means 26 may comprise a box-shaped frame that includes a pair of brackets 46 arranged either side of the electric cable reel 18 aligned with the reel's axle 24. The brackets 46 may rotatably receive and support the axle 24 and may be provided with locking means for releasably locking the axle 24 into the brackets 46. In the example depicted, each bracket 46 comprises a metal clasp and a pivotable fastening member that can be pivoted in use to move over the top of the axle 24 when the axle 24 is resting on the clasp. The fastening member may be secured down onto the clasp using a wing bolt or similar releasable fastener.

[0034] The apparatus 10 may also comprise a hose guide assembly 50 that is provided toward a frontmost end 52 the skid 12. The hose guide assembly 50 may comprise a hose guide member 54 that is adapted to receive and guide the hose of the hose reel 14 relative to the mouth of the borehole during use. In the example depicted, the hose guide assembly comprises an arm 50 that is pivotably attached to the skid 12, and the guide member is provided by an idler wheel 54 that is attached to an uppermost end of the arm 50. A pair of linear hydraulic actuators 56 may be used to pivot the arm 50 about an axis aligned generally parallel with the rotational axis of the hose reel 14. In this configuration, the relative distance between the idler wheel 54 and the end 52 of the skid 12 is adjustable by pivoting the arm 50.

[0035]The apparatus 10 may also comprise a cable guide assembly 60 positioned on the skid 12 relative to the electric cable reel 18. The guide assembly 60 may comprise a cable guide member 62 that is configured to receive and guide the electric cable relative to the reel 18 when the cable is being wound and unwound during use. In the example depicted, the cable guide assembly comprises an actuable arm 60 that is pivotably attached to the skid 12, and the cable guide member 62 attached to an uppermost end of the arm 60. As best shown in Figure 4, a linear hydraulic actuator 64 may be used to pivot the arm 60 about an axis that is aligned generally orthogonal to the rotational axis of the cable reel 18. In this configuration, the position of the guide member 62 across the face of the cable reel 18 can be adjusted by pivoting the arm 60. As best shown in Figure 5, the guide member 62 may comprise a set of frame elements that are connected together to form an aperture that receives the electric cable. A small portion of the cable is shown in cross sectional form and labelled 66 in Figure 5. In other examples, the guide member 62 may comprise an idler pulley wheel or other mechanism for retaining and guiding the position of the cable relative to the face of the reel 18.

[0036] Referring to Figure 6, the actuable clamp assembly 16 may comprise a static clamp member 70 that is provided with a pair of jaws 72. The jaws 72 may be pivotable about a pair of respective pivot axes at opposed ends of the static clamp member 70. In this configuration, the jaws 72 are operatively configured to clamp the hose of the hose reel 14 against the static clamp member 70. The clamp assembly 16 may comprise a pair of linear hydraulic actuators 74 connected to the jaws 72 for pivoting the jaws 72 about their respective pivot axes. The clamp assembly 16 may be attached to the arm 50 of the hose guide assembly and may be positioned below the idler wheel 54. In this configuration, the clamp assembly 16 moves together with the idler wheel 54 when the arm 50 is pivoted by the actuators 56.

[0037] In use, the apparatus 10 is used to lower the submersible pump into a borehole and to retrieve the pump subsequently from the borehole once pumping has been completed. The skid 12 is initially transported to the site at which the borehole has been drilled in advance. The cable reel 18 may be delivered to the site separately to the skid 12 with the electrical cable already wound around the reel 18 and with the submersible pump attached to the end of the cable. The cable reel 18 may be mounted to the skid 12 by lowering its axle 24 onto the brackets 46 and so that the coupling members 42 and 44 engage each other. The fastening members provided on the brackets 46 may then be used to secure the axle in the brackets 46. In other examples, the cable reel 18 may be mounted to the skid 12 in the same manner before the skid 12 is transported to the borehole site.

[0038] The end of the hose is then attached to the submersible pump and the motorised hose reel 14 and cable reel 18 may then be operated to lower the pump into the borehole in a controlled manner. The hose guide assembly 50 may be used to adjust the position of the hose relative to the end 52 of the skid 12 so that the hose is aligned with the mouth of the borehole before it is lowered.

[0039] When the pump is being lowered, the clamp assembly 16 may be used to hold sections of the hose periodically. For example, the operator may wish to stop the hose and pump from moving further into the borehole to allow the operator to tie the cable to the side of the hose periodically. When the pump needs to be removed from the borehole, the motorised hose reel 14 and cable reel 18 may be operated in reverse to lift the hose and electric cable out of the borehole. During this process, the cable guide assembly 60 may be used to cause the guide member 62 to move back and forth across the face of the cable reel 18 so that the cable is wound evenly onto the reel 18. The cable guide assembly 60 may be operated automatically by the master control system 39 in this manner or it may be operated manually by an operator of the apparatus 10.

[0040] Now that examples embodiments of the apparatus have been described in detail, it will be apparent that it provides a number of advantages over the prior art, including the following:

(i) The coupling mechanism 28 allows the electric cable reel 18 to be mounted to the skid 12 (and connected to the rotatable drive member 22) in a fast, convenient and releasable manner. The reel 18 can, therefore, also be easily removed from the skid 12, with the cable wound on the reel 18, to allow the reel 18 and cable to be stored separately from the skid 12. The reel 18 and cable can, therefore, be reattached to the skid 12 (or attached to a different skid) at a later date in a fast and efficient manner.

(ii) The two jaws 72 of the clamp assembly 16 clamp the hose securely between the jaws 72 and the static clamp member 70 with a substantial force that avoids slippable of the hose when deploying and removing the hose to and from the borehole. In particular, using two jaws 72 (and two linear actuators 74) provides for a strong clamping force that is significantly more powerful and reliable than a clamping arrangement that uses, for example, a single actuable jaw member;

(iii) The hose guide assembly 50 may be used to adjust the position of the hose relative to the end 52 of the skid 12 so that the hose is aligned with the mouth of the borehole before it is lowered into the borehole;

(iv) The cable guide assembly 60 allows the cable to be wound evenly back onto the reel 18 when the pump is being removed from the borehole.

[0041] For the purpose of this specification, the word "comprising" means "including but not limited to", and the word "comprises" has a corresponding meaning. It is to be understood that, if any prior art is referred to herein, such reference does not constitute an admission that the prior art forms a part of the common general knowledge in the art, in Australia or any other country.

[0042] The above embodiments have been described by way of example only and modifications are possible within the scope of the claims that follow.

Claims

1. An apparatus for deploying and removing a submersible pump to and from a borehole, the apparatus comprising: a support structure; a hose reel mounted on the support structure for winding and unwinding a hose for connection to the submersible pump; an actuable clamp assembly for clamping the hose relative to the support structure when deploying and removing the submersible pump; an electric cable reel for winding and unwinding an electric cable for supplying electrical power to the submersible pump; a drive means comprising a rotatable drive member for axially rotating the electric cable reel; and a mounting arrangement for releasably mounting the electric cable reel to the support structure, wherein the mounting arrangement comprises an axle extending axially through the electric cable reel, mounting means arranged on the support structure, wherein the mounting means rotatably receives and supports the axle releasably, and a coupling mechanism configured to connect the axle releasably to the rotatable drive member of the drive means.

2. The apparatus according to claim 1, wherein the coupling mechanism comprises first and second coupling members that are provided on the axle and on the rotatable drive member respectively, wherein the coupling members are mutually dimensioned to engage one another in a mating arrangement.

3. The apparatus according to claim 2, wherein the coupling members comprise a tongue and groove arrangement.

4. The apparatus according to claim 3, wherein a tongue of the tongue and groove arrangement is provided on the axle, and wherein a groove of the tongue and groove arrangement is provided on the rotatable drive member.

5. The apparatus according to claim 3 or 4, wherein a tongue and a groove of the tongue and groove arrangement are each mutually cuboidal in shape.

6. The apparatus according to any one of claims 2 to 5, wherein the coupling members comprise a pair of cylindrical bodies axially aligned with the axle and rotatable drive member.

7. The apparatus according to any one of the preceding claims, wherein the drive means comprises a hydraulic motor configured to rotate the rotatable drive member.

8. The apparatus according to any one of the preceding claims, wherein the mounting means comprises a pair of brackets provided on the support structure, wherein the brackets are provided with locking means for releasably locking the axle into the brackets.

9. The apparatus according to any one of the preceding claims, wherein the actuable clamp assembly comprises a static clamp member provided with a pair of jaws, wherein the jaws are pivotable about a pair of respective pivot axes at opposed ends of the static clamp member to clamp the hose against the static clamp member.

10. The apparatus according to claim 9, wherein the clamp assembly comprises a pair of linear actuators connected to the jaws for pivoting the jaws about the pivot axes.

11. The apparatus according to claim 10, wherein the linear actuators comprise hydraulic actuators.

12. The apparatus according to any one of the preceding claims, wherein the apparatus comprises a hose guide assembly provided toward an end the support structure, wherein the hose guide assembly comprises a hose guide member to receive and guide the hose relative to a mouth of the borehole.

13. The apparatus according to claim 12, wherein the hose guide assembly is actuable such that a position of the hose guide member relative to the end of the support structure is adjustable.

14. The apparatus according to claim 13, wherein the hose guide assembly comprises an arm that is pivotably attached to the support structure, and wherein the hose guide member is provided on the arm.

15. The apparatus according to claim 14, wherein the hose guide assembly comprises one or more linear actuators configured to pivot the arm relative to the support structure.

16. The apparatus according to claim 14 or 15, wherein the actuable clamp assembly is provided on the arm to move with the hose guide member.

17. The apparatus according to any one of claims 12 to 16, wherein the hose guide member comprises an idler wheel.

18. The apparatus according to any one of the preceding claims, wherein the apparatus comprises a cable guide assembly positioned relative to the electric cable reel, wherein the cable guide assembly comprises a cable guide member to receive and guide the electric cable relative to the electric cable reel.

19. The apparatus according to claim 18, wherein the cable guide assembly is actuable such that a position of the cable guide member is adjustable at least along an axis extending generally parallel to a rotational axis of the electric cable reel.

20. The apparatus according to claim 19, wherein the cable guide assembly includes an arm that comprises the cable guide member, and wherein the arm is pivotably attached to the support structure to pivot about an axis orientated generally orthogonal to the rotational axis.