NO340093B1 - ROBUST AND EASY INSTALLABLE UNDERGROUND ESP - Google Patents

Description

ROBUST AND EASY TO INSTALL UNDERWATER ESP.

The invention area

The present invention relates to undersea connection (tie in), undersea production and undersea pressure boosting, of hydrocarbons or other flows handled within the petroleum industry. More specifically, the invention describes a subsea horizontal ESP system that is robust and easy to install, replace and retrieve, without leaks to the environment and without exceeding the structural capacity of existing subsea structures.

Background for the invention

There is a need for a number of different submersible pumps for different areas of application. Traditional subsea booster pumps are typically designed to handle relatively large flow rates and the need for high pressure boosters. Extensive monitoring and manifold arrangements will also make such installations complex and expensive to manufacture and install.

In cases where there is a need to boost pressure at small flow rates, from a single well or a few wells, various attempts have been made to use downhole pumps - so-called electric submerged pumps (ESP - electric submerged pumps) - on the seabed. Such pumps are widely used for artificial lifting from wells by being placed down in the wellbore. These pumps are driven by an electric motor which is supplied with power through a cable clamped to the production pipe. These are developed machines with extensive results. Since they are intended to be placed in a narrow wellbore, they are typically long and narrow. The length can be up to 40 meters and the total installed power can be over 1 MW.

An arrangement for placing such ESPs on the seabed is described in US patent no. 7,565,932 "Subsea flowline jumper containing ESP" from Baker Hughes Inc. The patent describes the basic concept of installing an ESP in the horizontal section of a production connection line (flowline jumper). Such drilling flow pipes are typically used to connect different units in a subsea production system with vertical connectors at each end. By replacing the horizontal pipe section of such a drill rod with an enlarged section containing an ESP, a simple installation is obtained.

Another arrangement is described in US patent no. 8,500,419 "Subsea pumping system with interchangeable pumping units" from Schlumberger. This patent describes a similar arrangement of one or more ESPs in underwater horizontal pipe sections. This patent describes a pump module including one or more pump units on a sliding frame. Two or more pump units may be operationally connected in series or parallel. Each of the pump units, each of which may have electrically driven pumps (ESPs) assembled into a tubular section, can be retrieved individually. On the pump frame there are a number of additional subsystems: regulator, sensor, pipe coupling, hydraulic and electrical couplings, isolation valves for the assemblies and at least one fluid by-pass valve.

US patent no. 8,083,501 "Subsea pumping system including a skid with mateable electric and hydraulic connections" from Schlumberger, describes a more generalized version of the system described in US 8,500,419. The two patents were filed on the same date. This patent has the same arrangement as US 8,500,419, but describes a complete horizontal pump module containing a centrifugal pump driven by an electric motor.The description may this ESPs or other electrically driven horizontal pumps - assembled in a pressurized housing.

Pumps that are long and slender due to their intended application in a wellbore are not ideal for subsea use. Underwater applications have no room for other events. Typical submersible pumps are therefore more compact and typically arranged for vertical installation and retrieval. The pump is typically mounted on a flow foundation that has a simple manifold arrangement to direct the flow into and out of the pump as well as allow by-pass in the event of pump stoppage. US patents 8,500,419 and 8,083,501, mentioned above, have this typical arrangement with the pump mounted on a foundation. Such foundations are expensive both to produce and to install. The pumps are also arranged in a construction which entails additional weight and costs. Such arrangements negate the main motivation and drivers, described above, for installing ESPs on the seabed.

The motivation/drivers for using ESPs on the seabed, despite their form, are the following:

- Tested through extensive use in a challenging environment,

- Simple - only needs a supply of electrical current to work,

- More affordable than comparable submersible pumps,

- Subsea allows the use of shorter, larger diameter pumps, which run at a lower speed than downhole versions - potentially increases reliability, - Capacity can be increased by parallel arrangement (due to more available space on the seabed),

- Increased pressure amplification capability can be obtained by serial arrangement.

To achieve the advantages indicated above, the arrangement described in US patent 7,565,9352 has more potential than that described in the other mentioned patents. However, this arrangement will suffer from the following limitations in terms of reliability, robustness and installability: - Weight increases due to the larger horizontal section and the installed ESP will place additional strain on the connectors at each end, possibly beyond what they are intended to accommodate . - Risk of bending of the pipe containing the ESP due to the increased weight and/or crooked setting. Thermal effects due to heating from the produced fluid can also result in dimensional change and bending. Such bending or sagging of the pipe containing the ESP can challenge the rotordynamic stability of the ESP motor-pump assembly. The ESP shaft is long (typically > 20 metres) and bending will result in increased vibrations and reduced service life. - Increased ESP pipe wall thickness to avoid bending will further increase the vertical load and is not a good solution.

- The arrangement does not enable flow bypass.

- The arrangement does not include the possibility of parallel or serial arrangements of two or more ESPs. - A typical production connecting line (jumper) arrangement does not have isolation valves since they are not meant to be picked up after they are first installed. When an ESP is installed in the horizontal section, easy retrieval and installation without spillage of hydrocarbons to sea is of crucial importance.

Further relevant technology is described in the patent publications US 5417553 A, US 5203682 A and US 2010/119382 A1. Bracing arrangement comprising a truss construction, combined with connector or connector adapter with isolation valve at each end is not described in any of the above publications.

Summary of the invention

Robust and easily installable horizontal underwater ESP (electrical submersible pump) system, arranged in a horizontal production connecting line, which system includes arrangements for lifting and a connector at each end, characterized in that the system further includes: a bracing arrangement, which ensures a straight ESP axle at all times during lifting, installation and operation, whereby the bracing arrangement comprises a truss construction,

an arrangement to limit or eliminate the stress on underwater connectors to which the system is connected during operation and also other underwater structures present, and

each connector or connector adapter includes an isolation valve, to enable environmentally friendly installation, replacement and retrieval of the system.

Preferably includes the arrangement to limit or eliminate the stress on underwater connectors to which

the production connecting line is connected during operation and also to the existing subsea structure, buoyancy elements, in particular buoyancy elements based on syntactic foam, preferably with a lifetime and total buoyancy to

compensating for the increased weight of the system compared to a traditional production connecting wire.

The system according to the invention provides an improved lifetime of the EPS by eliminating the increased weight of the ESP preferably with the buoyancy elements as well as ensuring the straightness of the ESP tube by including a bracing structure/arrangement, which eliminates the weight and cost of manufacturing a pump frame and ensures reliable vertical connection and insulation layer.

The system according to the invention provides an improved version of a subsea installer ESP based on the basic concept of ref. 1 by dealing with three main problems: - The increased weight of the installed ESP will put additional stress on the connector supports at each end of the production connecting line. - The danger of bending the pipe containing the ESP (due to the increased weight) and thereby challenging the rotor-dynamic stability of the ESP motor-pump assembly. - The original, permanently installed connector hub will typically lack isolation valves that may contain hydrocarbons during installation and retrieval. Such modifications cannot be made to the permanently installed connector hubs.

The pump module in ref. 2 (pipe containing an ESP-type pump unit) and the pump module in ref. 3 (a more generalized pump unit) are mounted on a foundation. This represents additional complexity, weight and cost. This can be avoided with the proposed production tie-line mounted ESP since the production tie-line solution uses existing foundations at the connection points.

1) US patent 7,565,932 "Subsea flowline jumper containing ESP" from Baker Hughes Inc. describes the basic concept of installing an ESP in the horizontal section of a production connecting line. Such production connecting lines are typically used to connect different units in a subsea production system with vertical connectors at each end. By replacing the horizontal pipe section of such a connecting line with an enlarged section containing an ESP, a simpler installation can be achieved. 2) US patent 8,500,419 "Subsea pumping system with interchangeable pumping units" from Schlumberger describes a similar arrangement with one or more ESPs in underwater, horizontal pipe sections. This patent describes a pump module containing one or more pump units on a frame. Two or more pump units may be operationally connected in parallel or series. Each of the pump units, each of which has electrically driven pumps (ESPs) assembled in a pipe section, can be retrieved individually. The pump frame contains a number of additional subsystems: regulator, sensor, pipe assembly, hydraulic and electrical connections, isolation valves for the frames and at least one fluid by-pass valve. 3) US patent 8,083,501 "Subsea pumping system including a skid with mateable electrical and hydraulic connections" from Schlumberger, describes a more generalized version of the system described in US 8,500,419. The two patents were filed on the same day. This patent has the same arrangement as US 8,500,419, but describes a complete horizontal pump module, containing a centrifugal pump driven by an electric motor. The description may cover ESPs and other electrically driven horizontal pumps - assembled in a pressurized housing.

The system according to the invention is light in weight, easy to install with minimal additional equipment to establish a pressure boosting station.

Figures

Figures 1 to 12 show various designs and features of the system according to the invention.

Detailed description

The limitations of the state of the art are remedied by one or more of the following changes according to the present invention: - In order to avoid additional weight loading on the landing structures and vertical connectors beyond the initial load on these connectors, buoyancy elements are included to compensate for the increased weight because of the ESP and the larger pipe that contains it. - The weight of the production connection line is different in air and immersed in water. Therefore, a bracing arrangement and a suitable lifting arrangement will also be provided to ensure a straight pipe during lifting so that the pipe containing the ESP will have minimal bending during lifting, installation and in the landed, operating position. Long pumps, typically such as the ESP type, should preferably be driven by a straight shaft. The rotor-dynamic behavior of this long shaft passing through the motor, compensator and pump typically needs to be as appropriate as possible. Minimization of oscillations and vibrations to minimize wear on bearings and seals and ensure a long service life. Such axle straightness can be obtained with a bracing arrangement on the ESP pipe. - The vertical connector design at each end of the production connecting wire, typically pre-installed in a modification arrangement, will differ from supplier to supplier. In cases where such a production connection wire ESP installation is to be retrofitted to existing production systems, it is of crucial importance to have an arrangement that can be adapted to such connectors. A connector adapter is introduced, the lower end of which fits with the existing connector and the upper end of which fits with a standardized connector profile. Such an adapter will typically be a complete connector housing that is permanently placed on the existing connector hub and terminated at the upper end with the standardized vertical connector hub. Such a connector adapter has the following additional features: o Isolation valve: isolation of the inboard and outboard pipeline ends is critical to contain hydrocarbons from leaking to the environment when the production connection line is retrieved. Such isolation valves are incorporated into the vertical connector adapter housing to minimize weight and size. Such a valve is typically operated with an ROV (Remote Operated Vehicle). Connector adapter version 1 has a lower connector housing that mates with the original hub, an isolation valve and an upper connector hub.

o To enable increased capacity, a parallel arrangement can be obtained with two pipes containing one ESP each, with connector adapter version 2. Such version 2 connector adapters will have a lower connector housing that fits with the original junction, an isolation valve, a Y-branch and two upper connector node connected to the two outlets from the Y branch.

o To enable increased pressure amplification capability, two ESPs can be arranged in series. This can be arranged using connector adapter version 3. This version 3 of the connector adapter will have a lower connector housing that mates with the original hub, an isolation valve, an upper connector hub connected to the isolation valve and two connector hubs that are fluidly connected to each other and structurally connected to the isolation valve .

o Flow bypass can be obtained by having a parallel pipe arranged on connector adapter version 2 with a valve. The valve can be remotely controlled either electrically or hydraulically from the production tooling system. The valve can be electrically operated

with the electrical power supply to the ESP so that when the ESP runs, the valve will close.

The buoyancy elements and the bracing device can be combined in a single truss which ensures rigidity and will keep the buoyancy elements attached to the tube containing the ESP. Illustration in Figure 3.

This embodiment can accommodate more than one ESP in the following way and for the following functions: - One of the longitudinal beams can be replaced with a pipe to use for flow bypass. A remotely operated valve will need to be included in this pipe. Connector adapter ver. 2 must in such cases be used at each end. - The same arrangement of replacing one of the longitudinal beams with a tube can be used to house a second ESP. Parallel operation of the two ESPs will enable increased pumping capacity. Connector adapter ver. 2 must in such cases be used at each end. - Replacement of two of the longitudinal beams with fluid-carrying pipes can be used for serial arrangement of ESPs. Fluid is fed through the first ESP from the inlet connector end to the outlet connector end. Fluid is routed back through the other pipe (which has no ESP) to the inlet connector end. The fluid is pressurized through the second ESP to the outlet connector. Connector adapter ver. 3 must in such cases be used at each end.

In another embodiment, the tube stiffness is obtained by support profiles/plates mounted on the ESP tube and weight reduction is achieved with the buoyancy material that surrounds the ESP tube and the support plates. See figures 5 and 6.

For all these embodiments and variations thereof, means are provided to enable hydrate inhibition. It is install injection openings at suitable positions for the supply of methanol or other inhibitors. This arrangement will also be used for flushing the unit to remove hydrocarbons before it is recovered. Supply and control of such injection is typically provided from the system installed in the associated production system.

Condition monitoring of the ESP (pressure, temperature and vibration signals) can be done in several ways: - Signals modulated in the power supply cable, as is typically done for downhole use, can be used if the data update frequency is not critical.

- Signals can be routed through the production control system.

Signals can be routed through a signal wire or optical fiber in the ESP power control cable.

The system according to the invention will:

- Allow installation of a production link line mounted ESP without adding additional stress to the landing position - allow retrofitting on existing production systems without jeopardizing the structural integrity. - Increase ESP reliability and service life by allowing the ESP to run as a straight assembly without the risk of increasing rotational instability due to bending.

The system according to the invention may include any feature or step shown or described here, in any operative combination, where each such operative combination is an embodiment of the present invention.

Claims (2)

1. Robust and easily installable horizontal underwater ESP electrical submersible pump system, arranged in a horizontal production connecting line, which system includes arrangements for lifting and a connector at each end, characterized in that the system further comprises: a bracing arrangement, which ensures a straight ESP shaft at all times during lifting, installation and operation, whereby the bracing arrangement comprises a truss structure, an arrangement to limit or eliminate the load on underwater connectors to which the system is connected during operation and also other underwater structures present, and each connector or connector adapter includes an isolation valve, to enable environmentally friendly installation, replacement and retrieval of the system. 2. System according to claim 1, wherein the arrangement for limiting or eliminating the stress on the underwater connectors to which the production connecting line is connected during operation and also on existing underwater structures, comprises buoyancy elements, preferably buoyancy elements based on syntactic foam, preferably with lifetime and total buoyancy to compensate for increased weight to the system compared to a traditional subsea production connection line.