Patent ID: 12209487

DETAILED DESCRIPTION

The present disclosure describes an assembly and a method for powering a packer and an electrical submersible pump. Wellbores in an oil and gas well are filled with both liquid and gaseous phases of various fluids and chemicals including water, oils, and hydrocarbon gases. A packer and an electrical submersible pump are installed in the wellbore to seal a production tubing to an inner surface of the wellbore and to flow the fluids and gases in the wellbore from the formations of the Earth to the surface of the Earth. An electrical cable extends from the surface of the Earth to the packer and the electrical submersible pump. The electrical cable supplies electricity to power both the packer to seal the wellbore and the electrical submersible pump to pressurize fluids.

Implementations of the present disclosure realize one or more of the following advantages. Time to conduct completion operations can be reduced. For example, powering the packer and the electrical submersible pump with the same electrical cable can eliminate time required to position a second electrical cable with one cable powering one of packer and the other electrical cable powering the electrical submersible pump.

Complexity of wellbore completion operations can be reduced. For example, powering the packer and the electrical submersible pump with the same electrical cable can reduce the complexity of wellbore completion operations.

Personnel safety and environmental safety can be improved. For example, when the position of the packer needs to be shifted in response to a pressure control excursion (a kick), the position of the packer can be shifted immediately, without tripping a shifting tool or plug into the wellbore to shift the position hydraulically or mechanically, reducing risk to personnel and the environment.

FIG.1Ais a schematic view of a wellbore production system100having a packer102, an electrical submersible pump104, and a piston assembly106with the packer102in an unset mode.FIG.1Bis a schematic view of the wellbore production system100with the packer102, the electrical submersible pump104, and the piston assembly106ofFIG.1Awith the packer102in a set mode. The wellbore production system100has an electrical cable108electrically coupled to the piston assembly106and the electrical submersible pump104to supply electrical power to both the piston assembly106and the electrical submersible pump104.

The wellbore production system100(the packer102, the electrical submersible pump104, and the piston assembly106) can be disposed in a wellbore110. The wellbore110extends from a surface112of the Earth into the formations114of the Earth. The formations114of the Earth contain liquid and gaseous phases of various fluids and chemicals including water and hydrocarbons. The wellbore110includes an opening106that allow the liquid and gaseous phases of the various fluids including water, oils, and hydrocarbon gases to flow from the formations114into the wellbore110in the direction of arrow116and up to the surface112of the Earth for transport and refinement. The wellbore110has an inner surface118.

The wellbore production system100includes a production tubing120extending from the surface112to the packer102. The production tubing120receives the fluids from the electrical submersible pump104, the piston assembly106, and the packer102, then conducts the fluids to the surface112.

Referring toFIG.1A, the packer102is in a unset state. In the unset state, the packer102is spaced apart from the inner surface118of the of the wellbore110. The packer102includes a cylindrical body122, an expandable seal124, and multiple slips126.

The cylindrical body122defines an interval void128and apertures130extending from the internal voids128through the cylindrical body122. The interval void128receives the fluids from the piston assembly106, then conducts the fluids through the packer102to the production tubing120. The each of the apertures130are sized to accept and pass a single slip126to move the expandable seal124.

The expandable seal124coupled to the cylindrical body122and articulable by the multiple slips126. The expandable seal124has an inner surface132and an outer surface134. The inner surface132contacts the slips126. The outer surface134is a sealing surface.

The expandable seal124moves between a first position136and a second position138. In the first position136, the expandable seal124is spaced apart from the inner surface132of the wellbore110(the unset state as shown inFIG.1A). In other words, in the unset state, the outer surface134of the expandable seal124is not in contact with the inner surface132of the wellbore110. In the second position138, the expandable seal124is in contact with the inner surface132of the wellbore110(the set state as shown inFIG.1B). In other words, in the set state, the outer surface134of the expandable seal124contacts the inner surface124of the wellbore110. When the expandable seal124is in the set state in contact with the inner surface132of the wellbore110, fluid in the wellbore110is preventing from flowing outside the packer102in the wellbore110between an uphole location140and a downhole location142relative to the packer102as shown inFIG.1B.

The slips126move the expandable seal124between the first position136and the second position138. The slips126contact the piston assembly106and move responsive to the piston assembly106actuating on the slips. The slips126move in an outward direction144away from a central axis146of the packer102to move the expandable seal124from the first position136to the second position138(as shown inFIG.1B), that is the set state. The slips move in an inward direction182toward the central axis146of the packer102to move the expandable seal124from the second position138to the first position136(as shown inFIG.1A), that is, the unset state. In some cases, the slips126move orthogonally relative to the central axis146of the packer102.

The piston assembly106is coupled to the packer102and operates the expandable seal124of the packer102between the first position136and the second position138. The piston assembly106is also coupled to the electrical submersible pump104. The piston assembly106receives the fluids from the formations114from the electrical submersible pump104and conducts the fluids to internal void128of the packer102. The piston assembly106is electrically coupled to the electrical cable108and receives electrical power from the electrical cable to operate108.

The piston assembly106has a cylindrical body148, a piston150, a cone152, a gear assembly154, and a downhole power unit156. The piston150is movable within the cylindrical body148to engage and disengage the cone152from the slips126to move the expandable seal124between the first position136and the second position138. The downhole power unit156receives electricity from the electrical cable108, converts the electrical energy into mechanical energy to operate the gear assembly154to move the piston150and the cone152to position the expandable seal124.

The cylindrical body148has a void158extending through the cylindrical body148. The void158receives the formation fluids from the electrical submersible pump104. The void158conducts the formation fluids through the piston assembly106to the internal void128of the packer102.

The downhole power unit156is coupled to the electrical cable108and receives electricity from the electrical cable108. The downhole power unit156includes a motor160which is coupled to the electrical cable108. The motor160converts the electricity received from the electrical cable108into mechanical force to operate the gear assembly154.

The downhole power unit156is positioned interior to an outer surface162of the cylindrical body148. The downhole power unit156is contained within and integrated into the cylindrical body148between the void158and the outer surface162. The cylindrical body148seals and protects the downhole power unit156from corrosive elements contained in the fluids from the formations114.

In some cases, the electrical cable108conducts command signals to the downhole power unit156. For example, the command signals can direct the downhole power unit156energize the motor160to operate the gear assembly154to move the piston150and the cone152.

In some cases, the electrical cable108conducts status signals representing a condition of the downhole power unit156from the downhole power unit156. For example, the electrical cable108can transmit status signals representing a temperature, a pressure, a resistance, or an on/off state of the downhole power unit156, or a position of the gear assembly154.

The downhole power unit156operates to activate the slips126of the packer102. Activating the slips126sets and unsets elements of the packer102such as the expandable seal124.

The gear assembly154is operated by the downhole power unit156and transfers the mechanical force to the piston150and cone152to move the cone152to engage and disengage the cone152from the slips126, moving the expandable seal124between the first position136and the second position138. The gear assembly154has a first gear164and a second gear166. The first gear164is coupled to the motor160and the second gear166. The second gear166is coupled to the first gear164and the piston150. The first gear164receives the mechanical energy from the motor160and transfers the mechanical energy to the second gear166which positions the piston150and the cone152relative to the slips126.

In some cases, the first gear164is pinion and the second gear166is a rack. The first gear164can rotate counter-clockwise168(as shown inFIG.1A) or clockwise170(as shown inFIG.1B). Referring toFIG.1A, when the first gear164rotates counter-clockwise168, the second gear166, the piston150, and the cone152move in a downhole direction172away from the slips126and disengage from the slips126. Referring toFIG.1B, when the first gear164rotates clockwise170, the second gear166, the piston150, and the cone152move in an uphole direction174toward the slips126and engage the slips126.

The cone152extends from the piston150in the uphole direction174toward the slips126. The cone152is configured to alternately engage and disengage the slips126to actuate the slips126, moving the expandable seal124between the first position136and the second position138. The cone152is operable between a cone-first position176(shown inFIG.1A) and a cone-second position178(shown inFIG.1B). Referring toFIG.1A, when the cone152is in the cone-first position176, the cone152is spaced apart, separated, and disengaged from the slips126. Referring toFIG.1B, when the cone152is in the cone-second position178, the cone is engaged and in contact with the slips126and has moved the slips126to reposition the expandable seal124from the first position136to the second position138. The cone152has an angle surface180which, when the angle surface180moves in and out of contact with the slips126, moves the slips126.

The electrical submersible pump104is coupled to the piston assembly106. The electrical submersible pump104receives the fluids from the wellbore102and pressurizes the fluids. The electrical submersible pump104pressurizes the fluids to flow the fluids from a downhole location182in the wellbore110to the surface112in the uphole location140through the void158of the piston assembly106, the internal void128of the packer102, and the production tubing120.

The electrical submersible pump104is electrically coupled to the electrical cable108. The electrical submersible pump104receives electrical power from the electrical cable108.

In some cases, the electrical cable108conducts command signals to the electrical submersible pump104. For example, the command signals can direct the electrical submersible pump to start pumping, stop pumping, increase a rotational speed, or decrease the rotational speed.

In some cases, the electrical cable108conducts status signals representing a condition of the electrical submersible pump104from the electrical submersible pump104. For example, the electrical cable108can transmit status signals representing a temperature, a pressure, a resistance, an on/off state of the electrical submersible pump104, or a flow rate of the fluid from the formations114through the electrical submersible pump104.

Referring toFIGS.1A-1B, the wellbore production system100includes a controller184positioned at the surface112. The controller184has a power supply186. The controller184and the power supply186are coupled to the electrical cable108. The controller184transmits command signals to both the piston assembly106and the electrical submersible pump104along the electrical cable108to operate the electrical submersible pump104to flow the fluids in the wellbore110to the surface112and to operate the piston assembly104to move the expandable seal124between the first position136and the second position138to seal the packer102to the wellbore102. The controller184receives the status signals from the piston assembly106and the electrical submersible pump104via the electrical cable108. The power supply186transmits electricity to both the piston assembly154and the electrical submersible pump104via the electrical cable108.

The controller184can include a computer with a microprocessor. The controller184can include one or more sets of programmed instructions stored in a memory or other non-transitory computer-readable media that stores data (e.g., connected with the printed circuit board), which can be accessed and processed by a microprocessor. The programmed instructions can include, for example, instructions for sending or receiving signals and commands to operate the piston assembly106and the electrical submersible pump104. The controller184stores values (signals and commands) against which sensed values (signals and commands) representing the conditions of the piston assembly106and the electrical submersible pump104are compared.

FIGS.2A-2Dillustrate operations including deploying the wellbore production system100into the wellbore110, operating the packer102and the electrical submersible pump104, and retrieving the wellbore production system100from the wellbore110.FIG.2Ais a schematic view of the packer in the unset mode and the electrical submersible pump ofFIGS.1A-1Bbeing disposed in a wellbore. Referring toFIG.2A, a deploying operation200is performed. The electrical submersible pump104, the piston assembly106, and the packer102are run in the wellbore110by the production tubing120connected to a rig (not shown) at the surface112. The expandable seal124of the packer102is in the first position136. The electrical submersible pump104, the piston assembly106, the packer102, and the electrical cable108are positioned in the wellbore110at a desire depth202in the wellbore110by the rig.

FIG.2Bis a schematic view of the packer and the electrical submersible pump ofFIGS.1A-1Bin a wellbore with the packer shifting from the unset mode to the set mode. Referring toFIGS.1B and2B, the operation204of setting the packer is performed. With the electrical submersible pump104, the piston assembly106, and the packer102, the electrical cable108, and the production tubing120held stationary in the wellbore110by the rig. The controller184transmits a command signal to the piston assembly106to move the expandable seal124of the packer102from the first position136(unset) to the second position138engaged to the wellbore102, sealing the electrical submersible pump104such that the fluids from the formations114enter the electrical submersible pump104. The command signal and the electricity to operate the piston assembly108are conducted via the electrical cable108. The controller184can then transmit a command signal and electricity to the electrical submersible pump104to operate, pressurizing the fluid and conducting the fluid from the wellbore110to the surface112.

FIG.2Cis a schematic view of the packer and the electrical submersible pump ofFIGS.1A-1Bin a wellbore with the packer shifting from the set mode to the unset mode. Referring toFIGS.1A and2C, operations206unsetting the packer102are performed. The controller184transmits a command signal to the electrical submersible pump104to stop operating via the electrical cable108. The controller184stops flowing electricity to the electrical submersible pump104on the electrical cable108. The controller184transmits a command signal and electricity via the electrical cable108to the piston assembly106to move the expandable seal124from the second position138to the first position136, disengaged from the wellbore110.

In some cases, after the expandable seal124has been released by the slips126, the expandable seal124may take a period of time to relax (contract). For example, the expandable seal124can take up to 30 minutes or even more time to relax. In such cases, packer102should not be move in the wellbore110for 30 minutes or until relaxed to ensure the expandable seal124does not become stuck to the wellbore110while pulling the packer102out of the wellbore110.

FIG.2Dis a schematic view of the packer in the unset mode and the electrical submersible pump ofFIGS.1A-1Bbeing retrieved from the wellbore. Referring toFIGS.1A and2D, an operation208to retrieve the wellbore production system100from the wellbore110is performed. The rig at the surface112retrieves the production tubing120, the packer102, the piston assembly106, the electrical submersible pump104, and the electrical cable108to the surface112.

FIG.3is a flow chart of an example method300of powering a packer and an electrical submersible pump according to the implementations of the present disclosure. At302, a first command signal is conducted along an electrical cable to a piston assembly coupled to a packer configured to actuate from a retracted position to an extended position. The first command signal commands the piston assembly to actuate the packer from the retracted position to the extended position. In some implementations, a controller operatively coupled to the piston assembly generates the first command signal. For example, referring toFIGS.1B and2B, the controller184transmits a command signal via the electrical cable108to the piston assembly106to move the expandable seal124to move from the first position136to the second position138.

At304, the first command signal and electricity is received at the piston assembly. For example, referring toFIGS.1B and2B, the electrical cable108conducts the command signal from the surface112to the piston assembly106in the wellbore110. The downhole power unit160of the piston assembly106receives the command signal and electricity.

At306, responsive to receiving the first command signal and electricity at the piston assembly, the packer is moved, by the piston assembly, from the retracted position to the extended position. For example, referring toFIGS.1B and2B, the motor160is energized, rotating the pinion164to move the rack166. The piston150and the cone152move in the uphole direction174such that the cone152to contact the slips126. Responsive to the cone152contact the slips126, the slips move in the outward direction144extending the expandable seal124from the first position136(the retracted position) to the second position138(the extended position).

At308, a second command signal and electricity is conducted along the electrical cable to an electrical submersible pump assembly. The second command signal commands the electrical submersible pump to operate to flow a production fluid through the electrical submersible pump. In some implementations, the controller is operatively coupled to the electrical submersible pump and generates the second command signal. For example, referring toFIGS.1B and2B, the controller184transmits the second command signal and electricity via the electrical cable108.

At310, the second command signal is received at the electrical submersible pump. For example, referring toFIGS.1B and2B, the electrical submersible pump104receives the second command signal and the electricity from the electrical cable108.

At312, responsive to receiving the second command signal at the electrical submersible pump, the electrical submersible pump is operated to start the flow of the production fluid. For example, referring toFIGS.1B and2B, the electrical submersible pump104pressurizes the fluid within the electrical submersible pump104.

In some implementations, the powering the hydrocarbon production system further includes conducting a third command signal along the electrical cable to the electrical submersible pump assembly, the third command signal commanding the electrical submersible pump to operate to stop the flow of the production fluid through the electrical submersible pump; receiving the third command signal at the electrical submersible pump; responsive to receiving the third command signal at the electrical submersible pump, stopping the electrical submersible pump; conducting a fourth command signal along the electrical cable to the piston assembly, the fourth command signal commanding piston assembly to actuate the packer from the extended position to the retracted position; receiving the fourth command signal at the piston assembly; and responsive to receiving the fourth command signal at the piston assembly, moving, by the piston assembly, the packer from the extended position to the retracted position. For example, referring toFIGS.1A and2C, the controller184transmits a command signal to the electrical submersible pump104to stop pressurizing the fluid within the electrical submersible pump104and the controller184stops supplying electricity to the electrical submersible pump104via the electrical cable108. For example, the controller184can transmit a command signal to the motor160to rotate the first gear164(the pinion) in the counter-clockwise direction168, moving the second gear166(the rack) in the downhole direction172, disengaging the cone152from the slips126. The expandable seal124contracts from the second position138to the first position136.

In some cases, the method further includes, before conducting the first command signal along an electrical cable to the piston assembly coupled to the packer, disposing the electrical submersible pump, the piston assembly, and the packer in a wellbore. For example, referring toFIG.2A, the rig positions the electrical submersible pump104, the piston assembly106, the packer102, and the electrical cable108in the wellbore110.

In some cases, the method further includes, after moving, by the piston assembly, the packer from the extended position to the retracted position, retrieving the electrical submersible pump, the piston assembly, and the packer from the wellbore. For example, referring toFIG.2D, the rig retrieves the electrical submersible pump104, the piston assembly106, the packer102, and the electrical cable108from the wellbore110.

Embodiments

In an example aspect, a wellbore production system includes a packer, a piston assembly, an electrical submersible pump, and an electrical cable. The packer is configured to move between an extended position and a retracted position to seal against an inner surface of a wellbore. The piston assembly is coupled to the packer. The piston assembly moves the packer between the extended position and the retracted position. The electrical submersible pump is coupled to the piston assembly. The electrical cable is coupled to the piston assembly and the electrical submersible pump. The electrical cable supplies electrical power to both the piston assembly and the electrical submersible pump.

In an example aspect combinable with any other example aspect, the electrical cable is configured to transmit command signals to the piston assembly and the electrical submersible pump and transmit status signals from the piston assembly and the electrical submersible pump.

In an example aspect combinable with any other example aspect, the wellbore production system includes a controller configured to perform operations including transmitting the command signals to the piston assembly and the electrical submersible pump on the electrical cable and receiving the status signals from the piston assembly and the electrical submersible pump on the electrical cable.

In an example aspect combinable with any other example aspect, the packer includes an expandable seal and multiple slips. The expandable seal is movable between the extended position and the retracted position to seal against the inner surface of the wellbore. The slips are coupled to the expandable seal. The slips are movable between a first position and a second position. Moving the slips from the first position to the second position extends the expandable seal to the extended position. Moving the slips from the second position to the first position retracts the expandable seal to the retracted position.

In an example aspect combinable with any other example aspect, the expandable seal moves orthogonally to a center axis of the packer and the piston assembly between the extended position and the retracted position. The slips move parallel to the center axis of the packer and the piston assembly between a first position and a second position.

In an example aspect combinable with any other example aspect, the piston assembly includes a downhole power unit coupled to the electrical cable. The downhole power unit has a motor move the slips between the first position and the second position.

In an example aspect combinable with any other example aspect, the piston assembly includes a first gear and a second gear. The first gear is coupled to the motor. The second gear coupled to the first gear and the slips. The second gear moves the slips between the first position and the second position.

In an example aspect combinable with any other example aspect, the first gear is a pinion and the second gear is a rack.

In an example aspect combinable with any other example aspect, the piston assembly includes a piston and a cone. The piston is coupled to the downhole power unit. The cone extends from the piston. The cone moves from a first position spaced apart from the slips to a second position engaged to the slips. Responsive to the cone moving from the first position spaced apart from the slips to the second position engaged to the slips, the slips move from the first position to the second position, extending the expandable seal to the extended position.

In an example aspect combinable with any other example aspect, when the cone is in the second position engaged to the slips, the slips move from the second position engaged to the cone to the first position spaced apart from the cone. Responsive to the slips moving from the second position engaged to the cone to the first position spaced apart from the cone, the expandable seal moves to the retracted position.

In an example aspect, hydrocarbon production method includes conducting a first command signal along an electrical cable to a piston assembly coupled to a packer configured to actuate between a retracted position to an extended position, the first command signal commanding the piston assembly to actuate the packer from the retracted position to the extended position; receiving the first command signal at the piston assembly; responsive to receiving the first command signal at the piston assembly, moving, by the piston assembly, the packer from the retracted position to the extended position; conducting a second command signal along the electrical cable to an electrical submersible pump assembly, the second command signal commanding the electrical submersible pump to operate to flow a production fluid through the electrical submersible pump; receiving the second command signal at the electrical submersible pump; and responsive to receiving the second command signal at the electrical submersible pump, operating the electrical submersible pump to start the flow of the production fluid.

In an example aspect combinable with any other example aspect, the hydrocarbon production method includes generating, by a controller operatively coupled to the piston assembly and the electrical submersible pump, the first command signal and the second command signal.

In an example aspect combinable with any other example aspect, the hydrocarbon production method includes conducting a third command signal along the electrical cable to the electrical submersible pump assembly, the third command signal commanding the electrical submersible pump to operate to stop the flow of the production fluid through the electrical submersible pump; receiving the third command signal at the electrical submersible pump; responsive to receiving the third command signal at the electrical submersible pump, stopping the electrical submersible pump; conducting a fourth command signal along the electrical cable to the piston assembly, the fourth command signal commanding piston assembly to actuate the packer from the extended position to the retracted position; receiving the fourth command signal at the piston assembly; and responsive to receiving the fourth command signal at the piston assembly, moving, by the piston assembly, the packer from the extended position to the retracted position.

In an example aspect combinable with any other example aspect, the hydrocarbon production method includes before conducting the first command signal along an electrical cable to the piston assembly coupled to the packer, disposing the electrical submersible pump, the piston assembly, the packer, and the electrical cable in the wellbore.

In an example aspect combinable with any other example aspect, the hydrocarbon production method includes after moving, by the piston assembly, the packer from the extended position to the retracted position, retrieving the electrical submersible pump, the piston assembly, the packer, and the electrical cable from the wellbore.

Although the present implementations have been described in detail, it should be understood that various changes, substitutions, and alterations can be made hereupon without departing from the principle and scope of the disclosure. Accordingly, the scope of the present disclosure should be determined by the following claims and their appropriate legal equivalents.