CLAIM OF PRIORITY

[0001] This application claims priority to U.S. Patent Application No. 18/219,571 filed on July 7. 2023, which claims priority to U.S. Provisional Application No. 63/491 ,233 filed on March 20, 2023 and U.S. Provisional Application No. 63/377,162 filed on September 26, 2022, the entire contents of which are hereby incorporated by reference.

TECHNICAL FIELD

[0002] This disclosure relates to artificial lift systems deployed on cable.

BACKGROUND

[0003] Most wells behave characteristically different over time due to geophysical, physical, and chemical changes in the subterranean reservoir that feeds the well. For example, it is common for well production to decline. This decline in production can occur due to declining pressures in the reservoir, and can eventually reach a point where there is not enough pressure in the reservoir to economically realize production through the well to the surface. Downhole pumps and/or compressors can be deployed into the well to increase production. Additionally or alternatively, a topside compressor and/or pump are sometimes used to extend the life of the well by decreasing pressure at the top of the well.

SUMMARY

[0004] This disclosure relates to deploying an artificial lift string on cable.

[0005] Certain aspects encompass an electric submersible artificial lift system includes an electric motor configured to reside in a wellbore, a fluid end, and an interconnect. The fluid end is coupled to the electric motor and configured to be driven to propel wellbore fluids through the wellbore when driven by the electric motor. The interconnect is at an uphole end of the electric submersible artificial lift system, and is configured to (i) couple to a cable extending from a topside facility into the wellbore to support the artificial lift system depending from the cable and (ii) release from the cable while the artificial lift system is residing in the wellbore. i [0006] Certain aspects encompass a method including supporting an electric submersible artificial lift system at an interconnect thereof by a cable as the artificial lift system is lowered into a wellbore. The cable extends from a topside facility. The cable is then released from the artificial lift system while the artificial lift system is in the wellbore.

[0007] Certain aspects encompass an artificial lift system including an electric powered fluid end configured to propel wellbore fluids through the wellbore and a cable interconnect coupled to the electric powered fluid end. The interconnect is configured to couple to a cable to support and power the electric powered fluid end and configured to release from the cable while the electric powered fluid end is in the wellbore.

[0008] Certain of the aspects can include some, none or all of the following features. The electric motor, fluid end and interconnect can be configured to reside within a production tubing within a casing of the wellbore. The artificial lift system can include an outer housing having a seal and a latch configured to seal and latch into a corresponding profile of the production tubing. The artificial lift system can include a packer configured to seal and grip an interior wall of the production tubing. The interconnect can include a line connector configured to couple an electric and/or hydraulic line extending from a topside facility into the wellbore to an aspect of the artificial lift system. The line connector can be configured to allow the line to release from the aspect of the artificial lift system while the artificial lift system is residing in the wellbore. In certain instances, the interconnect is configured to release the cable before the line connector allows the line to release from the aspect of the artificial lift system. In certain instances, the cable includes the line and the interconnect includes a cable connector configured gnp the exterior of the cable. In certain instances the interconnect is configured to release from the cable in response to a specified tension applied to the cable. The interconnect can include a tubular housing configured to internally receive the cable, a wedge in the housing moveable into gripping contact with an exterior of the cable, and a cap coupled to the tubular housing retaining the wedge in the housing, where the cap configured to release from the tubular housing upon a specified tension applied to the cable. In certain instances, the interconnect is configured to release from the cable in response to a signal supplied to the interconnect. In certain instances, the interconnect includes a tubular housing configured to internally receive the cable, a body configured to grip an exterior of the cable, and an actuator actuable to release the interconnect from gripping the cable in response to a signal. In certain instances, the body includes a wedge moveable to grip the cable by the actuator and the actuator includes a hydraulic piston coupled to a hydraulic line extending from a topside facility ⁷ into the wellbore. The piston is movable by a hydraulic signal transmitted on the hydraulic line. The artificial lift system can include an outer housing extending to an uphole end of the artificial lift system with a profile adapted to engage with a corresponding profile of a retrieval tool for retrieving the artificial lift system.

[0009] The details of one or more implementations of the subject matter described within this disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the subject matter described herein will be apparent from the description and drawings, and from the claims.

DESCRIPTION OF DRAWINGS

[0010] FIG. 1 is a side, half cross-sectional view of an example downhole artificial lift string.

[0011] FIG. 2 is a side, half cross-sectional view of another example downhole artificial lift string. FIGS. 2A-A, 2B-B, and 2C-C are sectional views of the artificial lift string of FIG. 2.

[0012] FIG. 3 is a side, half cross-sectional view of an interconnect of FIG. 2.

[0013] FIG. 4 is a side, half cross-sectional detail view of an example cable connector.

[0014] FIG. 5 is a side, half cross-sectional detail view of another example cable connector.

[0015] FIG. 6 is a side, half cross-sectional detail view of another example cable connector.

[0016] FIG. 7 is a side, half cross-sectional detail view of another example cable connector.

[0017] FIGS. 8-10 are side, half cross-sectional detail views of different configurations of line connectors.

[0018] FIG. 11 is a side, half cross-sectional view of another example downhole DETAILED DESCRIPTION

[0019] This disclosure describes an artificial lift string that allows for easy retrieval and repair of artificial lift systems, such as electric submersible pumps. The implementations described herein include an artificial lift string, such as an electric submersible pump, and a receptacle configured to receive and retain the artificial lift string. The artificial lift string is coupled to a wellhead or other topside equipment by a cable that includes electrical and/or hydraulic lines. The electric and/or hydraulic lines power, control and/or lubrication to the artificial lift string.

[0020] FIG. 1 is a side, half cross-sectional view of an example downhole artificial lift system 100a. The artificial lift system 100a includes an artificial lift string 102 within a wellbore 104. During operation, the artificial lift string 102 operates fully submersed in production fluid, assisting in flowing production fluid from a production zone 106, up through production tubing 108, to a topside facility, such as a wellhead 110. In some implementations, the topside facility includes a land based or subsea wellhead. While this disclosure primarily describes implementations using an artificial lift string having an electric submersible pump, other downhole artificial lift systems, such as electric submersible compressors, top-driven pumps or compressors, plunger pumps and compressors, and gerotor pumps can be used without departing from this disclosure. Other artificial lift devices, including positive displacement and centrifugal fluid movers, can be used without departing from this disclosure.

[0021] In some instances, such as during deployment, a cable 116, such as a wireline, slickline, e-line or other type of cable, supports the artificial lift string. The cable 116 supports the weight of artificial lift string 102 during deployment. The cable 116 includes a smooth outer surface such that the cable can be fed through a lubricator or similar structure. Electric and/or hydraulic lines to operate the artificial lift string can be incorporated with and/or separate from the cable 116. At an uphole end of the artificial lift string 102 is an interconnect 114. The interconnect 114 allows for the cable 116 extending between the wellhead 110 and the artificial lift string 102 to be released at an uphole end of the artificial lift string 102 while the string 102 is downhole. That is, the cable 116 is released at the interconnect 114 such that the cable 116 and any electric and/or hydraulic lines can be removed completely or nearly completely from the wellbore while the artificial lift string 102 remains within the wellbore 104. [0022] The artificial lift string 102 is stabbed into a downhole receptacle 118 in the production tubing 108. The downhole receptacle 118 can include a polished bore receptacle, a packer configured to receive the artificial lift string 102, or any other receptacle that is appropriate for the operations described herein. The artificial lift string 102 and the downhole receptacle 118 seal against one another when the artificial lift string is fully received by the downhole receptacle 118. That is. fluid flows primarily through the downhole receptacle 118 and artificial lift string 102 with little-to-no leakage past the seals (shown in later figures). In some implementations, the downhole receptacle 118 includes a latch configured to secure and retain the artificial lift string 102 within the downhole receptacle 118. Such latches are described in greater detail later within this disclosure.

[0023] The interconnect 114 is configured to enable a safe release of the artificial lift string 102 from its cable 116 to facilitate easy retrieval of both the cable 116 and the string 102 in two trips such that there is no lost time due to fishing the string 102 or any aspect thereof from the production tubing 108. The interconnect 114 is helpful where the cable 116 strength itself is marginal over that required to retrieve, i.e., lift, the artificial lift string 102 after it has been deployed and then needs to be removed. Over time, there is the possibility of w eakening of the cable 116 due to erosion, corrosion or temperature effects; added force required to release the artificial lift string 102 due to scale, paraffin or other factors; and the possibility of manufacturing defects along the length of the cable 116 that may become apparent when subjecting it to its highest force (the release event).

[0024] In certain instances, the mechanism of release of the interconnect 114 can be a shear to release mechanism, with a tension member(s) being tied to a shear sub of the interconnect 114 that could be set to a given value with high precision using either shear pins, bolts or studs; the subsequent working members of the cable (electrical conductors, hydraulic lines, data cable) would progressively release in sequence at a substantially lower value via a specialized splice with a known pull to failure value. This could be accomplished with a w eakened cross section of the tension member of each item. For example, in the case of a tubing encapsulated conductor, a data cable or the hydraulic line, the w eakened section could be the body section the tubing ferrule nut connects into. In certain instances, the mechanism of release of the interconnect 114 could be an active system, especially via hydraulic or electrical communication to actuate the active interconnect 114. In the case of hydraulically actuated interconnect 114, the hydraulics could shift a piston that would release a collet, or a lug or shear a mechanism like the one described above for the straight pull methodology. It could also trigger a cutting mechanism that is either chemical or explosive based. Similarly, an electronically actuated interconnect 114 could actuate a linear actuator that releases a collet, or a lug or shears a mechanism as previously described. This could be done via a data cable or via the conductor for the downhole electric machine (e.g., motor and/or generator within the artificial lift string 102). An electric mechanism could actuate a rotational mechanism that allowed free axial travel to facilitate shear mechanisms to engage or could provide the shearing force. Another embodiment would use an electrical signal to actuate a perforating charge that would sever the interconnect 114. Yet another embodiment could use a simple electronic release mechanism where there was a mechanical coupling or latch that is defeated with an appropriate signal.

[0025] Given the inherent risk with interv ention activities, each of the abovedescribed types of active interconnect 114 configurations could have a mechanical release as a backup in the case of an interruption in electric or hydraulic communication that defeats these active methods. As a result, there is the possibility that both an electric or hydraulic system could be coupled with the mechanical system. Some embodiments can include three or more of the above described release mechanisms for tertiary’ redundancy.

[0026] In some implementations, the polished bore receptacle 118 (e.g., in packer 119) includes a latch. The artificial lift string 102 is secured to the polished bore receptacle 118 (and packer 119, if used) by the latch.

[0027] In some instances when the artificial lift string 102 is removed from the wellbore 104, the following steps are taken. The cable 116 containing electrical and/or hydraulic lines is released, e.g., sheared, over pulled, or otherwise separated from an uphole end of the electric submersible artificial lift string 102. The cable 116 is released via the interconnect 114 at the electric submersible artificial lift string 102. In the case of a shearable interconnect 1 14, the interconnect is released by an over-pull of the cable 116 from the wellhead or topside facility ⁷ . Once the cable 116 is released, it is recovered from the wellbore 104. Once the cable 116 is recovered, a fishing or running tool (not shown) is run into the wellbore 104 on wireline or tubing and received by the artificial lift string 102. The tool grips and pulls up the artificial lift string 102 so it can be retrieved from the wellbore 104. In some implementations, the tool performs an overpull to release the artificial lift string 102 from the latch of the receptacle. In some implementations, a jarring tool is used to release the artificial lift string 102 from the latch of the receptacle. In some implementations, the latch has already been released prior to removing the artificial lift string 102, for example, in implementations where the latch is hydraulically actuated, the latch is released when the cable 116 is sheared.

[0028] Turning to FIG. 2, a more detailed example of an artificial lift string 202 in accordance with the concepts herein is shown, namely artificial lift string 202 shown in a side, half cross-sectional view. The artificial lift string 202 can be used in lieu of the artificial lift string 102, and is similar to artificial lift string 102, except as described below. The artificial lift string 202 includes an outer tubular housing 204 w ith a profile 206 at its uphole end that is configured to be gripped by atool for retrieval of the artificial lift string 202 from the w ellbore (e.g., fishing tool, running tool, or other type of tool) after the cable 116 has been released. The artificial lift string 202 includes a fluid end 208 within the housing 204 configured to pump, compress and/or otherwise drive (i.e., propel) fluid flow from intakes 224 to outlets 226 of the fluid end 208, which in turn, drives fluid through the production tubing 108. The intakes 224 reside in a low er portion of the housing 204 that is fluid isolated from an upper portion of the housing 204 having the outlets 226. The fluid end 208 has a stator 232 with a rotor 230 that is driven by a motor 210, and the motor 210 has its own rotor 236 and stator 234. The motor 210 is controlled by a motor controller 222, and the motor 210 and/or motor controller 222 (both residing in the housing 204) are connected to one or more electric and/or hydraulic lines 218 of the cable 116 for power, control, sensing and/or lubrication of the motor 210 and motor controller 222. The artificial lift string 202 can include other aspects, such as sensors 212 (e.g., a permanent downhole gauge including pressure and/or temperature sensors) that are connected to the cable 116 to send and/or receive data, a hydraulic reservoir 228, and/or other aspects.

[0029] The artificial lift string 202 includes an interconnect 214. similar to interconnect 114, that allows controlled release of the cable 116 from the artificial lift string 202. Here the interconnect 214 is affixed to or integrated with the housing 204 and includes a cable connector 220 configured to releasably couple the cable 116, as a whole, to the artificial lift string 202 (e.g., to the housing 204). as well as line connectors 216 configured to releasably couple the individual electric and/or hydraulic line 218 of the cable 116 the artificial lift string 202. The cable connector 220 and line connectors 216 are configured to separate or release upon specified conditions, e.g., in response to a specified tension applied through cable 11 , in response to an actuation signal, and/or upon another specified condition. In instances where the cable connector 220 and line connectors 216 are both configured to release upon application of a specified tension, the specified tension can be different, e.g., higher for the cable connector 220 than for the line connectors 216. In any instance, the cable connector 220 can grip the cable 116 with enough strength and resist separating or releasing in a manner to support the entire weight of the artificial lift string 202 as it is run into position within the wellbore. The interconnect 114 allows the cable 116 to be released from the artificial lift string 202, thus clearing the wellbore above the artificial lift string 202 so that a tool (e.g., fishing tool, running tool, and/or other tool) can be run into the wellbore on wireline or tubing (e.g., continuous coiled tubing or jointed tubing), grip the profile 206, and retrieve the artificial lift string 202 to the surface.

[0030] The lower end of the housing 204 includes a seal 240 on its exterior and a latch 242 for stabbing into, sealing and gripping a corresponding interface in the downhole receptacle 118, e.g., polished bore receptacle, stab receptacle and/or other ty pe of interface, in the production tubing 108. In certain instances, the latch 242 can be actuable, e.g.. mechanically and/or via electric or hydraulic signals via lines 218. to engage and grip the corresponding interface of the downhole receptacle 118.

[0031] Sections A- A, B-B and C-C of FIG. 2, show the routing of the lines 218 through the artificial lift string 202. As noted above, some of the lines 218 extend to the sensor 212, motor 210, motor controller 222. hydraulic reservoir 228 and/or other aspects. The lines 218 split from the housing of the cable 116 in the interconnect 214, and extend into and through axial bores in the housing 204 around the fluid end 208, motor controller 222 and motor 210 and other components of the artificial lift string 202. In certain instances, e.g., in the case of hydraulics, the bores themselves can be the lines 218. The housing 204 can also accommodate fluid passages 238 in spaces between the bores of lines 218 to allow fluid flow around the motor 210 and motor controller 222 to the fluid end 208.

[0032] FIG. 3 is a side, half cross-sectional detail view' of the interconnect 114 showing the connectors 216 in the lines 218 within the interconnect 214. The connectors 216 are configured to separate or release an upper portion of the lines 218 from a lower portion of the lines 218 with further tension applied via the cable 116, after the cable 116 is released from the cable connector 220. The lower portion of the lines 218 can enter the sidewall of the housing 204 to enter the axial bores discussed above.

[0033] FIG. 4 is a side, half cross-sectional detail view of an example cable connector 420 that can be used as cable connector 220. The cable connector 420 includes a tubular housing 422 that is affixed to housing 204 of the artificial lift string 202. The cable connector’s housing 422 internally receives the cable 116, and includes a cap 424 affixed to the housing 422 to retain annular wedges 426 and a compression ring 428 surrounding the cable 116. The compression ring 428 is threaded to the interior of the housing 422 such that it can be screwed toward the cap 424, compressing the wedges 426 against the cap 424, and driving the wedges 426 to radially contract and grip the cable 116 with enough force to support a specified tension. The cap 424 is affixed to the housing 422 in a manner configured to release when the specified tension is applied to the cable 116. In certain instances, the cap 424 is affixed to the housing 422 with one or more shear pins 430 (e.g., pins, screws and/or another shape) configured to shear when the cable 11 is subjected to the specified tension. The specified tension can be selected high enough that the cable 116 safely supports the artificial lift string 202 when being run in and set in the production tubing 108 (e.g., the specified tension is higher than the weight of the artificial lift string 202), but low enough that the specified tension can be readily attained by jarring or over pulling on the cable 116 when the latches of the artificial lift string 202 are engaged in the production tubing 108.

[0034] FIG. 5 is side, half cross-sectional detail view of another example cable connector 520 that can be used as cable connector 220. The cable connector 520 includes a tubular housing 522 that is affixed to housing 204 of the artificial lift string 202. The cable connector’s housing 522 includes annular wedges 526 and an actuator defined by an annular release piston 528 that is releaseably secured in a position compressing the wedges 526 to grip the cable 116. In certain instances, the piston 528 is pinned with a shear pin 530. The piston 528 has a hydraulic passage 532 coupled to a hydraulic control line 218 of cable 116. The passage 532 communicates hydraulic fluid from the line 218 to a sealed chamber 534 between the piston 528 and housing 522. When a control signal, i.e., pressure above a specified pressure, is supplied through the cable 116 (e.g., from outside the well) to the sealed chamber 534 via the line 218. it drives the piston 528 away from wedges 526, allowing the wedges 526 to release the cable 116. In instances where the piston 528 is pinned in location by shear pins 530, the specified pressure is a function of the strength of the shear pins 530. In other words, the piston 528 releases only when the pressure in the chamber 534 is enough to shear the shear pins 530. Alternatively, the piston 528 could be carried on a linear servo operated electrically (via an electric control line 218) to shear the shear pins 530, and drive the piston 528 away from the wedges 526 and allowing the wedges 526 to release the cable 116.

[0035] FIG. 6 is a side, quarter cross-sectional detail view of another example cable connector 620 that can be used as cable connector 220. The cable connector 620 includes a tubular housing 622 that is affixed to housing 204 of the artificial lift string 202. The cable connector’s housing 622 includes a ferrule (not shown) that grips the cable 116, via friction, wedges with compression ring (as above) and/or in another manner. The ferrule includes one or more downwardly extending collets 626 trapped in gripping engagement with a profile 624 of the housing 204 by an annular piston 628, radially inward from the collets 626. A hydraulic passage 632 through the piston 628 communicates hydraulic fluid from a hydraulic line 218 to a sealed chamber 634 between the piston 628 and the housing 622. When a control signal, i.e., pressure above a specified pressure, is supplied through the cable 116 (e.g., from outside the well) to the sealed chamber 634 via the line 218. it drives the piston 628 away from collets 626, freeing the collets 626 to move radially inward and release from gripping engagement with the profile 624. Once the collets 626 release, the ferrule, and thus cable 116, is likewise released from the remainder of the cable connector 220, and the cable 116 can be retrieved.

[0036] FIG. 7 is a side, half cross-sectional detail of an example cable connector 720 that can be used as cable connector 220. The cable connector 720 includes a tubular housing 722 that is affixed to housing 204 of the artificial lift string 202. The cable connector’s housing 722 includes a cap 724 affixed to the housing 722 to retain annular wedges 726. The cap 724 includes a compression nng 728 that is threaded to the remainder of the cap 724 such that it can be screwed to compress the wedges 726 against the housing 722, and drive the wedges 726 to radially contract and grip the cable 116 with enough force to support a specified tension. The cap 724, including the compression ring 728. is affixed to the housing 722 in a manner configured to release when the specified tension is applied to the cable 116. In certain instances, the cap 724 is affixed to the housing 722 with one or more shear pins 730 configured to shear when the cable 116 is subjected to the specified tension. As above, the specified tension can be selected high enough that the cable 116 safely supports the artificial lift string 202 when being run in and set in the production tubing 108, but low enough that the specified tension can be readily attained by jarring or over pulling on the cable 116 when the artificial lift string 202 latches are engaged in the production tubing 108.

[0037] FIGS. 8-10 are side, half cross-sectional detail views of different configurations of line connectors (connectors 816, 916, 1016) that can be used as line connector 216. FIG. 8 shows a line connector 816 that is configured to fail when subjected to a specified tension by having a housing 818 with a necked portion 820 of a specified cross-sectional area selected to fail at the specified tension. A ferrule 822 that grips the line 218 is threaded into the housing 816 to couple the line 218 to the housing. FIG. 9 shows a line connector 916 that is configured to fail when subj ected to a specified tension by having a two part housing 918 connected with a shear pin 920 (e.g., a shear ring, one or more straight pins or screws, and/or another configuration) of a specified cross-sectional area selected to fail at the specified tension. As above, a ferrule 922 that grips the line 218 is threaded into the housing 918 to couple the line 218 to the housing. FIG. 10 shows a line connector 1016 that is configured to separate when subjected to a specified tension by having a two part housing 1018 connected by one or more collets 1020 that engage and grip a corresponding profile 1024. The collets 1020 are biased into the profile 1024, but flex inward and are driven out of the profile 1024 when the housing 1018 is subjected to the specified tension. As above, a ferrule (not shown) can be threaded into the housing 1018 to couple the line to the housing.

[0038] FIG. 11 shows an alternate alternative artificial lift string 1102 that is similar to the artificial lift string 202 discussed above, except as noted below. Notably, the artificial lift string 1102 need not land in a receptacle 118 in the production tubing 108, but instead has a packer 1140 configured to seal and grip the interior of the production tubing 108. The packer 1140 can be mechanically actuated and released, for example, via by manipulation of the string 1102 and/or it can be hydraulically and/or electrically actuated via a control signal supplied through the cable 116. Notably, in this configuration, the lines 218 are shown traversing the exterior of the housing 204. Additionally, the string 202 includes a safety valve 1150 configured to shut in the flow through the production tubing 108 upon failure of the artificial lift string 1102. [0039] While this disclosure has described some aspects in terms of electric submersible pumps, other downhole artificial lift systems, such as electric submersible compressors, top-driven pumps or compressors, plunger pumps and compressors, and gerotor pumps can be used without departing from this disclosure. Other mechanical lift devices, including positive displacement and centrifugal fluid movers, can be used without departing from this disclosure. Also, while the artificial lift strings have been described herein as coupling and sealing to production tubing, they could alternatively be configured to couple and seal with casing to pump, compress or otherwise drive fluid in the casing. [0040] A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of this disclosure. Accordingly, other implementations are within the scope of the following claims.