GB2430701A

GB2430701A - Clamp which fixes bypass tubing to submersible pump

Info

Publication number: GB2430701A
Application number: GB0519722A
Authority: GB
Inventors: Richard Mccann; Paul Lamont
Original assignee: Schlumberger Holdings Ltd
Current assignee: Schlumberger Holdings Ltd
Priority date: 2005-09-28
Filing date: 2005-09-28
Publication date: 2007-04-04
Anticipated expiration: 2025-09-28
Also published as: GB2430701B; GB0519722D0

Abstract

A clamp 42 for use in an electrical submersible pump bypass system with an electrical submersible pump assembly (14, Fig.1) adjacent bypass tubing (38, Fig.1). The clamp includes a first clamping mechanism 53 and a second clamping mechanism 55, the first clamping mechanism including two members 57,59 for clamping to a portion of the electrical submersible pump assembly, and the second clamping mechanism for clamping to a portion of the bypass tubing. The distance between the two members of the first clamping mechanism is adjustable. The second clamping mechanism preferably includes a clamping structure providing a first clamping surface 75 for clamping bypass tubing of a first predetermined size. An insert 79 shaped to conform to the first clamping surface may be provided. The insert includes interface means that fit within grooves 77 in the first clamping surface and provides a second clamping surface 81 for clamping to bypass tubing of a second predetermined size smaller than the first predetermined size.

Description

CLAMP FOR ELECTRICAL SUBMERSIBLE PUMP BYPASS SYSTEMS

BACKGROUND OF THE INVENTION

Field of the Invention

1] This invention relates broadly to electrical submersible pump (ESP) bypass systems. More particularly, this invention relates to clamps that secure the bypass tubing to parts of the ESP assembly and protect the cables and auxiliary lines associated with the ESP.

Description of Related Art

2] In a conventional completion, an ESP assembly can be run on the bottom of the completion string in a wellbore. It is therefore not possible to gain access below the ESP assembly without first pulling the completion.

3] An ESP bypass system provides access to the welibore below the ESP assembly by hanging the ESP assembly from one side of a Y-tool. It is then possible to run past the ESP assembly in order to carry out various operations, such as logging, setting bridge plugs, perforating, running wireline and coiled tubing tools.

(0004] Clamps are typically spaced apart along the length of the ESP assembly. Each clamp secures together a section of the ESP assembly and the bypass tubing adjacent to the ESP assembly section. The ciamp can also protect cables/lines adjacent to the ESP assembly section. Disadvantageously, each clamp is specifically designed for a particular ESP section size, bypass tubing size, and cable/line size. This makes for a vast combination of clamps that must be maintained in inventory over the lifetime of the completion, which significantly increases the time and expenses in maintaining the completion.

(0005] Thus, there remains a need for improved clamps that can be adjusted to fit a range of ESP section sizes, bypass tubing sizes, and cable/line sizes, and thereby significantly reduce the costs of maintaining a completion over its operational lifetime.

BRIEF SUMMARY OF THE INVENTION

6] It is therefore an object of the invention to provide an improved clamp for an ESP bypass system that can be adjusted to fit a range of ESP section sizes.

7] It is another object of the invention to provide such a clamp that can be adjusted to fit a range of bypass tubing sizes.

8] It is a further object of the invention to provide such a clamp that can be adjusted to fit a range of cable/line sizes.

9] In accord with these objects, which will be discussed in detail below, an improved clamp is provided for use in an ESP bypass system with an ESP assembly adjacent bypass tubing. The clamp includes a support structure that supports a first clamping mechanism and a second clamping mechanism, the first clamping mechanism including two members for clamping to a portion of the 02.0034 ESP assembly, and the second clamping mechanism for clamping to a portion of the bypass tubing. The distance between the two members of the first clamping mechanism is preferably adjustable. The second clamping mechanism preferably includes a clamping structure providing a first clamping surface for clamping bypass tubing of a first predetermined size and a set of grooves that extend in a lengthwise direction along said first clamping surface. An insert shaped to conform to the first clamping surface of the clamping structure may be provided. The insert includes interface means that fit within said set of grooves in the first clamping surface for fixing the insert to the first clamping surface. The insert provides a second clamping surface for clamping to bypass tubing of a second predetermined size that is less than the first predetermined size.

0] It will be appreciated that the first clamping mechanism can be adjusted to fit a range of ESP section sizes. Moreover, the second clamping mechanism can be adjusted to fit a range of tubing sizes and cable/line sizes.

1] According to one embodiment of the invention, threaded bolts couple the two members of the first clamping mechanism, and user manipulation of the threaded bolts adjusts the distance between the two members.

2] Additional objects and advantages of the invention will become apparent to those skilled in the art upon reference to the detailed description taken in conjunction with the provided figures.

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-i 32.0034

BRIEF DESCRIPTION OF THE DRAWINGS

3] FIG. I is a schematic diagram of an ESP bypass system in which the present invention can be embodied.

4] FIG. 2 is a top view of a universal clamp for use in the ESP bypass system of FIG. I in accordance with the present invention.

5] FIG. 3 is a perspective view of the universal clamp of FIG. 2 in accordance with the present invention.

6] FIGS. 4 and 5 are schematic views of the universal clamp of FIGS. 2 and 3 fixed in position securing an ESP section to a portion of bypass tubing.

DETAILED DESCRIPTION OF THE INVENTION

7] Turning now to FIG. 1, there is shown an ESP bypass system 10 in which the present invention can be used. The ESP bypass system 10 includes a Y-tool 12, which is preferably realized as an internally profiled one-piece casting.

The primary function of the Y-tool 12 is to offset the ESP assembly 14 away from the main production string, thereby allowing tool strings free vertical access past the ESP assembly 14 in order to carry out various operations (such as production logging, setting bridge plugs, through tubing perforating, wireline operations, coiled tubing operations, ESP pump isolation, and reservoir monitoring).

E001 The ESP 8ssernb!y 14 mey compr's a variety of components depending on the particular application or environment in which it is used. The C2. 3O34 exemplary ESP assembly 14 shown in FIG. 1 includes a discharge head 16, a pump section 18, an intake section 20, at least one protector/seal section (two shown as 22A, 22B), a motor section 24, and a motor plug 26. The discharge head 16 provides a top connector for the ESP assembly 14. The pump section 18 provides mechanical elements (e.g., impellers, vanes, pistons) that pump fluid from the wellbore through the intake section 20 and out the discharge head 16 for supply to the surface. The intake section 20 provides a fluid path for drawing fluid into the ESP assembly 14. The intake section 20 and the protector/seal sections 22A, 22B transmit torque generated by the motor section 24 to the pump section 18 for driving the pump. The protector/seal sections 22A, 22B also provide a seal against fluids/contaminants entering the motor section 24. The motor section 24 provides an electric motor assembly that is driven by electric power supplied thereto. The motor plug 26, which is disposed on the bottom of the ESP assembly 14, provides an additional clamping position, as well as protecting the ESP assembly when running the completion. A downhole monitoring tool (not shown) may be provided between the motor section 24 and the motor plug 26. The downhole monitoring tool provides for monitoring/telemetry of downhole conditions/parameters at or near the pumping location.

9] The ESP bypass system 10 includes a handling sub/crossover 28, which is preferably located directly above the Y-tool 12. The handling sub/crossover 28 preferab!y fricorporates en upset shoulder for handling the system during installation and acts as a crossover to the production tubing thread C2.3334 that leads to the top of the completion string.

0] The Y-tool 12 provides an inverted-Y-branched path from a top port 30 to an ESP-side port 32 and to a bypass-side port 34, respectively. A telescopic swivel nipple ("TSN") 36 is located directly below the Y-tool 12 and is coupled to the bypass-side port 34 of the Y-tool 12. The TSN 36 has a primary function to provide a seal bore for various bypass side tooling (e.g., blanking plugs, logging plugs, isolation sleeves as described herein). The profile of the TSN 36 is preferably adapted to ensure that the bypass side tooling is positioned below the production flow path to avoid erosion and sand ingress. The TSN 36 is capable of rotation and linear telescoping to assist system make-up. Bypass tubing 38, which is disposed below the TSN 36, allows for passage of tools down past the ESP assembly 14. A re-entry guide 40, which is disposed below the bypass tubing 38, acts as a guide for tools such as logging tools, wireline tools, and coiled tubing tools.

1] The TSN 36 can preferably support within its seal bore a wide variety of different tooling, such as blanking plugs, logging plugs, and isolation sleeves.

A blanking plug provides a seal to the bypass tubing 38, which prevents recycling of well fluid through the bypass tubing 38 and allows the ESP assembly 14 to pump the fluids to the surface as normal. A wireline logging plug prevents circulation around the ESP assembly 14 during wireline logging operations. The ESP assembly 14 can continue to run during wireline ioging operations in static or dynamic conditions. A coiled tubing jogging piug prevents circujation around 02.0034 the ESP assembly during coiled tubing logging operations. The ESP assembly can continue to run during coiled tubing logging operations in static or dynamic conditions. A coiled tubing logging string is connected to the coiled tubing logging plug. An isolation sleeve is supported with the seal bore of the TSN 36 and extends above the Y-tool 12 to effectively straddle the path through the Y- tool 12 leading from the top port 30 to the ESP-side port 32, which allows free flowing of the well. It can be used to protect the ESP assembly 14 in situations where bullhead ing of the fluids through the bypass tubing is required.

2] A flow sub 27, which is disposed between the discharge head 16 of the ESP assembly 14 and the ES P-side port 32 of the Y-tool 12, provides a connection between the ESP assembly 14 and the ESP-side port 32 of the Y-tool 12.

3] A set of clamps (e.g., five shown as 42A, 42B, 42C, 42D, 42E) are spaced apart along the length of the ESP assembly 14. Each clamp secures a section of the ESP assembly to bypass tubing 38 adjacent thereto. It also can guide cables/lines adjacent to the ESP assembly section. The clamps also aid in maintaining clearance between the outside diameter of the assembly and the inside diameter of the wellbore casing 91 (FIGS. 4 and 5).

4] In accordance with the present invention, each clamp 42 of the set is realized from a universal clamp design that can readily be adapted for different sizes of the ESP assembly sections and the bypass tubing as follows. FIGS. 2 and 3 illustrate the universal clamp design, which includes a frame structure 51 02.0034 (which is preferably realized by two parts 51A, 51B) supporting an ESP clamping mechanism 53 and a bypass tubing clamping mechanism 55.

5] The ESP clamping mechanism 53 includes a semi-circle-shaped member 57 (which is preferably realized by two parts 57A, 57B) and a semicircle-shaped band 59 that is adjustably connected to the member 57 by two threaded bolts 61A, 61 B. The distance between the member 57 and the band 59 is adjusted by tightening and/or loosening the threaded bolts 61A, 61B. The bolts 61A, 61 B are adjustable such that the member 57 and the band 59 securely clamp around the outer diameter surface of a section of the ESP assembly (for example, motor section 24 as shown in FIG. 4). With the member 57 and the band 59 securely clamped around the outer diameter surface of a section of the ESP assembly, the threaded bolts 61A, 61B also act to hold the two-part frame structure (51A, 51 B) together as best shown in FIGS. 2 and 3.

6] In the illustrative embodiment, the two parts 57A, 57B of the semicircle-shaped member 57 are integrally formed as parts of the two-part frame structure 51A, 51 B. Two swivel nuts 63A, 63B are supported near the terminal ends 65A, 65B of the member 57. Two boreholes 67A, 67B are provided in the terminal ends of the member 57. The boreholes 67A, 67B extend in a plane transverse to the central axis of the ESP clamping mechanism 53 (the central axis is normal to the page in FiG. 2) to provide access to female-type threads provided in the two swivel nuts 63A. 63B.

7] The two threaded bolts 61 A, 61 B extend in the plane transverse to the -8.

I 02.00S4 central axis of the ESP clamping mechanism and interface to corresponding female threads in the two swivel nuts 63A, 63B. The clamping surface 69 of the member 57 has a characteristic radius of curvature on the order of 1.75 inches (44 mm), while the clamping surface 71 of the band 59 has a characteristic radius of curvature of 2 inches (51 mm). The distance between the member 57 and the band 59 is adjusted by tightening and/or loosening the threaded bolts 61A, 61B. These features allow the member 57 and the band 59 to securely clamp around ESP sections of varying outside diameter. For example, one embodiment of the clamp 42 fits ESP sections with a range of diameters from 4 to 5.62 inches (102 to 143 mm), with varying flange neck sizes in the range of 1.9 to 3.5 inches (48 to 89 mm).

(0028] The by-pass clamping mechanism 55 is realized by a structure 73 that has a generally C-shaped cross-section as best shown in FIG. 2. The structure 73, which is preferably realized as two parts 73A, 73B, extends in a lengthwise dimension parallel to its central axis beyond the top and bottom sides of the ESP clamping mechanism 53 as best shown in FIG. 3. In the illustrative embodiment, the two parts 73A, 73B of the structure 73 are integrally formed as parts of the two-part frame structure 51A, 51 B. The clamping surface 75 of the structure 73 includes a set of grooves (or cutouts) 77A - 77D that extend along its lengthwise dimension. The grooves 77A - 77D are sized to retain and guide control lines of a predetermined size or to retain an insert which effectively changes the diameter of the bypass olamping mechanism as described below (FiGS. 4 and 5). ifl the illustrative embodiment, the clamping surface 75 of the structure 73 is sized to 102.0034 securely clamp bypass tubing of 2.875 inch (73 mm) diameter, two grooves 77A, 77B are sized to retain and guide control lines with an outside diameter of 0.375 inches (10 mm), and two grooves 77C, 77D are sized to retain and guide control lines with an outside diameter of 0.250 inches (6 mm).

9] An insert 79, which is preferably realized in two parts 79A, 79B as shown, may be provided. The insert 79 has a generally C-shaped crosssection as best shown in FIG. 2 such that it conforms to the clamping surface 75 of the structure 73 and has protruding flubs that run lengthwise along its rear side adjacent the clamping surface 75 and fit into corresponding grooves 77 in the clamping surface 75. The front side of the insert 79 provides a clamping surface 81 with a set of grooves (or cutouts) 83A, 83B that extend along its lengthwise dimension. The grooves 83A, 83B are sized to retain and guide control lines of a predetermined size (FIGS. 4 and 5). In the illustrative embodiment, the clamping surface 81 of the insert 79 is sized to securely clamp a bypass tubing of 2.375 inch (60 mm) diameter and the two grooves 83A, 83B are each sized to retain and guide two control lines with outside diameters of 0.250 inches (6 mm) and 0.375 inches (10 mm), respectively. Multiple inserts can be provided with clamping surfaces of different sizes to accommodate bypass tubing of varying sizes. Moreover, the grooves of such inserts can have different sizes/shapes in order to accommodate control lines of varying size.

0] A clip 85 is secured to the exterior of the frame structure 51. Dreferably by a threaded coupling. The cup 85 preferably extends in a direction parallel to - 10 - u..uU4 the lengthwise dimension of the bypass tubing clamping mechanism 55 and is adapted to protect the ESP cable and prevent the cable from slipping under its own weight. The clip 85 is designed to fit a range or ESP cable (Motor Lead Extension - "MLE") sizes. The cable clip fingers 86 maintain constant contact with the MLE. This contact, and the cable deflection created thereby, prevents the cable from slipping. In the present embodiment, the clip 85 can accommodate a range of cable sizes from 0.3 to 0.6 inches (8 to 15 mm) thick by increasing the deflection of the fingers 86.

(0031] As shown in FIGS. 4 and 5, the universal clamp design can readily be adapted to clamp to the discharge head 16 (clamp 42A of FIG. 1), the pump section 18 and/or intake section 20 (clamp 42B), the protector/seal section 22A, 22B (clamp 42C), the motor section 24 (clamp 42D), and/or the motor plug 26 (clamp 42E) of the ESP assembly 14. The universal clamp design can also readily be adapted to clamp to one or more of these ESP sections, or parts of another ESP assembly, that have different outside diameter dimensions in order to accommodate a variety of ESP assembly sizes.

2] The clamp 42 is preferably made of low alloy or stainless steels by investment casting and is finish machined to include threaded holes and clearance holes for pins and bolts. Alternatively, the clamp may be machined from bar stock, although casting is the most cost effective method of manufacture.

3] Advantageously, the universal ESP bypass clamp design described JJ'J'J-T herein significantly reduces the number of different clamps that must be maintained in inventory over the lifetime of a given completion and thus reduces the costs associated therewith.

4] There have been described and illustrated herein embodiments of a universal clamp for an ESP bypass system. While particular embodiments of the invention have been described, it is not intended that the invention be limited thereto. Thus, while particular ESP bypass configurations have been disclosed, it will be appreciated that other ESP bypass configurations can be used as well.

In addition, while particular sizes for the bypass tubing, ESP assembly section and control lines have been disclosed, it will be understood that other sizes can be used. Moreover, while particular two-part configurations have been disclosed in reference to the different parts of the clamp design, it will be appreciated that other configurations could be used as well. It will therefore be appreciated by those skilled in the art that yet other modifications could be made to the provided invention without deviating from its scope as claimed. - 32-

Claims

I U.UUs

What is claimed is: 1. A clamp for use in an electrical submersible pump bypass system having an electrical submersible pump assembly adjacent bypass tubing, the clamp comprising: a support structure that supports a first clamping mechanism and a second clamping mechanism, the first clamping mechanism including two members for clamping to a portion of the electrical submersible pump assembly, the two members having a distance therebetween, and the second clamping mechanism for clamping to a portion of the bypass tubing; wherein the distance between the two members of the first clamping mechanism is adjustable.
2. A clamp according to claim 1, wherein: the adjustable distance between the two members of the first clamping mechanism accommodates clamping to different portions of the electrical submersible pump assembly. 1I

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G2.0034
3. A clamp according to claim 1, wherein: the adjustable distance between the two members of the first clamping mechanism accommodates clamping to different electrical submersible pump assemblies of varying size.
4. A clamp according to claim 1, wherein: threaded bolts couple the two members of the first clamping mechanism, and wherein user manipulation of the threaded bolts adjusts the distance between the two members of the first clamping mechanism.
5. A clamp according to claim 4, wherein: one of the two members of the first clamping mechanism comprises swivel nuts that receive the threaded bolts via corresponding boreholes in the one member.
6. A clamp according to claim 4, wherein: the first clamping mechanism has a central axis and the threaded bolts extend in a direction perpendicular to the central axis.
7. A clamp according to claim 1, wherein: the seod campi1g mechaiism comprises a ciampin structure with a generally Cshaped cross-section, the clamping structure providing a first - 14 - f A UJU)'4 clamping surface for clamping bypass tubing of a first predetermined size.
8. A clamp according to claim 7, wherein: the clamping structure of the second clamping mechanism includes a set of grooves that extend in a lengthwise direction along the first clamping surface.
9. A clamp according to claim 8, wherein: a set of control lines are disposed in the grooves.
10. A clamp according to claim 8, further comprising: an insert shaped to conform to the first clamping surface of the clamping structure, the insert having interface means that fit within the set of grooves in the first clamping surface for fixing the insert to the first clamping surface, the insert providing a second clamping surface for clamping to bypass tubing of a second predetermined size that is less than the first predetermined size.
11. A clamp according to claim 10, wherein: the second clamping surface of the insert includes a set of grooves for guiding control lines therein.
12. A clamp according to claim 7, wherein: the support structure, one of the two members of the first clamping mechanism, and the clamping structure of the second clamping mechanism are each realized as two parts. - 15 f
13. A clamp for use in an electrical submersible pump bypass system having an electrical submersible pump assembly adjacent bypass tubing, the clamp comprising: a support structure that supports a first clamping mechanism and a second clamping mechanism, the first clamping mechanism for clamping to a portion of the electrical submersible pump assembly, and the second clamping mechanism for clamping to a portion of the bypass tubing, the second clamping mechanism including a clamping structure providing a first clamping surface for clamping bypass tubing of a first predetermined size; and an insert shaped to conform to the first clamping surface of the clamping structure, the insert providing a second clamping surface for clamping to bypass tubing of a second predetermined size that is less than the first predetermined size.
14. A Clamp according to claim 13, wherein: the second clamping surface of the insert includes a set of grooves for guiding control lines therein. \t' A
15. A clamp according to claim 13, wherein: the clamping structure of the second clamping mechanism has a generally C-shaped cross-section.
16. An electrical submersible pump bypass system for use in a downhole environment, the system comprising: an electrical submersible pump assembly; bypass tubing adjacent the electrical submersible pump assembly; and a set of clamps for clamping portions of the electrical submersible pump assembly to the bypass tubing; wherein at least one of the clamps comprises a support structure that supports a first clamping mechanism and a second clamping mechanism, the first clamping mechanism including two members for clamping to a given portion of the electrical submersible pump assembly, and the second clamping mechanism for clamping to a portion of the bypass tubing, wherein distance between the two members of the first clamping mechanism is adjustable.
17. An electrical submersible pump bypass system according to claim 16, wherein: the adjustable distance between the two members of the first clamping - 17- 32.3034 mechanism accommodates clamping to different portions of the electrical submersible pump assembly.
18. An electrical submersible pump bypass system according to claim 16, wherein: the adjustable distance between the two members of the first clamping mechanism accommodates clamping to different electrical submersible pump assemblies of varying size.
19. An electrical submersible pump bypass system according to claim 16, wherein: threaded bolts couple the two members of the first clamping mechanism, wherein user manipulation of the threaded bolts adjusts the distance between the two members of the first clamping mechanism.
20. An electrical submersible pump bypass system according to claim 19, wherein: one of the two members of the first clamping mechanism comprises swivel nuts that receive the threaded bolts via corresponding boreholes in the one member.
21. An electrical submersible pump bypass system according to claim 19, where ir: the first clamping mechanism has a central axis and the threaded bolts - is - r%,, rr)# extend in a direction perpendicular to the central axis.
22. An electrical submersible pump bypass system according to claim 16, wherein: the second clamping mechanism comprises a clamping structure with a generally C-shaped cross-section, the clamping structure providing a first clamping surface for clamping bypass tubing of a first predetermined size.
23. An electrical submersible pump bypass system according to claim 22, wherein: the clamping structure of the second clamping mechanism includes a set of grooves that extend in a lengthwise direction along the first clamping surface.
24. An electrical submersible pump bypass system according to claim 23, wherein: a set of control lines are disposed in the grooves.
25. An electrical submersible pump bypass system according to claim 23, further comprising: an insert shaped to conform to the first clamping surface of the clamping structure of the second clamping mechanism, the insert having interface means that fit within the set of grooves in the first clamping surface for fixing the insert to the first clamping surface, th insert proViding a second clamping surface for clamping to bypass tubing of a second predetermined size that is less than the - 19first predetermined size.
26. An electrical submersible pump bypass system according to claim 25, wherein: the second clamping surface of the insert includes a set of grooves for guiding control lines therein.
27. An electrical submersible pump bypass system according to claim 22, wherein: the support structure, one of the two members of the first clamping mechanism, and the clamping structure of the second clamping mechanism are each realized as two parts.
28. An electrical submersible pump bypass system for use in a downhole environment, the system comprising: an electrical submersible pump assembly; bypass tubing adjacent the electrical submersible pump assembly; and a set of clamps for clamping portions of the electrical submersible pump assembly to the bypass tubing, wherein at least one of the clamps comprises a support structure that supports a first clamping mechanism and a second clamping mechanism, the first clamping mechanism for clamping to a portion of the electrical subm&sibte pump assembty, and the second ciamping mechanism for clamping to a portion of the bypass tubing, the second clamping mechanism - 20 - 102.0034 including a clamping structure providing a first clamping surface for clamping bypass tubing of a first predetermined size and a set of grooves that extend in a lengthwise direction along the first clamping surface; and an insert shaped to conform to the first clamping surface of the clamping structure, the insert having interface means that fit within the set of grooves in the first clamping surface for fixing the insert to the first clamping surface, the insert providing a second clamping surface for clamping to bypass tubing of a second predetermined size that is less than the first predetermined size.
29. An electrical submersible pump bypass system according to claim 28, wherein: the second clamping surface of the insert includes a set of grooves for guiding control lines therein.
30. An electrical submersible pump bypass system according to claim 28, wherein: the clamping structure of the second clamping mechanism has a generally C-shaped cross-section. -21 -