Presented at

Electrical Submersible Pump Workshop

Houston, TX. USA.


Page 1 of 14

Recent Advances in Coiled Tubing Deployed ESPs

Juan J. Tovar D. and Craig M
c
K Webster, Innovative Engineering Systems Ltd.
Jeff Dwiggins and Steve Conner, Wood Group ESP Inc.


Abstract

This paper presents recent developments in Coiled Tubing (CT) completion systems using standard and
inverted configurations of ESPs with an internal power cable. In the past, various systems utilised
modified well intervention equipment as surface and subsurface components for CT / ESP completions.
All existing installations with power cable inside the CT string also utilise inverted pumps. Inverted
pumps were developed to be used with the Cable Deployed Pumping System
(1)
. Due to the inherent
design limitations and field problems encountered
(2,3,4)
with this type of system an alternative approach
was taken to design new systems that take full advantage of CT technology. Recent developments
include purpose designed and built surface and subsurface assemblies, including a production spool
featuring a non-enclosed type hanger without lock down screws. A non-permanent, non-damaging cable
suspension system has also been developed. Suspension is based on a friction concept and is provided in
such a manner that cable movement is permitted (but minimised) and no damage or indentation is
caused to the CT either internally or externally. The subsurface components allow integration of
conventional or inverted pump assemblies and the CT / cable assembly. This paper describes in detail
the new systems and their components.


Background

Alternative deployed ESP's have been a developing technology since the early 1970s
(5)
. One of the first
systems to be developed commercially utilised a strength bearing cable that was banded to the ESP
power cable
(1)
. Problems encountered in using this system involved the banding of the two cables, and
the rotational characteristics of the strength bearing cable. The second of these problems was overcome
by using a torque-balanced cable. Although the system could be run without the use of a drilling or
workover rig, greatly reducing cost of installation / retrieval. A dedicated winch unit was required to
deploy the completion. CDPS
*
continues to be used on a limited basis
(6)
.

In the early 90s further developments led to the deployment of ESPs with Coiled Tubing still using the
power cable outside the CT
(7)
. In 1995 the first CT deployed systems were installed placing the power
cable inside the CT string.
(2,8)
The major benefits of locating the power cable inside the CT are a
reduction in operational time and the ability to deploy the completion under live well conditions,
avoiding costly well killing operations and productivity impairment. Experience gained with the first
prototypes proved the feasibility of the concept and indicated that significant timesavings could be
realised. However, various events highlighted the need for further development. Packer discharge head
failure and relative short run life of the installation were clear indications of potential problems.
Premature commercialisation of the technology confirmed these problems during the first installations,

*
CDPS is a trademark of Schlumberger
Presented at
Electrical Submersible Pump Workshop
Houston, TX. USA.


Page 2 of 14
where the operator reported cable slippage and installation failure
(3)
. Further improvements have to
some extent solved these problems. Most of these systems utilised CDPS technology that includes
sacrificial tubing with a nipple located at a pre-determined depth where the pump is to be set. Table 1
presents the main characteristics of the currently available systems.

Other pump manufacturers have made significant progress towards developing alternative systems
(9)
,
making a particular effort on cable suspension mechanisms and subsurface systems functionality such as
packer discharge heads, release systems.


Internal Cable Suspension

Several methods for suspending cable have been developed since the two-cable system. The first
systems utilised a small clamp that is attached to the power cable
(2,8)
. The cable and clamps were then
pulled through the Coiled Tubing using wireline or a smaller diameter tubing. The clamps were
activated when the CT was pressurised. Within the clamp, the upper section of a cylinder surrounding a
piston extended outward against the wall of the tubing, indenting the CT and fixing the clamp and the
suspended cable in place. Another system was developed in the late 90s that suspends the cable by
indenting the CT around a spacer that is attached to the cable
(9)
. The connection mechanism is
analogous to that of a Dimple-On CT connector in which a number of external indentations are made
throughout the string length.

A disadvantage of both the above systems is that they involve deformation of the Coiled Tubing to some
extent. As the working limits of the tubing are already being maximised, such damage can reduce the
number of safe working cycles for the string. Independent testing has been carried out to evaluate the
level of damage caused by the indentation process
(4)
. Figure 1 illustrates indentation of the internal
walls of the CT caused by a suspension system. Field results indicate that both systems have worked
with varied rates of success.

One of the most common concepts that can be used in supporting the cable is buoyancy. Difference of
opinion still exists as to the loading that cables can support. Thus, there is a point at which the power
cable will fail mechanically under its own weight. Using buoyancy as means to suspend cable implies
that the weight of a submerged cable is reduced according to levels where no plastic deformation takes
place in the conductors. The buoyancy force considers the particular fluid and cable to be used and can
be calculated using the following equation:

F
b
= g x 8
f
x V
c

Where:

F
b

= Buoyancy Force

f
= Density of the supporting fluid
V
c
= Volume of the cable
g = Gravitational Acceleration Constant

Presented at
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Houston, TX. USA.


Page 3 of 14
Using this concept, high-density fluid such as solids laden muds can aid in the partial or total suspension
of the cable. Although effective in supporting the power cable, it is restricted because of the nature of
the suspension fluid. High-density mud has a tendency to segregate with the heavier particles settling
out. Should high-density brines be considered, a cost element needs to be accounted for. In addition to
this, the added weight of the fluid to the CT / Cable assembly can in some cases increase the running
and pulling loads to unacceptable limits. Furthermore circulation of fluids through the CT string cannot
be achieved as introducing a lighter fluid into the annulus results in a lower buoyancy force that may
cause cable failure. While the technical arguments continue, there is no doubt that for certain type of
wells cable suspension might not be required. However, that is not always the case and each particular
scenario needs to be analysed on its own merits. Figure 2 illustrates typical cable loading with and
without buoyancy for an application in the North Sea.

The concept of CT deployed ESPs with an internal cable assembly is a viable and cost effective
alternative despite the various technical problems encountered to date that have clouded its true
potential. The problems encountered are the result of limited engineering, testing and premature
commercialisation. Most of the concepts available in the industry work but could be significantly
improved. The opportunity to take full advantage of the cost and technical advantages of the technology
is still un-exploited. The following paragraphs present the development of a Reeled Electro-Submersible
Lifting Completion System - ReELIFT
*
for both conventional and inverted pump systems.


Completion Philosophy

The requirement for a CT deployed ESP completion system is aimed mainly at the economics, reliability
and safety aspects. Following the industry demand for optimised economics through better use of
technology, development of such a system has to be based on the following premises:

Operational viability and cost.
Integration of field proven technology.
Live well installation and retrieval.
Well barriers and safety philosophy
Rig-less deployment and retrieval

The economic implications of using this technology in high cost environments such as the North Sea
have been assessed before
(11)
. Based on the previous experience and the previous premises a completion
system was developed and is presented in the following paragraphs.


*
ReELIFT is a registered mark of Innovative Engineering Systems Limited
Presented at
Electrical Submersible Pump Workshop
Houston, TX. USA.


Page 4 of 14
Surface Assembly

An innovative surface assembly based on a new hanger, production spool and bonnet type has been
designed to increase the efficiency of running and retrieving the completion. The surface assembly is
common to both types of ESP completion (i.e. conventional or inverted pump) The most noticeable
difference between this system and more conventional designs is that there are no tie-down bolts.
Instead the hanger is locked in place by dogs, which locate inside the spool. When the running tool is
locked into the hanger, it activates a collar that allows the hanger's landing and release from the spool.
As the running tool is retrieved, the locking collar is pushed up by a spring, forcing the dogs to lock into
the spool body. An indicator pin stands out of the spool body until the hanger has been fully locked into
position. This also doubles as a leak detector. Should the seal systems between the hanger and the spool
body fail, the increase pressure will push out the indicator pin warning of lost seal integrity.

A conventional wellhead penetrator is passed up through the bonnet, and locked in place by a retaining
nut. Figure 3 illustrates the surface assembly in more detail. Additional features of the design include a
barrier between the CT and the hanger ensuring well isolation via the internals of the CT/Cable
assembly. Other options to the surface assembly include production wing outlets mounted on the spool.


Cable Suspension

An innovative cable suspension system was developed based on friction. One of the main concerns in its
development was for the cable suspension mechanism to reduce the risk of string failure due to internal
or external damage caused to the CT as with the current systems. As a result, a non-indenting type of
mechanism was developed and extensively tested which allows cable suspension without causing
mechanical damage to the CT. Variable Suspension Units - VSU
*
are attached to the cable and
significantly increase controllable friction between the units and the walls of the CT. Initial prototype
testing was carried out in a test well successfully. An AWG No.1 cable was equipped with cable
suspension devices and deployed into the well. An electronic load recording device was used to monitor
the load variations as the cable was lowered / pulled in the well. At least 15 different configurations
were successfully tried to validate the concept and select the optimum characteristics for maximum
suspension. Further trials were carried out using stainless steel as requested by an operator. As a result,
the system can be configured to provide optimum cable suspension for conventional A 606 alloys or
Super Duplex steels that have recently being introduced to the CT market. Figure 4 shows an early
prototype being lowered in the test well. The developed system has the following features:

Non damaging to the CT
Simple installation and retrieval
Suspension with or without buoyancy
Suitable for A606 or Super Duplex CT

The suspension units have non-moving parts that make manufacturing, installation and activation more
simple and cost effective. Continuing developments include features that will allow safe cable retrieval,

*
VSU is a registered trademark of innovative Engineering Systems Limited
Presented at
Electrical Submersible Pump Workshop
Houston, TX. USA.


Page 5 of 14
making the technology more cost effective in the years to come. Evolution of the cable suspension units
is shown in Figure 5.

Sub-Surface Assembly Conventional Pump

The most common configuration for CT deployed ESPs is the inverted pump assembly. The main
reason for utilising this configuration is that by placing the motor above the pump, the cable can be
connected directly onto the motor head housing. This eliminates the requirement for an MLE (motor
lead extension) from the head of the pump to the pothead on the motor. These features are original in the
CDPS system but CT has replaced the strength member, retaining the same pump configuration and
system limitations. The main disadvantage of this configuration is that it requires sacrificial tubing,
imposing a fixed pump setting depth giving limited flexibility. Inverted pumps are still perceived as new
technology, and continuous reliability problems with the system, inn particular the discharge head has
marred the perception of the technology.

In providing a BHA that allows a conventional pump assembly to be utilised, several new components
had to be designed. The function of these components is to pass the insulated cable conductors from the
base of the CT string through the packer and into the annulus and to the motor. At the same time the
components had to isolate the conductors from the produced fluids. This was achieved by developing
interfaces that ensure as much as possible the protection of the power cable while providing an effective
flow path. A robust and tested design removed the sealing problem previously encountered using "O"
rings that had led to premature cable failures. The subsurface assembly that incorporates conventional
pumps has the following main features:

Allows well circulation at depth
Safety and reliability by allowing timely release from the packer if required
Integrate a flow control function
Avoid fluid recirculation
Safely isolate the reservoir from potential damage from flow back.

In addition to this, a unique release system has been developed. This allows the well to be circulated
with fluids as required without releasing. To release from the BHA, fluids must be pumped through the
release tool until it is positioned for release. Straight pull will free the CT from the subsurface assembly
and cut the cable leaving a clean fish for further retrieval. This feature allows circulation of fluids up to
the top of the pump as many times as may be required. Release is not affected by circulation hence
removing the problem associated with multiple function subs of this type. Figure 6 illustrates the
circulating and release system.

A Flow Isolation and Control Device is situated at the base of the ReELIFT completion system. It is a
valve that is locked opened by flow. Extensive testing has been carried out to calibrate the flow rate to
lock open the valve. The current design requires approximately 50 gpm to lock the device open.
Pressurising a control line closes the valve. This is to be done when the ESP has been stopped. The
hydrostatic column above the valve energises the Teflon seal on the valve seat. Figure 7 shows most of
the main components of the subsurface assembly.
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Page 6 of 14
The general rule in the industry is the fewer splices / connectors the better. As a result, only one splice
downhole above the ESP motor (MLE splice) is used. The electrical termination at the bottom of the CT
utilises a centre tandem lead connector that is a bolt together connection. Figures 8 and 9 show the
electrical connectors on both pieces and the insulators. This connection will take the place of a wet
mateable field type connection reducing equipment cost and improving reliability.

The connection will allow the components to be assembled and tested in a clean environment, and then
taken to the field. The system may also be tested in the shop, insuring a clean and safe assembly. The
whole unit can then be shipped to site for immediate installation.


Sub-Surface Assembly Inverted Pump

Although the inverted pump configuration lacks some of the advantages of the conventional system, it is
still a cost effective means of artificial lift were an ESP is required. The main advantages are:

No MLE connection is required.
Direct connection of the cable to the motor.
Easy deployment no packer requirement.


However, its limitations and the requirement for sacrificial tubing and a fixed setting depth. In order to
overcome these problems, a packer discharge head has been developed which allows multiple setting
and re-setting of the pump at various depths.

The ReELIFT Series I completion system is designed to be run with an inverted pump. The motor
and seal section is placed above a single component of the system, a packer type component that also
allows discharge of the fluids into the annulus.

The packer is set and unset by a hydraulic control line that can either be run to surface or using fluids
within the CT. There is no requirement for hydrostatic pressure to be maintained during normal
operations. The design provides lock both rotationally and laterally within the casing string and will
hold high pressures from above. The system having many of the features of a conventional packer will
not drag in the well as can be a problem with bag type and similar systems. As the system is over 24
long, a bearing is included for the motor shaft, however further developments are aimed at removing this
limitation.

The flow control device and release mechanism used in the conventional system can also be
incorporated in this assembly. Figure 10 presents the subsurface assembly using inverted pumps.


Presented at
Electrical Submersible Pump Workshop
Houston, TX. USA.


Page 7 of 14
Manufacturing and Testing

Two completion systems using conventional pump configurations have been manufactured, tested,
certified and delivered to the Wood Group ESP Inc. They are to be installed during the second quarter of
this year. A thorough testing and certification program witnessed by certifying authorities was
completed. Testing included individual component and assembly integrity tests as well as function
testing. The flow isolation and control device was tested to rates in excess of 12,000 BFPD. The sealing
systems for cable isolation were tested in 6 sections and were able to sustain a differential pressure of
4000 psi when heated to 300F. Other components were tested to 5000 psi differential pressure. The
project was completed 5 weeks ahead of schedule. Figure 11 shows the two systems prior to shipping.


Conclusions and Recommendations

Utilisation of CT deployed ESP technology with the power cable located inside the CT string is reaching
a technically mature age and can provide a cost effective lift option.

Slow implementation to date has been mainly due to the poor field record and lack of technical
alternatives. Both problems are indications of premature release of a technology to the market.

At least four (4) cable suspension devices are available in the market. An Innovative, non-indenting type
avoids internal or external mechanical damage to the CT walls minimising the risk of string failure.

This new design of suspension system has been successfully tested with conventional A 606 alloys and
new super duplex CT materials.

Conventional pump configurations can now be utilised for CT ESP completions. As a result, the
requirement for the installation of costly and time consuming accessories (tubing, packers etc.)
associated with existing inverted pump configurations are no longer needed opening new options to
potential users.

A new completion system (ReELIFT) integrates field proven technology in the design of its surface
equipment, cable suspension and subsurface assemblies. New and improved sealing technology as well
as well safety systems increase reliability and functionality of the system avoiding common problems
encountered with existing installations.

ReELIFT Series I equipment for inverted pump configurations removes all the limitations imposed
by the older technology based on the CDPS units. The completion can be installed without sacrificial
tubing or fixed setting depth.

Series C equipment accommodates conventional pumping technology, improving reliability and choice
for a particular application.


Presented at
Electrical Submersible Pump Workshop
Houston, TX. USA.


Page 8 of 14
Acknowledgements

The authors wish to thank Innovative Engineering Systems and the Wood Group ESP for permission to
publish this paper. We are grateful to J. Patterson at ARCO for his sincere contribution to the
manufacturing and testing program, Dr M. McHugh at Lawrence Technology for his comments on cable
suspension and P. McCurdy at IESL for his efforts in the development of the cable suspension system.


References

1. Reda Pump Company Cable Deployed Pumping Systems, Brochure, Bartesville, Oklahoma, USA.

2. Tovar J. et al, First Field Installation of a Coiled Tubing Powered Electrical Submersible Pump Completion, SPE
paper 28914, presented at the European Petroleum Conference in London, England, October 1994.

3. Hightower C. H., ARCO Drilling and Completion Experience with Coiled Tubing presentation carried out at JNOC-
TRC Workshop on Reeled Tubing Systems, Tokyo, Japan, May 1997.

4. RTD Services Examination of Indentation Depth left by an Internal Cable Support Internal Report 1996.

5. Dwiggins J. and Willard L., Two Cable Deployed Pumping Systems, SPE Workshop, Houston, USA, April 1991.

6. Dublanko G. The Utilisation of a Cable Deployed Pumping System Gulf of Suez, Egypt, SPE Electrical
Submersible Pump Workshop, Houston, Texas, April 1995.

7. Coburn S. et al, Coiled Tubing Deployed Electrical Submersible Pumping Systems, paper 7322, presented at the
OTC, Houston, Texas, USA, 1993.

8. Tovar J. and Head P., ESP Development on Coiled tubing w. Internal Power Cable Technical and Economic
Considerations, presented at the 3
rd
International Conference on Coiled Tubing Operations, Houston, Texas, USA,
March 1995.

9. Centrilift Press Release, Electro-coil on inside track, Press and Journal, Offshore Journal Supplement, Aberdeen,
U.K., 1998.

10. European Patent Application EP 0 899 421 A2 Method of suspending an electrical submersible pump within a
wellbore Filed 25
th
of February 1998.

11. Tovar J. and Callander J., The Economics of Coiled Tubing Deployed ESP Completions in the North Sea. A Field
Lifecycle Perspective, SPE Paper 35566 presented at EPOC, Stavanger, Norway, 1996.

Presented at
Electrical Submersible Pump Workshop
Houston, TX. USA.


Page 9 of 14

Characteristic REDA Centrilift IESL ESP Inc.
Sacrificial Tubing Yes - No No
Type of Pump Inverted Inverted
Conventional &
Inverted
Conventional &
Inverted
Packer Discharge Head Discharge Head
Conventional /
Discharge Head
Conventional /
Discharge Head
Surface
Spool
None None Yes -
No of Connectors 2 connectors -
1 connector
1 splice
-
Cable Suspension
Fixed Anchors
& Friction
Swelling & Fixed
Clamp
Friction Based Friction Based
CT Damage Indentation Indentation None None
Emergency Release Yes - Yes Yes
Circulation Yes - Yes Yes
Flow Control External - Yes Yes
Number of Wells 8* 1 1** 2**
* 5 more at planning phase
** At planning phase
Table 1 General Characteristics of CT/ESPs


Figure 1 Indentation on Coiled Tubing
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Houston, TX. USA.


Page 10 of 14






























Figure 2 Cable Loading Graph
0
500
1000
1500
2000
2500
3000
3500
4000
4500
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Depth (ft)
S
u
r
f
a
c
e

L
o
a
d

(
l
b
s
)
0
7
14
21
28
35
42
49
56
63
W
e
l
l

I
n
c
l
i
n
a
t
i
o
n

(
d
e
g
)
Supported
cable case 1
C ABLE DATA
AW G Round No.1
W eight = 1.77 lb /ft
W ell Inclination
Unsupported cable
Supported cable
case 2
M ax Allow ed Load
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Page 11 of 14


































Item Description
1 Bonnet
2 Spool Body
3 Hanger
4 Indicator Pin
5 Cable Sealing Unit

Figure 3 Surface Assembly








Figure 4 VSU Prototype




Figure 5 - Evolution of the VSU
1
2
3
5
4
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Page 12 of 14







Figure 6 Circulation / Release Sub







Item Description
1 Coiled Tubing
2 Circulation & Release
3 Discharge Head
4 Packer
5 Control Line
6 ESP Cable Conductors
7 MLE Splice
8 Control Line
9 Hydraulic Control Line
10 Flow Control Device
11 Pump & Motor Assm.
Figure 7 Conventional Assembly

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Page 13 of 14


Figure 8 Electrical Connectors




Figure 9 Electrical Connectors


















Item Description
1 Coiled Tubing
2 Circulation & Release
3 Control Line
4 Packer Discharge Head

Figure 10 Inverted Assembly





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Page 14 of 14







Figure 11 ReELIFT Ready for Shipping