Selectively powering an electrical submersible pump assembly
A completion assembly to be disposed in a wellbore to produce a hydrocarbon. The completion assembly has electrical conductors, a docking station for an electrical submersible pump assembly, and a downhole electrical connector selector. The docking station is coupled to the electrical conductors in the wellbore and has multiple electrical connectors to flow electricity from the electrical conductors to the electrical submersible pump assembly. The downhole electrical connector selector couples to the docking station between the docking station and the electrical submersible pump assembly. The downhole electrical connector selector is configurable to switch between a first subset of the electrical connectors and a second subset of electrical connectors to control a flow of electricity from the electrical connectors of the docking station to the electrical submersible pump assembly to maintain the flow of electricity to the electrical submersible pump assembly.
1 . A completion assembly configured to be disposed in a wellbore to produce a hydrocarbon, the completion assembly comprising:
a plurality of electrical conductors extending from a surface of the Earth to a downhole location in the wellbore, the plurality of electrical conductors comprising a first three-phase electrical cable and a second three-phase electrical cable;
a docking station for an electrical submersible pump assembly, the docking station coupled to the plurality of electrical conductors in the wellbore, the docking station comprising a plurality of electrical connectors configured to flow electricity from the plurality of electrical conductors to the electrical submersible pump assembly, each phase of the first and second three-phase electrical cables coupled to a different electrical connector, wherein the docking station comprises a first side pocket comprising a first set of the plurality of the electrical connectors coupled to the first three-phase electrical cable and a second side pocket spaced apart from the first side pocket, the second side pocket comprising a second set of the plurality of the electrical connectors coupled to the second three-phase electrical cable, the second set of the plurality of the electrical connectors different than the first set of the plurality of the electrical connectors; and
a downhole electrical connector selector configured to couple to the docking station between the docking station and the electrical submersible pump assembly, the downhole electrical connector selector configurable to switch between a first subset of the plurality of electrical connectors and a second subset of the plurality of electrical connectors to control a flow of electricity from the plurality of electrical connectors of the docking station to the electrical submersible pump assembly to maintain the flow of electricity to the electrical submersible pump assembly.
2 . The completion assembly of claim 1 , wherein the first subset of the plurality of electrical connectors and the second subset of the plurality of electrical connectors comprise at least one common electrical connector.
3 . The completion assembly of claim 1 , wherein the plurality of electrical conductors comprises a partial donut-shaped flat-pack cable comprising between four and seven conductors, each conductor coupled to a different electrical connector.
4 . The completion assembly of claim 1 , wherein the downhole electrical connector selector comprises a first shuttle motor connector configured to couple to the first side pocket and a second shuttle motor connector configured to couple to the second side pocket.
5 . The completion assembly of claim 1 , wherein each of the electrical connectors corresponding to a first phase are positioned at a first axial location along a length of the docking station, each of the electrical connectors corresponding to a second phase different than the first phase are positioned at a second axial location different than the first axial location along the length of the docking station, and each of the electrical connectors corresponding to a third phase different than the first phase and the second phase are positioned at a third axial location different than the first axial location and the second axial location along the length of the docking station.
6 . The completion assembly of claim 1 , wherein the electrical connectors are arranged in an axial line parallel to a longitudinal axis of the docking station.
7 . The completion assembly of claim 1 , wherein the electrical connectors are arranged radially at the same axial location along a length of the docking station.
8 . The completion assembly of claim 7 , wherein the electrical connectors are arranged in three spaced apart pairs.
9 . The completion assembly of claim 8 , wherein the electrical connectors are arranged about a circular flow bore of the docking station.
10 . The completion assembly of claim 8 , wherein the electrical connectors are arranged about a bore of the docking station, the bore defining a circular cross-section.
11 . The completion assembly of claim 8 , wherein the electrical connectors are arranged about a bore of the docking station, the bore defining a cross section comprising:
an inner circular cross-section; and
a plurality of outer circular cross-sections extending from the inner circular cross-section,
wherein each pair of the three spaced apart pairs are separated by at least one of the outer circular cross-sections.
12 . The completion assembly of claim 8 , further comprising a downhole test electrical connector selector configurable to couple to the plurality of electrical connectors, the downhole test electrical connector selector comprising:
a plurality of diagnostic test jumpers configured to electrically couple to a subset of the plurality of electrical connectors;
a sensor configured to detect a condition of the subset of the plurality of electrical connectors electrically connected by the plurality of diagnostic test jumpers; and
a controller coupled to the sensor, the controller configured to perform operations comprising:
receiving, from the sensor, a signal representing the condition of the plurality of electrical connectors;
comparing the signal representing the condition of the plurality of electrical connectors to a threshold condition; and
based on a result of the comparison, determining the condition of the plurality of electrical connectors.
13 . The completion assembly of claim 12 , wherein the condition of the plurality of electrical connectors comprises a location and a type of fault of one or more failed electrical connectors of the plurality of electrical connectors.
14 . The completion assembly of claim 13 , wherein the condition of the electrical connectors comprises one or more of a condition of an insulation of the electrical conductor, a resistance of the electrical connectors, or a time domain reflectometry condition of the electrical connectors.
15 . A method for completing a wellbore, the method comprising:
disposing a completion assembly in the wellbore extending from a surface of the Earth to a subterranean hydrocarbon reservoir at a downhole location, the completion assembly comprising:
a production tubing;
a plurality of electrical conductors extending from the surface of the Earth to the downhole location in a wellbore annulus defined by the production tubing and the wellbore; and
a docking station configured to be positioned in the wellbore, the docking station comprising a plurality of electrical connectors, each electrical connector of the plurality of electrical connectors electrically coupled to one of the plurality of electrical conductors;
configuring, at the surface, a downhole electrical connector selector to control a flow of electricity from a first subset of the plurality of electrical connectors to an electrical submersible pump assembly to power the electrical submersible pump assembly, the downhole electrical connector selector reconfigurable between the first subset and a second subset of the plurality of electrical connectors;
coupling, at the surface, the downhole electrical connector selector to a downhole end of the electrical submersible pump assembly;
positioning the downhole electrical connector selector and the electrical submersible pump assembly in the wellbore;
coupling the downhole electrical connector selector to the docking station,
based on a failure of the electrical submersible pump assembly to operate electrically, retrieving the downhole electrical connector selector and the electrical submersible pump assembly from the wellbore to the surface;
determining the first subset of the plurality of electrical connectors has failed;
reconfiguring the downhole electrical connector selector to control the flow of electricity from the second subset of the plurality of the electrical connectors to the electrical submersible pump assembly to power the electrical submersible pump assembly;
positioning the downhole electrical connector selector and the electrical submersible pump assembly in the wellbore; and
coupling the downhole electrical connector selector to the docking station.
16 . The method of claim 15 , after retrieving the downhole electrical connector selector and the electrical submersible pump assembly from the wellbore to the surface subsequent to determining one or more of the first subset of the plurality of electrical connectors has failed, the method further comprises determining a condition and a type of fault of one or more failed electrical connectors of the plurality of electrical connectors, wherein the condition of the electrical connector comprises one or more of which electrical connectors have failed, an insulation of the plurality of electrical conductors, a resistance of each of the electrical connectors, and a time domain reflectometry condition of the electrical connectors.
17 . A test assembly comprising:
a plurality of diagnostic test jumpers configurable to switch between a first subset and a second subset of a plurality of electrical connectors to control a flow of electricity from a docking station configured to couple to an electrical submersible pump assembly to maintain the flow of electricity from the docking station to the electrical submersible pump assembly;
a sensor coupled to the plurality of diagnostic test jumpers, the sensor configured to detect a condition of the plurality of electrical connectors when a subset of the plurality of diagnostic test jumpers are coupled to the plurality of electrical connectors; and
a controller coupled to the plurality of diagnostic test jumpers, the controller configured to perform operations comprising:
receiving, from the sensor, a signal representing the condition of the plurality of electrical connectors;
comparing the signal representing the condition of the plurality of electrical connectors to a threshold condition; and
based on a result of the comparison, determining the condition of the plurality of electrical connectors, the condition of the electrical connector comprises one or more of a condition of which electrical connectors have failed, an insulation of a plurality of electrical conductors configured to extend from a surface of the Earth, the plurality of electrical conductors coupled to the plurality of electrical connectors, a resistance of each of the electrical connectors, and a time domain reflectometry condition of the electrical connectors.