Downhole DAS Slug Detection for ESP Pump Protection

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Solution Overview

Problem

ESPs in wells face challenges due to gas and sand slugs, leading to inefficient operation, damage, and high failure rates, particularly in unconventional wells, where slugs cause sudden flow changes, cavitation, and temperature fluctuations, reducing efficiency and lifespan.

Innovation Solution

Implementing a distributed acoustic sensing (DAS) system with a fiber optic cable to detect slugs downhole, allowing a controller to alter the ESP's operation based on detected parameters, such as slug depth, tension, and acoustic signals, preventing damage by stopping or idling the pump before the slug reaches it.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If an ESP is used to lift fluid from the well, then fluid production is achieved, but the pump experiences damage and reduced lifespan due to slug flow

Engineering Contradiction:

Improvefluid productionVSAvoidESP operational longevity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The DAS system detects slugs downhole before they reach the ESP, allowing the controller to alter the ESP's operation (stop or idle) in advance. This preliminary detection and response prevents slug-related damage while maintaining continuous fluid production capability.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses DAS to continuously monitor downhole conditions and provides feedback to the controller, which adjusts ESP operation based on detected slug parameters. This closed-loop feedback enables real-time protection against slug flow while optimizing fluid production.

Inventive Principle:

Principle #23Feedback

2Productivity

If the ESP operates continuously to maintain production, then fluid extraction rate is maximized, but damage from slugs increases

Engineering Contradiction:

Improvefluid extraction rateVSAvoiddamage from slugs

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

By detecting slugs downhole before they reach the ESP, the system allows the ESP to be stopped or idled in advance. This preliminary action prevents damage while minimizing interruption to overall fluid extraction rates.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system converts the harmful effect of slugs into beneficial information by using DAS to detect slug presence and characteristics. This information is then used to protect the ESP, turning the previously harmful slug flow into a detectable signal that enables protective action.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If flow conditioning and slug catchers are installed upstream, then slug effects are reduced, but device complexity and cost increase

Engineering Contradiction:

Improveprotection from slugsVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The DAS system acts as an intermediary between the slug flow and the ESP, providing early detection and enabling remote control of the ESP. This intermediary approach protects the ESP without requiring physical flow conditioning equipment or slug catchers upstream.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system replaces mechanical flow conditioning devices with a sensing and control system. Instead of using physical slug catchers or flow conditioners, the patent uses DAS acoustic sensing combined with electronic control of the ESP to achieve protection, reducing mechanical complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If the ESP is stopped to avoid slug damage, then pump longevity is improved, but production downtime increases

Engineering Contradiction:

ImproveESP longevityVSAvoidproduction downtime

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The DAS system detects slugs downhole before they reach the ESP, allowing the controller to stop or idle the ESP in advance. This preliminary detection minimizes the duration of shutdowns by providing early warning, thereby reducing overall production downtime while protecting ESP longevity.

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enhances ESP longevity and well production efficiency by reducing downtime and damage from slugs, enabling higher fluid extraction rates and lower operational costs.

Implementation Method 1

a distributed acoustic sensing (DAS) system comprising a fiber optic cable extending downhole in the wellbore

Methodology Applied

Scientific EffectDistributed acoustic sensing: Acoustic Emission

Data Source

PatentUS12378856B1Producing fluid from a well using distributed acoustic sensing and an electrical submersible pump

Publication Date: 2025.08.05 HALLIBURTON ENERGY SERVICES INC

AI summary

In some embodiments, a system for producing fluid from a well can include an electrical submersible pump (ESP) disposed in a wellbore of the well and configured to pump the fluid. The system may further include a distributed acoustic sensing (DAS) system, for example having an interrogator unit and a fiber optic cable extending downhole in the wellbore. An end of the fiber optic cable can be disposed downhole relative to the ESP. In embodiments, the system may further include a controller configured to receive data from the DAS system, process the data to detect a slug, determine a parameter of the detected slug, and alter operation of the ESP in response to determining that the parameter exceeds a threshold.