Downhole Flow Meter Vibration Isolation for ESP Applications
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Solution Overview
Problem
In hydrocarbon well development, electrical submersible pumping systems (ESPs) create high-vibration environments that inaccurately measure flow rates due to noise production, affecting the evaluation of in-flow performance.
Innovation Solution
A system comprising a downhole sensor module with dynamic pressure sensors and a processor to measure pressure fluctuations and determine flow rates, using a metering module with vibration control mechanisms to mitigate the effects of vibrations from the ESP.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a flowmeter is used to measure flow rate below the ESP, then flow rate measurement is enabled, but measurement precision deteriorates due to vibration noise from the ESP
Solution Approach 1:
A metering module is introduced as an intermediary component between the ESP and the flowmeter. This module includes vibration isolation elements (such as elastomeric mounts or dampers) that mechanically decouple the flowmeter from the ESP, preventing vibration transmission while allowing the flowmeter to accurately measure flow rate in the fluid stream.
Solution Approach 2:
The patent replaces mechanical coupling (direct mounting) with non-mechanical or softened mechanical coupling (elastomeric mounts, magnetic coupling, or wireless transmission). This substitution eliminates the rigid mechanical path that transmits vibration noise from the ESP to the flowmeter, thereby improving measurement precision.
2Measurement precision
If vibration isolation mechanisms are added to the flowmeter, then measurement precision improves, but device complexity increases
Solution Approach 1:
The system is divided into separate functional modules: the ESP, the metering module with vibration isolation, and the flowmeter. This segmentation allows the vibration isolation functionality to be added as a distinct component rather than integrating it into the flowmeter's core measurement mechanism, thereby reducing overall system complexity while maintaining measurement precision.
Solution Approach 2:
The patent employs passive vibration isolation parameters (such as elastomeric material properties, mounting geometry, or magnetic field strength) that can be optimized during design without adding active control systems. By changing these parameters, effective vibration isolation is achieved through material selection and structural design rather than complex mechanical assemblies.
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
Accurately measures flow rates below ESPs in high-vibration environments, enhancing the evaluation of in-flow performance and reservoir productivity.
Implementation Method 1
a plurality of dynamic pressure sensors connected to an outer diameter of the metering module, wherein the plurality of dynamic pressure sensors are configured to measure a pressure fluctuation of the fluid
Implementation Method 2
A system comprising a downhole sensor module with dynamic pressure sensors and a processor to measure pressure fluctuations and determine flow rates, using a metering module with vibration control mechanisms to mitigate the effects of vibrations from the ESP
Data Source
AI summary
A system for determining a flow rate of a fluid in a well includes an electrical submersible pump disposed in the well, a motor disposed on the electrical submersible pump, and a downhole sensor module connected to the motor. The electrical submersible pump includes a vertical axis. The system includes a metering module extending from the downhole sensor module including a plurality of dynamic pressure sensors along the vertical axis. The plurality of dynamic pressure sensors are connected to an outer diameter of the metering module. The plurality of dynamic pressure sensors are configured to measure a pressure fluctuation of the fluid. The system includes a processor configured to receive data from the plurality of dynamic pressure sensors and determine the flow rate of the fluid based on the received data.