Downhole Pump Phasing Control via Backspin Detection
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Solution Overview
Problem
Current systems for controlling electric submersible pumps in downhole oil production require manual determination of proper phasing, leading to inefficiencies and downtime, as pumps often operate in reverse direction due to incorrect electrical connections, resulting in reduced production and increased operational costs.
Innovation Solution
A method and system where a variable speed drive automatically determines the proper phasing for forward direction by generating an initial drive signal, establishing a fluid column, allowing it to backspin, and detecting the reverse phasing to determine and notify the operator or restart the pump in the forward direction, potentially using a rotation sensor or check valve to facilitate this process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual determination of pump phasing is used, then the pump can be operated, but significant downtime and lost production occur while determining proper phasing
Solution Approach 1:
The pump system automatically determines its own phasing by utilizing the backspin of the pump motor after shutdown. The system monitors the direction of backspin and automatically adjusts the phasing configuration without requiring manual intervention or trial-and-error operation, thereby eliminating downtime and lost production.
Solution Approach 2:
The system incorporates feedback mechanisms that monitor the pump motor's backspin direction and use this information to automatically determine the correct phasing. The control system receives feedback about the rotational direction and automatically configures the phasing accordingly, preventing the need for manual determination and associated downtime.
2Measurement precision
If manual phasing determination is performed by operating pump in both directions, then proper forward phasing can be identified, but operational complexity and risk of errors increase
Solution Approach 1:
The pump system automatically determines its own phasing by utilizing the backspin of the pump motor after shutdown. The system monitors the direction of backspin and automatically adjusts the phasing configuration without requiring manual intervention or trial-and-error operation, thereby eliminating downtime and lost production.
Solution Approach 2:
The system replaces manual mechanical trial-and-error operation with an automated electrical control system that monitors backspin direction through sensors and automatically configures phasing through electrical switches or relays, eliminating the need for manual intervention and reducing operational complexity.
3Reliability
If pump operates in reverse direction due to incorrect connections, then fluid can still be pumped, but efficiency and production volume decrease
Solution Approach 1:
The system performs preliminary determination of the correct phasing configuration before initiating normal pump operation. By detecting the backspin direction and automatically configuring the correct phasing in advance, the system ensures the pump operates in the forward direction from the start, maximizing efficiency and production volume.
Solution Approach 2:
The system incorporates feedback mechanisms that monitor the pump motor's backspin direction and use this information to automatically determine the correct phasing. The control system receives feedback about the rotational direction and automatically configures the phasing accordingly, preventing the need for manual determination and associated downtime.
4Ease of manufacture
If multiple wire switches occur in cabling, then electrical connections are established, but phasing is reversed causing reverse rotation
Solution Approach 1:
The system incorporates feedback mechanisms that monitor the pump motor's backspin direction and use this information to automatically determine the correct phasing. The control system receives feedback about the rotational direction and automatically configures the phasing accordingly, preventing the need for manual determination and associated downtime.
Solution Approach 2:
The pump system automatically determines its own phasing by utilizing the backspin of the pump motor after shutdown. The system monitors the direction of backspin and automatically adjusts the phasing configuration without requiring manual intervention or trial-and-error operation, thereby eliminating downtime and lost production.
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
This approach significantly reduces the time required to determine and maintain proper phasing, minimizing downtime, lost production, and operator errors, while ensuring efficient operation of the pump in the forward direction.
Implementation Method 1
generating an initial drive signal and driving the pump for an initial period of time
Implementation Method 2
allowing the column of fluid to fall through the pump and cause the pump to backspin
Data Source
AI summary
Systems and methods for controlling an electrical drive such as is used with electric submersible pumps used in downhole oil production, wherein the drive automatically determines the proper phasing to drive the pump motor in a forward direction. In one embodiment, a method includes generating a drive signal having an initial phasing and driving the pump to establish a column of fluid in the borehole. The drive signal is then discontinued, allowing the column of fluid to fall through the pump and cause the pump to backspin and generate a signal having phasing corresponding to the reverse rotational direction. The forward phasing is then determined to be the opposite of the phasing corresponding to the reverse rotational direction. The pump can be restarted in the forward direction, or an operator can be notified of the proper phasing to produce forward rotation of the pump.