Downhole Pump Reverse Rotation Detection via Magnetic Sensor

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Solution Overview

Problem

Downhole pumping systems face challenges in reliably detecting and correcting reverse rotation of electric motors during startup, leading to costly delays and potential premature failure, especially in unconventional wells where debris can damage equipment.

Innovation Solution

A downhole pumping system equipped with a rotational movement sensor and control system that measures and controls the rotational parameters of the shaft, including direction, speed, and acceleration, allowing for prompt correction of reverse rotation and improved operational efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a rotational movement sensor is installed on the shaft to detect reverse rotation, then the reliability of detecting reverse rotation is improved, but the device complexity increases

Engineering Contradiction:

Improvereverse rotation detection reliabilityVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical rotational sensors with a simplified magnetic field-based detection system. A magnet is attached to the shaft and a magnetic sensor on the circuit board detects its position and rotation direction, eliminating the need for complex mechanical encoders or resolvers while achieving reliable reverse rotation detection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a magnet as an intermediary element between the shaft and the detection system. This magnet serves as a simple yet effective mediator that enables the magnetic sensor to detect shaft position and rotation direction without requiring direct mechanical contact or complex sensor assemblies.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If the pump continues to operate after reverse rotation detection to prevent debris fallback, then productivity is improved, but harmful factors increase due to potential equipment damage

Engineering Contradiction:

Improvepump operation continuityVSAvoidequipment damage risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent implements a feedback control system where the magnetic sensor continuously monitors shaft rotation direction and provides real-time feedback to the control circuit. Upon detecting reverse rotation, the system immediately sends a feedback signal to stop the pump motor, preventing both productivity loss from shutdown and equipment damage from prolonged reverse operation.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent takes preliminary action by detecting reverse rotation immediately at startup before significant debris can fall back into the pump. The magnetic detection system identifies reverse rotation within seconds of motor startup, allowing the control system to stop the pump before debris accumulation reaches damaging levels, thus protecting equipment while minimizing operational interruption.

Inventive Principle:

Principle #10Preliminary action

3Measurement precision

If pressure sensors are used to detect reverse rotation by monitoring pressure changes, then measurement precision is improved, but loss of time increases due to delayed detection

Engineering Contradiction:

Improvereverse rotation detection accuracyVSAvoiddetection delay

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces pressure-based detection with direct magnetic field sensing of shaft rotation. This substitution eliminates the time delay inherent in pressure wave propagation and fluid column response, providing immediate detection of reverse rotation the moment the shaft begins rotating in the wrong direction, while maintaining precise detection capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent skips the intermediate step of waiting for pressure changes to propagate through the fluid system. By directly sensing shaft rotation via magnetic field detection, the system rushes through the detection process and identifies reverse rotation instantly at startup, before pressure changes can be observed, thereby eliminating detection delay entirely.

Inventive Principle:

Principle #21Skipping (Rushing through)

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

The system effectively detects and corrects reverse rotation in real-time, reducing downtime, preventing damage from debris, and enhancing the reliability and efficiency of downhole pumping operations across various well types.

Implementation Method 1

A downhole pumping system equipped with a rotational movement sensor and control system that measures and controls the rotational parameters of the shaft

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentEP3692377B1Method and system for monitoring moving elements

Publication Date: 2023.03.29 MAGNETIC PUMPING SOLUTIONS LLC

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AI summary

An apparatus and method for sensing a rotational parameter of a rotating member of a downhole pumping system. The apparatus is capable of detecting motor rotation and pump operating conditions and includes control systems for methods utilizing the rotational parameters to control the operation of the downhole pumping system.