Electrical Submersible Pump Monitoring via Current Wavelet Analysis
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Solution Overview
Problem
Submersible pumps in wells experience frequent failures due to scale build-up, which is difficult to predict and detect in real-time, leading to production interruptions and costly downtime, as existing failure analysis methods require the pump to be removed and inspected.
Innovation Solution
A monitoring system that analyzes the frequency spectrum, waveform, and dynamic behavior of the pump's electrical current using Fourier, wavelet, and phase space analysis to detect disturbances and predict potential failures before they occur, allowing for proactive maintenance and minimizing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If detailed DIFA failure analysis is performed after pump removal, then failure causes can be identified, but production downtime increases and operational efficiency decreases
Solution Approach 1:
The patent implements real-time monitoring of pump electrical current parameters before failure occurs, enabling early detection of scale build-up and performance degradation. This preliminary detection allows maintenance to be scheduled proactively, avoiding unplanned downtime and the need for emergency pump removal and detailed post-failure analysis.
Solution Approach 2:
The patent replaces the mechanical approach of physical pump removal and manual inspection with an electrical/electronic monitoring system that continuously analyzes electrical current characteristics. This substitution enables remote, real-time monitoring without requiring physical access to the pump, thereby eliminating production downtime associated with pump extraction and manual inspection.
2Reliability
If real-time monitoring of pump performance is implemented, then failure prediction capability improves, but system complexity and monitoring cost increase
Solution Approach 1:
The patent uses electrical current as an intermediary parameter to indirectly monitor pump performance and detect scale build-up. Instead of directly measuring physical conditions inside the pump (which would require complex sensors and pump removal), the system monitors the electrical current signature, which changes in response to pump performance degradation. This intermediary approach simplifies the monitoring system while maintaining effective failure prediction capability.
Solution Approach 2:
The patent monitors changes in electrical current parameters (magnitude, frequency spectrum, waveform characteristics) to detect pump performance degradation. By tracking parameter changes over time rather than requiring direct measurement of physical conditions, the system achieves reliable failure prediction with relatively simple monitoring equipment.
3Reliability
If frequent pump inspections and maintenance are performed, then pump reliability improves, but production efficiency decreases due to repeated interruptions
Solution Approach 1:
The patent implements continuous feedback monitoring of pump electrical current parameters, providing real-time information about pump performance and scale build-up progression. This feedback enables condition-based maintenance scheduling, where maintenance is performed only when monitoring data indicates approaching failure thresholds, rather than following fixed preventive maintenance schedules. This approach optimizes the balance between reliability and production efficiency by minimizing unnecessary maintenance interruptions.
Solution Approach 2:
The patent enables proactive maintenance scheduling by detecting performance degradation trends before failure occurs. The monitoring system provides advance warning of impending failures, allowing maintenance to be planned during scheduled downtime rather than causing unplanned production interruptions. This preliminary detection approach improves both reliability (through timely maintenance) and productivity (by avoiding unexpected downtime).
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
Enables real-time prediction of pump failures due to scale build-up, allowing for proactive control and maintenance, reducing downtime and avoiding costly work-overs, and extending the operational life of the pump.
Implementation Method 1
analyzer of the frequency spectrum of the energy in the pump electrical current
Implementation Method 2
a wavelet analyzer of the waveform of the pump electrical current identifying time variations of the pump electrical current
Implementation Method 3
a phase space analyzer forming a measure of the identified dynamic behavior of the pump based on fluctuations in the pump electrical current
Data Source
AI summary
Current supplied to electrical submersible pumps in wells is monitored, and signal processing based on wavelet analysis and phase diagram analysis is performed on the data obtained from monitoring. An incipient malfunction of the electrical submersible pump, such as one due to scale build-up in and around the pump, can be detected at an early stage.