ESP Safety Disconnect Switch for Upstream Voltage Isolation
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Solution Overview
Problem
The use of permanent magnet motors in oil and gas wells poses a safety risk during pump installation, maintenance, or removal, as the rotating motor can generate power and transmit lethal voltage to the surface, potentially electrocuting technicians unaware of the spinning system.
Innovation Solution
A safety disconnect switch is integrated into the pumping system, positioned downstream from the variable frequency drive and upstream from the electrical submersible pump, which controls the electrical circuit to prevent power generated by the motor from flowing upstream, ensuring safety by opening the circuit when necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a permanent magnet motor is used in the electrical submersible pump, then efficiency and power factor are improved, but safety risk increases due to potential generation of lethal voltage during installation or maintenance
Solution Approach 1:
A safety disconnect switch is introduced as an intermediary device between the motor and the surface equipment. This switch acts as a mediator that physically interrupts the electrical circuit, preventing any voltage generated by the spinning motor from reaching the surface where technicians work, thus eliminating the safety hazard while preserving the motor's efficiency benefits
Solution Approach 2:
The safety disconnect switch is positioned to proactively block potential harmful voltage before it can travel upstream to the surface. By placing the disconnect switch upstream from the motor and downstream from the variable frequency drive, the system preemptively prevents any electrical hazard from reaching technicians during installation or maintenance operations
2Object-affected harmful factors
If the safety disconnect switch is positioned upstream from the motor, then technician safety is improved, but device complexity increases
Solution Approach 1:
The safety disconnect switch serves multiple functions simultaneously: it acts as a safety device to prevent voltage transmission, a circuit control element for maintenance operations, and a protective barrier for surface equipment. By consolidating these functions into a single component, the patent avoids adding excessive complexity while achieving comprehensive safety coverage
Solution Approach 2:
The safety disconnect function is extracted as a separate, dedicated component rather than being integrated into the motor or control system. This extraction allows the switch to be independently positioned in the optimal location for safety (upstream from the motor) while keeping the motor and control system designs simple and unchanged
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 safety disconnect switch effectively prevents electric power from reaching technicians on the surface, mitigating the risk of electrocution during system operations like installation, maintenance, or removal by ensuring power does not flow upstream when the system is powered off.
Implementation Method 1
opening a circuit in the safety disconnect switch to prevent electric power from a motor attached to an electrical submersible pump from flowing upstream from the safety disconnect switch
Data Source
AI summary
A pumping system including a safety disconnect switch. The pumping system includes a variable frequency drive, an electrical submersible pump, and a motor connected to the electrical submersible pump. The pumping system also includes a safety disconnect switch disposed downstream from the variable frequency drive and upstream from the electrical submersible pump to prevent electric power generated by the motor from traveling upstream from the safety disconnect switch in the pumping system. A method of preventing electric power from flowing upstream from a safety disconnect switch in a pumping system includes the step of opening a circuit in the safety disconnect switch to prevent electric power from a motor attached to an electrical submersible pump from flowing upstream from the safety disconnect switch to other components of the pumping system.