ESP Drive Setpoint Control for Changing Well Conditions
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Solution Overview
Problem
Existing ESP systems face challenges in optimizing operation due to rapidly changing well conditions and lack of accurate data for physics model calibration, leading to increased costs and complexity.
Innovation Solution
A control system that automatically adapts the operation of an electric drive system for ESPs by receiving live measurements and calculating adjustments to settings without user intervention, thereby stabilizing and optimizing ESP operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a comprehensive physics model (digital twin) is created to predict ESP response and optimize setpoints, then the ESP operation can be optimized, but the system complexity and difficulty of creation increase due to lack of data and need for accurate measurements
Solution Approach 1:
The patent creates a simplified digital twin (virtual model) of the ESP system that replicates essential dynamics without requiring comprehensive physics models. This virtual model is calibrated using readily available data from existing sensors and production logs, avoiding the need for complex physics-based modeling while still enabling prediction of ESP response to setpoint changes.
Solution Approach 2:
The system implements continuous feedback loops where production data from the ESP is automatically collected, processed, and used to update the virtual model and optimize setpoints in real-time. This automated feedback mechanism eliminates the need for manual model calibration and maintains accuracy without requiring complex interventions.
2Measurement precision
If physics models are calibrated to changing downhole conditions using accurate flow measurements, then model accuracy improves, but the cost and frequency of well tests increase
Solution Approach 1:
The system uses existing sensors and production data already available at the wellsite to automatically calibrate and maintain the virtual model. The ESP's own operational data serves to continuously refine the model without requiring external intervention or additional measurement equipment, making the system self-sustaining.
Solution Approach 2:
The system leverages multi-functional use of existing production data and sensors for multiple purposes: monitoring ESP performance, calibrating the virtual model, detecting anomalies, and optimizing setpoints. This eliminates the need for dedicated calibration activities or additional specialized measurement systems.
3Adaptability or versatility
If manual adjustment of ESP setpoints is performed to adapt to changing well conditions, then some level of optimization can be achieved, but the time and operational complexity increase
Solution Approach 1:
The control system automatically monitors well conditions, updates the virtual model, calculates optimal setpoints, and adjusts ESP operation without human intervention. The system serves itself by using its own data to make adaptive decisions, eliminating the need for manual monitoring and adjustment while maintaining continuous adaptation to changing conditions.
Solution Approach 2:
The system implements dynamic, real-time adjustment of ESP setpoints based on continuously changing well conditions. The virtual model captures the dynamic behavior of the ESP system, enabling the controller to adapt setpoints rapidly as conditions change, rather than relying on static or manually adjusted parameters.
4Reliability
If frequent well tests are conducted to calibrate physics models for dynamic unconventional wells, then model accuracy improves, but the cost and operational disruption increase
Solution Approach 1:
The patent creates a simplified virtual representation of the ESP system that captures essential dynamics without requiring the complexity of comprehensive physics models. This streamlined model can be calibrated using routine production data, avoiding the need for complex calibration procedures while maintaining sufficient accuracy for control purposes.
Solution Approach 2:
The system continuously self-calibrates using automatically collected production data, eliminating the need for manual calibration activities. The virtual model is updated in real-time as new data becomes available, maintaining accuracy without requiring external expertise or complex calibration protocols.
Data Source
AI summary
Systems and methods for automatically adapting operation of an electric drive system for an electric submersible pump (ESP). A control system for an electric drive receives live measurements of operating conditions of the ESP as the ESP is operating. The control system calculates adjustments to settings of the electric drive which generates output power that drives the ESP, where the adjustments are calculated based at least in part on the live measurements, and without user intervention. The control system thereby automatically controls the drive to modify the output power provided to the ESP, which in turn controls the operation of the ESP. The adjustments may increase the stability of the ESP's operation, improve the performance of the ESP, and adapt the ESP's operation to changing well conditions.