Electrical Submersible Pump Control Using Indirect Flow and Density Sensing
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Solution Overview
Problem
Existing electrical submersible pump (ESP) systems lack efficient methods for determining flow rate and fluid density, which are crucial for optimal operation and preventing conditions like gas lock.
Innovation Solution
The system includes sensors for measuring current, voltage, and pressure, coupled with a processor that calculates shaft speed, fluid density, and flow rate based on these measurements, and adjusts the pump speed accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional ESP systems operate without real-time flow rate and density measurement, then the system structure remains simple, but the ability to detect and respond to gas lock conditions deteriorates
Solution Approach 1:
The patent replaces direct mechanical measurement devices with an electrical measurement system. The processor calculates flow rate and density by analyzing electrical parameters (current, voltage, frequency) from the motor, substituting complex mechanical flow meters and density meters with electrical sensing and computational methods.
Solution Approach 2:
The patent introduces electrical parameters (current, voltage, frequency) as intermediary measurements. Instead of directly measuring flow rate and density, the system measures electrical parameters and uses the processor to calculate the desired physical quantities, serving as an indirect measurement pathway.
2Productivity
If the ESP operates at high speed to maximize production, then productivity increases, but the risk of gas lock and operational issues increases
Solution Approach 1:
The patent implements a feedback control system where the processor continuously monitors calculated flow rate and density, compares them against optimal operating parameters, and adjusts motor speed accordingly. This closed-loop feedback enables the system to maintain high productivity while preventing gas lock conditions by reducing speed when abnormal conditions are detected.
Solution Approach 2:
The patent makes the motor speed dynamic rather than fixed. The processor adjusts the motor operating speed in real-time based on calculated flow rate and density, allowing the system to adapt its speed to prevent gas lock while maximizing production during normal operation.
3Measurement precision
If the system calculates multiple parameters (speed, density, flow rate, torque) using electrical measurements, then measurement precision improves, but the computational complexity increases
Solution Approach 1:
The patent makes the processor perform multiple functions: measuring electrical parameters, calculating motor speed from frequency, determining torque from electrical characteristics, computing flow rate, and calculating density. This multi-functional approach consolidates what would otherwise require separate measurement devices into a single computational unit.
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 solution enables precise control of the ESP, improving production efficiency by maintaining optimal fluid flow and reducing the risk of gas lock and other operational issues.
Implementation Method 1
The processor is configured to calculate speed of a shaft of the electric motor based on a frequency, induced by rotation of the motor, detected in the current
Implementation Method 2
The current sensor is configured to measure a current of the electrical signal
Implementation Method 3
The voltage sensor is configured to measure a voltage of the electrical signal
Implementation Method 4
The processor may also be configured to determine a torque in the ESP based on a measured current of the electrical signal, a measured voltage of the electrical signal, a resistance of a conductor that electrically couples the ESP to the drive circuitry, and a resistance of a stator of the ESP
Data Source
AI summary
A system, method, and computer-readable medium for determining the flow rate and fluid density in an electrical submersible pump (ESP) and controlling the ESP based on the flow rate and density. In one implementation, an ESP system includes an ESP, drive circuitry, a current sensor, a voltage sensor, and a processor. The ESP includes an electric motor. The drive circuitry is electrically coupled to the ESP and is configured to provide an electrical signal to power the ESP. The current sensor is configured to measure a current of the electrical signal. The voltage sensor is configured to measure a voltage of the electrical signal. The processor is configured to calculate speed of a shaft of the electric motor based on a frequency induced by rotation of the motor detected in the current. The processor is also configured to calculate a density of fluid in the ESP based on the speed.