ESP Flow Monitoring via Electrical Power Measurement
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Solution Overview
Problem
Existing downhole flow measurement technologies, such as venturi flowmeters, cause pressure loss and are unreliable due to moving parts, while surface flow measurement methods like thermal flowmeters require additional energy and are costly for low flowrate gases.
Innovation Solution
A system utilizing a thermal flowmeter that calculates flowrate based on electrical power supplied to the downhole ESP assembly, eliminating the need for internal flow restrictions and moving parts, and leveraging the ESP as the fluid heating element to measure flowrate without additional energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If venturi flowmeters are used for downhole flow measurement, then flowrate can be measured, but pressure loss occurs due to flow restriction at the venturi throat
Solution Approach 1:
The patent replaces the mechanical venturi flow restriction system with an electrical power measurement system. Instead of using a venturi throat to create pressure differential for flow measurement, the system measures electrical power consumption of the ESP motor and uses correlation between power and flowrate to determine flow. This eliminates the need for physical flow restriction and the associated pressure loss.
Solution Approach 2:
The patent introduces electrical power measurement as an intermediary parameter to infer flowrate. Rather than directly measuring flow through mechanical means that cause pressure loss, the system measures electrical power (an intermediary quantity) and uses it to calculate flowrate, thereby avoiding the harmful pressure loss effect.
2Measurement precision
If turbine flowmeters are used for downhole flow measurement, then flowrate can be measured, but reliability decreases due to moving parts and bearings
Solution Approach 1:
The patent replaces mechanical turbine flowmeters with moving parts with an electrical measurement system. Instead of using a turbine rotor and bearings that are subject to wear and failure in harsh downhole environments, the system measures electrical power parameters and uses computational algorithms to determine flowrate, eliminating all moving parts and significantly improving reliability.
Solution Approach 2:
The patent uses the ESP motor itself as the measurement tool. The motor's electrical power consumption naturally correlates with the load it experiences, which is directly related to flowrate. By monitoring the motor's own electrical characteristics, the system obtains flow information without requiring separate measurement devices with moving parts.
3Measurement precision
If thermal flowmeters are used for surface flow measurement of low flowrate gases, then flowrate can be measured, but additional energy consumption and cost increase
Solution Approach 1:
The patent makes the ESP motor serve multiple functions: it performs its primary function of pumping fluid while simultaneously serving as the heating element and temperature sensor for flow measurement. The motor's electrical power input provides the thermal energy needed for thermal flow measurement, and the motor body itself acts as the thermal sensor, eliminating the need for separate heating elements and temperature sensors that would consume additional energy.
Solution Approach 2:
The ESP motor provides its own electrical power for thermal flow measurement purposes. The power already being consumed to drive the motor is utilized to heat the fluid and create the thermal gradient necessary for flow measurement. The motor's own thermal characteristics are used to detect temperature changes, making the system self-sufficient and avoiding additional energy consumption.
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 provides a cost-effective, reliable, and efficient method for monitoring downhole flow without pressure loss or the need for additional energy, enabling real-time flowrate calculation and improved ESP performance monitoring.
Implementation Method 1
The ESP assembly is leveraged as the fluid heating element... calculating flowrate based on electrical power supplied to the ESP assembly
Data Source
AI summary
A system for monitoring a condition of a downhole electrical submersible pump (ESP) assembly is disclosed. The system includes: a downhole assembly configured to be disposed in a wellbore in an earth formation; the ESP assembly connected to the downhole assembly and including a motor and a pump, the ESP assembly in electrical communication with a surface electrical source via a conductor; a power gauge unit configured to measure the electrical power supplied to the ESP assembly; and a processor configured to receive data from the power gauge unit and calculate a flowrate of the ESP assembly based on at least the electrical power supplied to the ESP assembly. Also disclosed is a method of monitoring a condition of a downhole ESP assembly.