ESP Motor Hub Power-Line Communication for Downhole Flow Sensing
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Solution Overview
Problem
Existing systems for measuring wellbore fluid characteristics in hydrocarbon production lack efficient power and communication capabilities for downhole pumps, limiting effective data collection and operational optimization.
Innovation Solution
A power and communications sub-assembly for an electrical submersible pump (ESP) that includes a motor hub with toroidal transformers to generate secondary electrical power and facilitate power line communication, enabling data transmission and flow characteristic measurement using an i-wire protocol.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing systems are used for measuring wellbore fluid characteristics, then the system structure is simple, but the power and communication capabilities are insufficient for effective data collection
Solution Approach 1:
The motor hub combines multiple functions into a single integrated component: it serves as the motor drive interface, power distribution center, and communication hub. The power line communication cable merges power transmission and data communication into a single conduit, eliminating the need for separate communication wiring and enhancing system reliability.
Solution Approach 2:
The motor hub performs multiple functions simultaneously: it drives the pump motor, distributes electrical power to downhole components, and facilitates two-way communication between surface and downhole devices. This multi-functionality resolves the contradiction by providing robust power and communication capabilities without proportionally increasing system complexity.
2Productivity
If downhole pump operation is optimized using flow characteristic data, then pump efficiency improves, but data collection and transmission capabilities are limited
Solution Approach 1:
The system implements continuous feedback loops where the flowmeter measures downhole flow characteristics, transmits data to the motor hub via power line communication, and the motor hub uses this information to optimize pump operation. The motor module can adjust its operation based on real-time flow data, creating a closed-loop control system that maximizes pump efficiency while maintaining robust data collection.
Solution Approach 2:
The power line communication cable serves dual purposes: it provides power to downhole devices and simultaneously transmits communication data. This self-service approach eliminates the need for separate communication infrastructure, ensuring reliable data transmission without adding significant system complexity or power consumption.
3Loss of information
If power and communication are integrated into the motor hub, then data transmission capability improves, but the device complexity increases
Solution Approach 1:
The motor hub integrates power distribution and communication functions into a single device. The power line communication cable combines power transmission and data communication in one conduit, eliminating the need for separate wiring systems. This merging approach improves data transmission capability while minimizing the increase in device complexity.
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
Enhances the communication of wellbore fluid flow characteristics, allowing for improved operation and optimization of downhole pumps by providing power and data transmission capabilities directly from the motor hub to the flowmeter.
Implementation Method 1
The motor hub includes one or more toroidal transformers configured to generate the secondary electrical power from the primary electrical power
Implementation Method 2
a power line communication cable electrically and communicably coupled between the flowmeter and the motor hub
Data Source
AI summary
A downhole pumping system includes a downhole pump configured to couple to a downhole conveyance that is run into a wellbore from a terranean surface to one or more subterranean formations; a motor module driveably coupled to the downhole pump and configured to operate the pump upon receipt of primary electrical power from the terranean surface to circulate a wellbore fluid from the wellbore, through the downhole pump, and to the terranean surface; a flowmeter coupled to the downhole pump and configured to measure one or more flow characteristics of the wellbore fluid upon receipt of secondary electrical power; and a motor hub coupled to the downhole pump and the motor module. The motor hub is configured to generate the secondary electrical power from the primary electrical power that is electrically coupled to the motor module through the motor hub.