Proximity Sensor for ESP Axial Displacement Monitoring
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Solution Overview
Problem
Electric submersible pumps (ESPs) operating in geologic environments face challenges due to transient and persistent conditions, such as the presence of condensed steam, which can impact their longevity and efficiency, particularly in steam-assisted gravity drainage (SAGD) systems where equipment must endure for decades, and existing monitoring and control systems do not effectively address these issues.
Innovation Solution
The implementation of a proximity sensor configured as a diffuser sensor to sense axial displacement between adjacent diffusers in the ESP stack, along with other sensors for speed, vibration, and hydraulic seal monitoring, allows for real-time monitoring and control of ESP operations, improving pump performance and longevity by detecting issues like shaft vibration, axial displacement, and hydraulic seal wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional monitoring systems are used in ESPs, then the system structure remains simple, but the ability to detect axial displacement and monitor hydraulic seal wear is insufficient
Solution Approach 1:
The patent replaces traditional mechanical monitoring systems with a proximity sensor-based measurement system. The proximity sensor uses electromagnetic fields to detect axial displacement between diffusers, eliminating the need for mechanical contact sensors and providing non-contact measurement with higher precision while reducing mechanical wear.
Solution Approach 2:
The proximity sensor acts as an intermediary device that indirectly measures axial displacement and hydraulic seal wear conditions without direct contact with the moving parts. This intermediary approach enables precise measurement of parameters that would be difficult to access directly, such as the gap between rotating impellers and stationary diffusers.
2Reliability
If real-time monitoring of ESP operations is implemented, then operational reliability improves, but the device complexity increases
Solution Approach 1:
The proximity sensor is designed to perform multiple monitoring functions simultaneously, including axial displacement measurement, hydraulic seal wear detection, and vibration monitoring. This multi-functional approach consolidates what would otherwise require multiple separate sensors and systems, improving reliability while limiting the increase in overall device complexity.
Solution Approach 2:
The monitoring system implements feedback control by continuously measuring operational parameters and providing real-time data to control systems. This enables automatic adjustments to maintain optimal performance and detect anomalies early, significantly improving operational reliability through closed-loop control.
3Measurement precision
If multiple sensors are added to monitor shaft vibration and hydraulic seal wear, then measurement precision improves, but device complexity increases
Solution Approach 1:
The patent combines multiple measurement functions into a single proximity sensor system. The same sensor that measures axial displacement also detects vibration patterns and hydraulic seal wear conditions, eliminating the need for separate sensors for each parameter and reducing overall system complexity while maintaining high measurement precision.
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 enhances the operational reliability and longevity of ESPs by enabling real-time monitoring and feedback-controlled adjustments, thereby improving pump performance and extending the equipment's lifespan in harsh subterranean environments.
Implementation Method 1
a proximity sensor operatively coupled to the housing, the proximity sensor configured as a diffuser sensor that senses axial displacement between at least one pair of adjacent diffusers in the stack of diffusers
Data Source
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AI summary
An electric submersible pump (ESP) can include a shaft; an electric motor configured to rotatably drive the shaft; a housing; a stack of diffusers disposed in the housing; impellers disposed in the housing and operatively coupled to the shaft; and a proximity sensor operatively coupled to the housing.