Self-Propelled Sensor Array for ESP Gas Slugging Detection
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Solution Overview
Problem
Conventional electric submersible pumps (ESPs) face challenges in deviated wellbores due to gas slugging, which can cause production cessation and overheating, and existing solutions have not effectively addressed these issues.
Innovation Solution
An electric submersible pumping system with a detachable self-propelled sensor array vehicle that measures wellbore conditions and adjusts the pumping system's performance in real-time, using a sensor module connected to a motor assembly and a drive mechanism to deploy and retract the sensor array for data collection and system optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional electric submersible pump is deployed in a deviated wellbore, then the pump can operate in horizontal wells, but gas slugging accumulates causing production cessation and overheating
Solution Approach 1:
The sensor array is deployed ahead of the pump to detect gas slugs before they reach the pump. This preliminary detection allows the control system to take preventive action by adjusting pump speed or shutting down before gas accumulation causes production cessation and overheating, thereby maintaining reliability while operating in deviated wellbores
2Reliability
If a sensor array is deployed ahead of the pump, then gas slugging can be detected early, but the system complexity increases
Solution Approach 1:
The sensor array vehicle serves multiple functions: it detects gas slugs, measures wellbore conditions (temperature, pressure, fluid composition), and transmits data to the surface. This multi-functionality consolidates what could be multiple separate systems into one integrated unit, reducing overall system complexity while maintaining reliable production through comprehensive monitoring
3Ease of operation
If the sensor array is self-propelled and detachable, then it can be deployed and retrieved efficiently, but the device complexity increases
Solution Approach 1:
The sensor array is designed as a detachable, self-propelled vehicle that can be separated from the pump assembly. This segmentation allows the sensor vehicle to be independently deployed ahead of the pump on a payout reel, operated autonomously, and then retrieved separately. The modular design simplifies deployment and retrieval operations while the self-propelled capability eliminates the need for complex external deployment mechanisms
Data Source
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AI summary
An electric submersible pumping system has an electric motor, a pump assembly driven by the electric motor and a sensor module. The sensor module preferably includes a detachable sensor array that can be selectively released from the sensor module. In preferred embodiments, the detachable sensor array includes a self-propelled sensor array vehicle that has a drive motor, a drive mechanism driven by the drive motor and a sensor array. The detachable sensor array provides a wellbore condition signal that can be used to automatically adjust the performance of the electric submersible pumping system.