ESP Sensor Wiring Across Motor, Seal, and Pump Modules
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Solution Overview
Problem
Challenging to reliably place sensors or other electronic devices in modules of an electrical submersible well pump (ESP) other than the motor and gauge unit module due to the ESP's modular structure, which complicates the integration of power and data transmission.
Innovation Solution
A system where sensors and electronic devices are connected through jumper wires and slip rings, allowing easy integration into the motor, seal section, and pump modules, with power and data transmission facilitated by a power cable or dedicated instrument line, and supplemented by a controller and supplemental power supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If sensors are placed in modules other than the motor and gauge unit module, then operational monitoring capabilities are enhanced, but the complexity of integrating power and data transmission increases
Solution Approach 1:
The ESP system is divided into separate modules (motor, seal section, pump) with dedicated electrical connectors for each module. This segmentation allows sensors to be independently placed in any module while maintaining modular assembly and disassembly capabilities.
Solution Approach 2:
The electrical connectors are designed with universal functionality to handle both power transmission and data communication. The same connector infrastructure supports multiple purposes: powering sensors, transmitting sensor data, and maintaining motor control functions across all modules.
2Ease of operation
If the ESP is made up of separate modules, then installation and maintenance become easier, but it becomes challenging to reliably place sensors or other electronic devices in modules other than the motor and gauge unit module
Solution Approach 1:
The ESP system is divided into separate modules (motor, seal section, pump) with dedicated electrical connectors for each module. This segmentation allows sensors to be independently placed in any module while maintaining modular assembly and disassembly capabilities.
Solution Approach 2:
The adapter serves as an intermediary component that bridges the motor and seal section modules. It includes electrical connectors that facilitate reliable sensor placement and signal transmission at the interface between modules, enabling sensors to be positioned at critical boundaries.
3Ease of manufacture
If jumper wires are used to connect sensors across modules, then sensor integration is simplified, but the risk of signal interference and connection reliability issues increases
Solution Approach 1:
The adapter serves as an intermediary component that bridges the motor and seal section modules. It includes electrical connectors that facilitate reliable sensor placement and signal transmission at the interface between modules, enabling sensors to be positioned at critical boundaries.
Solution Approach 2:
The system replaces external jumper wire connections with internal electrical connectors integrated into the modular adapters. This substitution eliminates the need for separate jumper wires and reduces connection points, thereby improving reliability while maintaining ease of integration.
Data Source
Figure 1~2
Figure 3~5
Figure 4
AI summary
An electrical submersible well pump (ESP) (11) has a motor electrical connector (77) mounted to an exterior of the motor (13). A motor sensor (45) connects to an interior side of the motor electrical connector (77). Seal first and second electrical connectors (79a, 79b) mount to an exterior of a seal/motor adapter (19). A seal internal wire (91) within the seal section (17) electrically connects interior sides of the seal first and second electrical connectors (79a, 79b) together. An external motor jumper wire (39) extends alongside the motor (13) between the motor electrical connector (77) and the seal first electrical connector (79a). A pump electrical connector (81a) mounts to an exterior of a pump/seal adapter (23) and connects to a pump sensor (47) within the pump (21). An external seal jumper wire (41) connects between the seal second electrical connector (79b) and the pump electrical connector (81a).