Electric Submersible Pump Upthrust Protection
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Solution Overview
Problem
Traditional electric submersible pumps (ESP) face challenges in operating efficiently over a wide range of production volumes, requiring frequent equipment changes and increasing inventory and downtime, while also posing safety risks during installation and exposure to open well bores.
Innovation Solution
The development of high-speed electric submersible pump assemblies with a permanent magnet synchronous motor, active cooling system, and high-speed self-aligning bearings, which include a modular design and real-time downhole sensor control, allowing for operation across varying production volumes without the need for equipment changes and reducing exposure risks during installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional ESP equipment is used for a specific production volume, then the equipment can operate efficiently at that volume, but frequent equipment changes are required when production volumes change
Solution Approach 1:
The patent applies dynamics by implementing variable speed control of the motor, allowing the ESP to adapt its operating speed to match different production volumes. The motor speed can be dynamically adjusted based on real-time production requirements, eliminating the need for physical equipment changes when production volumes vary. This is achieved through a control system that receives feedback from downhole sensors and adjusts motor speed accordingly.
Solution Approach 2:
The patent changes the operational parameters of the ESP system by introducing variable speed operation and real-time monitoring capabilities. By changing the speed parameter dynamically and monitoring production parameters through downhole sensors, the system can adapt to different production volumes without requiring equipment replacement. This parameter-based adaptation resolves the contradiction between efficiency at specific volumes and adaptability to volume changes.
2Ease of operation
If traditional ESP installation procedures are used, then equipment can be installed, but safety risks arise from exposure to open well bores during installation
Solution Approach 1:
The patent applies preliminary action by implementing a pre-assembled, pre-tested ESP package that can be lowered into the well bore as a complete unit. The motor, pump, and associated components are assembled and tested on the surface before deployment, eliminating the need for open well bore operations during installation. This pre-preparation approach allows the entire system to be installed through a single, controlled operation, reducing safety risks from well bore exposure.
3Adaptability or versatility
If multiple ESP inventories are maintained for different production volumes, then equipment can be matched to specific volumes, but capital requirements and inventory costs increase
Solution Approach 1:
The patent applies universality by designing a single ESP system that can perform multiple functions across different production volumes through variable speed operation. The motor-pump system is designed to operate efficiently across a wide speed range, allowing one piece of equipment to replace multiple volume-specific units. This multi-functional capability eliminates the need to maintain separate inventories for different production scenarios.
Solution Approach 2:
The patent implements feedback mechanisms through downhole sensors that monitor production parameters in real-time. This feedback allows the control system to optimize motor speed and pump performance for current production conditions, enabling a single ESP to adapt to varying production volumes. The feedback loop ensures efficient operation across different volumes without requiring multiple specialized equipment units.
4Use of energy by moving object
If high-speed components are used in ESP, then power efficiency and cooling are improved, but upthrust forces on bearings increase
Solution Approach 1:
The patent applies the counterweight principle by designing the pump impellers to generate downward thrust forces that counterbalance the upward reactive forces (upthrust) generated by the motor at high speeds. The pump load is specifically engineered to create a downward force on the motor shaft that offsets the upward reactive force, thereby reducing the net upthrust burden on the bearings. This force balancing allows high-speed operation with improved power efficiency while protecting the bearings from excessive upthrust loads.
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
The solution enables ESPs to maintain efficiency and reliability across a wide range of production volumes, reducing the need for frequent equipment changes and enhancing safety during installation by utilizing a modular design with real-time monitoring and cooling systems.
Implementation Method 1
a permanent magnet synchronous motor with a control system for speed regulation
Implementation Method 2
an active cooling system that increases heat removal from the system via lubricant circulation through a heat exchange module
Implementation Method 3
high-speed self-aligning bearings
Implementation Method 4
The seal section is located between the motor and the pump which serves to reduce any pressure difference between the wellbore fluid exterior of the motor and the lubricant on the interior of the motor
Data Source
AI summary
An electric submersible pump assembly with upthrust protection is described. The described pump assembly, modules, and components may be used for operating an electric submersible pump at high speeds as well as over a wide range of speeds and flowrates without replacing downhole equipment. The described pump assembly may be shorter than comparable pump assemblies and may be assembled offsite, thereby leading to faster and easier installation with less down time. By operating over a wide range of speeds, the disclosed pump assembly allows the operator to reduce overall inventory, reduce down time for the well, and avoid other complications associated with replacing a pump assembly or other downhole components.