ESP Vibration Orbit Analysis Using Orthogonal Accelerometers
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Solution Overview
Problem
The challenge of assessing the condition of an electric submersible pump (ESP) using vibration data is hindered by the practical limitations of installing multiple sensors in the downhole environment, where space and operating conditions are constrained.
Innovation Solution
Utilizing two orthogonal accelerometers mounted on the ESP to gather acceleration data, which is processed to determine the condition by converting to velocity and displacement data, allowing for the analysis of harmonics and orbit shapes to diagnose potential issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple sensor types (accelerometer, velometer, proximity sensor) are installed to assess vibration data, then measurement precision is improved, but device complexity and difficulty of installation increase due to limited space and harsh downhole environment
Solution Approach 1:
The patent extracts only the essential acceleration measurement function using a single accelerometer type, eliminating the need for multiple sensor types (velometer, proximity sensor) while maintaining sufficient measurement precision through signal processing techniques
Solution Approach 2:
The single accelerometer is designed to perform multiple functions: measuring acceleration, inferring velocity and displacement through integration, and detecting various vibration conditions, thereby replacing what would traditionally require multiple specialized sensors
2Reliability
If multiple vibration sensors are installed to gather comprehensive vibration data, then reliability of ESP condition assessment is improved, but ease of operation and installation deteriorate due to physical constraints in downhole environment
Solution Approach 1:
The patent extracts the core vibration monitoring function into a single accelerometer, removing the complexity of installing and operating multiple sensors while maintaining reliable ESP condition assessment through sophisticated signal processing
Solution Approach 2:
The system uses signal processing algorithms to automatically derive velocity and displacement information from acceleration data, eliminating the need for additional sensors and reducing operational complexity while maintaining assessment reliability
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
Enables effective monitoring of ESP health, enabling early detection of problems, preventing damage, and optimizing operation by adjusting motor speed based on harmonic analysis, thus enhancing reliability and reducing the need for additional sensor types.
Implementation Method 1
gathering acceleration data from a first accelerometer and a second accelerometer
Data Source
AI summary
A method of determining a condition of an electric submersible pump (ESP) includes gathering acceleration data from a first accelerometer and a second accelerometer. The first accelerometer and the second accelerometer are affixed to the ESP. The first accelerometer is oriented orthogonally with respect to the second accelerometer. The method further includes obtaining orbit data from the acceleration data, determining a magnitude and/or phase angle of a harmonic of a rotational frequency of a motor of the ESP based on the orbit data, and determining a condition of the ESP based on the magnitude and/or phase angle of the harmonic.