Permanent Magnet Motor Asynchronous Torque for Debris Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
ESP systems in oil and gas wells face high operational costs and frequent failures due to sand accumulation and debris, leading to costly and time-consuming replacements, especially in remote locations where workover rigs are scarce.
Innovation Solution
Implementing asynchronous operation of permanent magnet motors (PMMs) with controlled cyclic torque variations to loosen and remove debris by varying current frequencies and amplitudes, allowing for the motor to operate effectively even when rotor shafts are restricted.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional ESP systems operate continuously, then production is maintained, but sand and debris accumulate causing pump restriction and motor failure
Solution Approach 1:
The system implements periodic asynchronous operation cycles where the motor alternates between synchronous and asynchronous modes. During asynchronous periods, the motor creates cyclic torque variations that loosen sand and debris without requiring pump shutdown, thereby maintaining continuous production while periodically clearing restrictions that would otherwise lead to failure
Solution Approach 2:
The invention converts the harmful effect of sand accumulation into a beneficial clearing mechanism. By intentionally inducing controlled asynchronous operation, the system generates torque variations that exploit the presence of sand and debris to create loosening effects, transforming the problem of sand restriction into a self-cleaning mechanism
2Reliability
If ESP systems are replaced when failures occur, then reliability is restored, but operational time is lost during removal and replacement
Solution Approach 1:
The system performs preliminary cleaning action through periodic asynchronous operation before sand and debris can accumulate to restrictive levels. This preventive maintenance approach eliminates the need for frequent pump removal and replacement, thereby reducing operational downtime while maintaining continuous production
Solution Approach 2:
The motor performs self-maintenance by generating its own cleaning action through controlled asynchronous operation. The cyclic torque variations produced during asynchronous periods automatically loosen and remove sand and debris without requiring external intervention or system shutdown, enabling the system to maintain itself during continuous operation
3Reliability
If workover rigs are deployed to replace failed ESP systems, then system reliability is restored, but operational costs and deployment time increase
Solution Approach 1:
The ESP system performs its own maintenance through periodic asynchronous operation that automatically clears sand and debris restrictions. This self-maintenance capability eliminates the need for external workover rig intervention, thereby reducing both deployment time and operational costs associated with rig mobilization and deployment
4Productivity
If pump rotation is restricted by sand embedding, then pump performance decreases, but motor damage occurs due to excessive loads
Solution Approach 1:
The system applies periodic asynchronous operation that creates cyclic torque variations to continuously loosen sand and debris before they can embed and create excessive restriction. This periodic intervention prevents the development of high loads that would damage the motor while maintaining pump rotation and performance
Solution Approach 2:
The system applies preliminary counter-action by inducing controlled asynchronous operation that generates loosening torque variations before sand and debris can accumulate to restrictive levels. This preliminary anti-action prevents the development of harmful restriction and excessive loads on the motor
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 method reduces the need for frequent replacements by effectively clearing debris, extending the operational life of ESP systems and maintaining production without requiring external intervention, thus lowering costs and improving efficiency in challenging environments.
Implementation Method 1
a rotor shaft within a PMM is substantially restricted; interrupt motor operation for the PMM that operates the PMM at a prescribed drive frequency and a prescribed drive amplitude; and vary between a plurality of current frequencies and a plurality of current amplitudes supplied to the PMM to produce a cyclic impact
Data Source
AI summary
A method for implementing asynchronous operation of a permanent magnet motor (PMM) by detecting asynchronous operation of the PMM and creating cyclic variations in the PMM output using the asynchronous operation of the PMM. In another embodiment, an apparatus that comprises a microcontroller that obtains computer executable instructions stored on a non-transitory medium that when executed by the microcontroller causes the apparatus to determine that a rotor shaft within a PMM is rotationally restricted and to vary a plurality of frequencies and a plurality of amplitude currents supplied to the monitor to produce a reverse impact on a downhole tool coupled to the PMM.