Submersible Pump Lift Diagnosis via Differential Pressure Probe
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Solution Overview
Problem
The existing methods for conducting ongoing analysis of submersible pump systems in deep wells cannot accurately determine the actual lift, which is essential for diagnosing the technical condition and efficiency of the pump, due to the inability to measure linear flow loss in vertical pressure lines, leading to incomplete characterization of the pump's operational parameters.
Innovation Solution
A method involving differential pressure measurement between the liquid pressure in the pipeline near the pump and the hydrostatic pressure outside the pump, using pressure transducers with piezo-resistive silicon sensors, to calculate the actual lift and compare it with the known lift as a function of capacity, allowing for continuous monitoring and diagnosis of the pump's technical condition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If approximate determination of pump lift is made by adding water surface height to pressure value measured upstream of damper gate, then measurement can be conducted with simple equipment, but measurement precision is insufficient due to inability to determine linear flow loss in vertical pressure line
Solution Approach 1:
The measurement system is segmented into multiple pressure measurement points: one at the pump outlet (upstream of damper gate) and another at a known distance downstream. This segmentation allows separate measurement of pressure differential and flow loss components, enabling precise calculation of actual pump lift by accounting for linear flow loss in the vertical pressure line.
Solution Approach 2:
A differential pressure transducer serves as an intermediary device that directly measures the pressure difference between two points in the system. This intermediary measurement eliminates the need for complex calculations involving separate pressure measurements and manual addition of flow loss estimates, providing direct and accurate pump lift data.
2Reliability
If actual pump lift is not accurately determined, then ongoing analysis cannot be conducted, but implementing accurate measurement requires complex measurement system
Solution Approach 1:
The measurement system is segmented into multiple pressure measurement points: one at the pump outlet (upstream of damper gate) and another at a known distance downstream. This segmentation allows separate measurement of pressure differential and flow loss components, enabling precise calculation of actual pump lift by accounting for linear flow loss in the vertical pressure line.
Solution Approach 2:
A differential pressure transducer serves as an intermediary device that directly measures the pressure difference between two points in the system. This intermediary measurement eliminates the need for complex calculations involving separate pressure measurements and manual addition of flow loss estimates, providing direct and accurate pump lift data.
3Measurement precision
If pressure transducers are installed close to pump pressure port (within 0.15% of pump installation depth or 4 meters), then measurement accuracy is improved, but installation complexity increases
Solution Approach 1:
Multiple pressure transducers and their associated measurement functions are merged into a single integrated probe assembly. This combined design simplifies installation by reducing the number of separate components that need to be individually positioned and connected, while maintaining the required measurement precision through the integrated differential pressure measurement capability.
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 precise diagnosis of the submersible pump's technical condition, detects potential issues early, reduces energy consumption, and optimizes the operation of submersible pump systems by accurately tracking changes in pump characteristics and evaluating energy efficiency.
Implementation Method 1
the pressure transducers feature piezo-resistive silicon sensors, isolated from the liquid being measured by a separating membrane enclosing a manometer liquid
Data Source
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AI summary
The method concerns a pump system comprising a submersible pump (1) with a known lift as a function of capacity determined on a test stand, with the submersible pump immersed in a liquid contained in a deep well (2), and a pressure pipeline (5) with fittings, which discharges the pumped liquid, and is connected to the pressure port (4) of the same submersible pump (1). The method is characterised in that for a given capacity of the pump system measured at its downstream end, differential pressure is determined between the liquid pressure in the pipeline (5) near the pump (1) pressure port (4) and the hydrostatic pressure of the same liquid outside of the pump (1) at the pump pressure port (4). The differential pressure determined in this way is then compared against the lift (H), which results from the known lift as a function of capacity (Q), for the capacity value being the given capacity of the pump system for which the differential pressure has been determined. The probe comprises two pressure transducers (11, 15) of the forced liquid pressure provided with electrical outputs. One of the pressure transducers (15) measures the pressure of the liquid forced by the pump (1) to the pipeline (5) connected to its pressure port (4). The other pressure transducer (11) measures hydrostatic pressure of the liquid the pump (1) is immersed in. Each of the pressure transducers (11, 15) features a separate body (14, 16) and on one end of each body (14, 16) there is a metering orifice (12, 18). The pressure transducer (11, 15) bodies (14, 16) are installed generally perpendicularly to each other in a common coupling body (22).