Progressing Cavity Pump Power Disturbance Control
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Solution Overview
Problem
Progressing cavity and electrical submersible pumps experience significant safety, reliability, and production issues due to power disturbances, leading to uncontrolled backspin, fluid drainage, and prolonged restart delays, which reduce productivity and risk equipment damage.
Innovation Solution
A method and system that includes a power dip controller, backspin controller, and phase loss controller to maintain pump operation by detecting power disturbances and controlling motor field current and flux, allowing the pump to operate at reduced capacity during brownouts, using regenerative power to prevent backspin, and adjusting power output during phase losses or imbalances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical, electrical, or hydraulic braking systems are added to PCP drive heads to prevent backspin, then safety and equipment protection are improved, but device complexity increases and maintenance requirements increase
Solution Approach 1:
The patent replaces mechanical braking systems with an electronic control system that uses the variable speed drive to detect power disturbances and control motor torque to prevent backspin. The microprocessor monitors power conditions and adjusts motor operation electronically, eliminating the need for mechanical brakes, clutching mechanisms, and associated hardware while achieving the same safety objectives.
Solution Approach 2:
The system uses the existing motor and variable speed drive components to prevent backspin without requiring separate braking mechanisms. The motor itself provides the protective function by being controlled to maintain one-way rotation or coast to a stop through electronic torque management, making the system self-protecting without additional dedicated safety components.
2Reliability
If restart delays are introduced to prevent starting into a backspinning load, then equipment damage is reduced, but productivity decreases due to prolonged shutdown time
Solution Approach 1:
The system performs preliminary action by preventing backspin from occurring in the first place through electronic control during power disturbances. By maintaining motor control and preventing reverse rotation during the power event, the system eliminates the need for extended restart delays, allowing immediate or near-immediate restart when power is restored.
Solution Approach 2:
The microprocessor continuously monitors power conditions and motor operation, providing real-time feedback control. When power disturbance is detected, the system immediately adjusts motor torque to prevent backspin. This closed-loop control enables the system to respond dynamically to power events and restart automatically when conditions normalize, eliminating fixed delay timers.
3Duration of action of stationary object
If the pump operates at reduced capacity during brownout conditions, then continuous operation is maintained, but power output is reduced
Solution Approach 1:
The system dynamically adjusts motor operation based on real-time power conditions. During brownout events, the variable speed drive and microprocessor modify motor torque and speed to match available power while preventing backspin. This dynamic control allows the pump to operate at reduced capacity when needed but maintain full capacity when power is sufficient, optimizing both continuous operation and power output.
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 system effectively maintains pump operation during power disturbances, minimizing production losses, reducing the risk of equipment damage, and requiring minimal maintenance, while ensuring safe and efficient operation with reduced restart delays.
Implementation Method 1
A power dip controller is provided to provide controlled operation of the motor when the power disturbance is determined to be a brownout condition by providing controlled weakening of motor field current and motor flux as the bus voltage decreases during the power disturbance condition
Data Source
AI summary
A system for controlling operation of a progressing cavity pump to maintain the motor operating under power disturbance conditions. For a blackout condition, a backspin controller uses regenerative power to provide controlled deceleration of the pump, counteracting backspin and preventing backspinning freely. For a brownout condition, a power dip controller weakens the motor field to maximize pump production consistent with reduced input power availability. For a phase loss or voltage imbalance condition, a phase loss controller reduces motor power output to keep drive system output power at or below single phase capacity.