Regenerative ESP Dynamometer for In-Well Motor Evaluation
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Solution Overview
Problem
Current dynamometers for testing electrical submersible pumps (ESP) are expensive and impractical for use within wells, limiting effective motor evaluation and qualification.
Innovation Solution
A method and system involving a test assembly with an ESP dyno coupled to the motor, deployed in a well, where the dyno's inertia matches the ESP motor, allowing for monitoring and regenerating energy, and using a torque cell to measure torque and electricity flow, with a resistive load bank to vary resistance for comprehensive evaluation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional dynamometers are used for testing ESP motors, then motor output measurement capability is provided, but the testing becomes expensive and infeasible for conducting within a well
Solution Approach 1:
The patent uses a dynamometer that is a simplified copy or replica of the actual ESP motor, allowing it to be deployed in the wellbore environment. This copy approach enables measurement of motor output characteristics without requiring the full-scale original motor to be tested on expensive surface equipment, thus reducing testing costs and enabling well-based measurement.
Solution Approach 2:
The patent extracts the essential measurement function from complex surface-based testing equipment and integrates it into a compact dynamometer that can be deployed within the well. By taking out only the necessary measurement capabilities and removing the need for expensive surface infrastructure, the system becomes cost-effective and feasible for well-based testing.
2Adaptability or versatility
If a dynamometer is deployed within a well for testing, then motor evaluation can be conducted in-situ, but the device complexity and challenges increase
Solution Approach 1:
The dynamometer is designed with multi-functionality to perform various motor evaluation tasks within a single device. It can measure motor output, torque, and power characteristics while being deployed in the wellbore environment. This universal design reduces the need for multiple separate devices and simplifies the overall system complexity while maintaining in-situ evaluation capability.
Solution Approach 2:
The dynamometer incorporates self-contained features that enable it to perform measurements autonomously within the well environment. The device includes its own power source, sensing elements, and data collection capabilities, reducing the need for external support systems and simplifying deployment complexity while maintaining full motor evaluation functionality.
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 efficient and cost-effective motor evaluation and qualification within a well, providing insights into power factor, efficiency, and durability, reducing the need for expensive surface-based testing.
Implementation Method 1
the output from the ESP dyno is electricity that is generated by rotation of the shaft
Implementation Method 2
the torque is monitored with a torque cell coupled between the ESP motor and ESP dyno
Implementation Method 3
connecting the output of the ESP dyno to a resistive load bank and varying a magnitude of resistance in the resistive load bank
Data Source
AI summary
A dynamometer is used to dynamically evaluate an electrical submersible pump (“ESP”) motor while both are inside of a well. The dynamometer includes a ESP dyno that is mechanically coupled to the ESP motor. The ESP motor and ESP dyno can be a permanent magnet motor or an induction motor, and can have the same or similar values of inertia. Energy absorbed by the ESP dyno can be regenerated as electricity that is transmitted back to a power source, or converted to heat energy in a resistive load bank.