Shaft Proximity Sensing for ESP Runout and Vibration Control
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Solution Overview
Problem
Electric submersible pumps (ESPs) operating in geologic environments face challenges due to transient and persistent conditions, leading to uncertainty in equipment integrity and longevity, particularly when exposed to conditions like condensed steam in steam-assisted gravity drainage (SAGD) operations, which can cause vibration and wear, affecting pump performance and lifespan.
Innovation Solution
A system comprising a shaft with proximity sensors and circuitry that determines runout values and operational states, including a thrust bearing and runner, to monitor axial distance and reduce vibration through real-time feedback control, thereby enhancing pump performance and longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If proximity sensors and real-time monitoring systems are installed on the shaft, then vibration and wear are reduced through feedback control, but device complexity increases
Solution Approach 1:
The patent implements feedback control by using proximity sensors to continuously monitor shaft position and runout, then feeding this information to a controller that adjusts the motor operation to minimize vibration and maintain proper shaft alignment. This closed-loop feedback system directly resolves the contradiction by using real-time data to improve reliability while managing the added complexity through automated control.
Solution Approach 2:
The patent replaces traditional mechanical vibration monitoring and adjustment mechanisms with electronic proximity sensors and digital control systems. Instead of mechanical switches or contact-based sensors, non-contact proximity sensing is used to detect shaft position, and instead of mechanical adjustment mechanisms, electronic control of the motor achieves the same alignment and vibration reduction goals, thereby improving reliability while containing complexity through electronic rather than mechanical solutions.
2Duration of action of stationary object
If real-time monitoring and feedback control are implemented, then equipment lifespan is extended and performance is maintained, but manufacturing precision and initial cost increase
Solution Approach 1:
The patent applies preliminary action by installing proximity sensors and monitoring systems during the manufacturing phase to establish baseline measurements and enable proactive maintenance. The system is pre-configured to detect early signs of wear or misalignment, allowing corrective action before critical failure occurs. This extends equipment lifespan by catching issues early, while the manufacturing precision requirement is managed through standardized sensor installation procedures and calibration protocols.
Solution Approach 2:
The feedback control system enables the equipment to self-monitor and self-adjust its operation to maintain optimal performance. The proximity sensors continuously measure shaft position and runout, and the control system automatically adjusts motor parameters to compensate for wear or misalignment, allowing the equipment to maintain performance without external intervention. This self-service capability extends lifespan by enabling continuous optimization while reducing the need for high-precision manual adjustments during manufacturing.
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 reduces vibration and wear, improving the operational reliability and longevity of ESPs by providing real-time monitoring and feedback control, thus extending the equipment's lifespan and maintaining performance in challenging geologic environments.
Implementation Method 1
proximity sensors directed at the shaft; and circuitry that receives information from the proximity sensors and that determines runout values of the shaft with respect to time
Data Source
AI summary
A system can include a housing that defines an interior space; a shaft disposed at least in part in the interior space of the housing where the shaft includes a longitudinal axis, a curved surface and an end surface; a submersible electric motor operatively coupled to the shaft where the submersible electric motor includes a cable connector; two proximity sensors where each of the proximity sensors includes a sensor aperture disposed in the interior space of the housing; and circuitry operatively coupled to the proximity sensors that determines position values of the shaft with respect to time based at least in part on output of the proximity sensors.