Submersible Pump Fluid Level Sensing Probe
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing fluid level sensing technologies for submersible pumps in harsh environments, such as oil wells, are unreliable and require manual intervention, leading to inefficiencies and potential damage due to inadequate cooling and operational issues.
Innovation Solution
A fluid level sensing system using a probe with a varying resistance conductor and electrode pairs that shunt resistance when in contact with conductive fluid, powered by induced voltage from adjacent motor conductors, allowing for automatic control of pump operation and robust sensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If optical, electromagnetic, or acoustic devices are used to measure fluid level, then measurement capability is provided, but the devices are stand-alone and require manual measurements reducing productivity
Solution Approach 1:
The patent combines the fluid level measurement function with the existing pump control system by integrating the probe with varying resistance conductor and electrode pairs directly into the pump assembly. This merging eliminates the need for separate stand-alone measurement devices and manual interventions, thereby maintaining measurement capability while improving productivity through automated operation.
Solution Approach 2:
The pump system performs its own fluid level measurement using the integrated probe that utilizes the pump's existing electrical conductors to induce voltage and activate switches at different fluid levels. This self-service approach eliminates the need for external measurement devices and manual measurements, resolving the contradiction between measurement precision and productivity.
2Measurement precision
If pressure transducer is used to measure fluid pressure, then fluid level information is obtained, but the device has limited life due to harsh operating environment
Solution Approach 1:
The patent replaces the mechanical pressure transducer with an electrical resistance-based sensing system. The probe uses a conductor with varying resistance and electrode pairs that activate electrical switches based on fluid contact, eliminating the mechanical components that are susceptible to harsh environment damage. This substitution maintains measurement precision while significantly improving reliability and device lifespan.
Solution Approach 2:
The invention changes the sensing parameter from mechanical pressure measurement to electrical resistance measurement. The varying resistance conductor responds to fluid level changes through electrical property changes rather than mechanical stress, making the system more reliable in harsh operating environments while maintaining accurate fluid level detection.
3Adaptability or versatility
If VSD is used to adjust motor speed and pump flow, then adaptability to changing well productivity is improved, but regulation attempts have failed due to application-specific factors
Solution Approach 1:
The patent segments the control approach by using discrete electrode pairs positioned at different heights along the probe, each associated with a switch and resistor. This segmentation creates distinct, reliable control points for different fluid levels, allowing the VSD to respond appropriately to changing well productivity without the complexity and reliability issues of continuous regulation attempts.
Solution Approach 2:
The system implements feedback through the varying resistance conductor that continuously monitors fluid level and provides information to the control system. This feedback mechanism enables the VSD to automatically adjust motor speed and pump flow in response to actual fluid level conditions, improving adaptability while maintaining reliability through a simple, proven feedback loop.
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 provides reliable and automatic fluid level sensing and control, ensuring efficient pump operation, reducing the risk of overheating and damage, and maintaining optimal fluid levels for enhanced productivity.
Implementation Method 1
a probe having a first insulated conductor with a resistance that varies as a function of distance within at least a sensing region of the probe and a plurality of electrode pairs spaced along the sensing region of the probe and electrically connected to the first conductor, wherein each electrode pair is positioned to shunt a portion of the resistance when in contact with a conductive fluid
Implementation Method 2
each electrode pair is positioned to shunt a portion of the resistance when in contact with a conductive fluid
Implementation Method 3
powered by voltage induced by adjacent, electrically isolated current carrying conductors
Data Source
AI summary
A system and method for sensing level of a fluid associated with a submersible pump having an impeller driven by an associated motor include a fluid level sensor having a probe with a plurality of discrete resistive elements each having an associated contact pair substantially evenly spaced along a length of the probe and an associated switch powered by an induced voltage or current generated by power provided to the submersible pump motor and activated by the fluid conducting across the contact pair to shunt the associated discrete resistive element.