Subsea Proximity Sensor Assemblies for Shaft Position Monitoring
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Solution Overview
Problem
In subsea fluid extraction wells, existing sensor assemblies struggle to accurately monitor the health of rotating equipment like subsea pumps and motor shafts due to harsh environmental conditions and indirect monitoring methods, leading to delayed detection of equipment issues and potential failures.
Innovation Solution
The development of proximity sensor assemblies that can directly monitor the position of a rotating shaft without physical contact, using RF radiation, light, or other energy types, and are designed to withstand high pressures and be flexible and adjustable for various configurations, allowing for precise monitoring of dynamic and static parameters of the motor shaft.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If indirect monitoring methods (accelerometers on motor case) are used, then the monitoring system is simpler to install, but the diagnostic accuracy and early detection capability deteriorate
Solution Approach 1:
The patent introduces a motor shaft adapter as an intermediary component that couples the sensor assembly to the motor shaft. This adapter serves as a mediator between the sensor and the rotating shaft, enabling direct measurement of shaft parameters (radial position, axial position, angular position) while maintaining ease of installation through standardized coupling mechanisms.
Solution Approach 2:
The patent replaces indirect mechanical monitoring (accelerometers on motor case detecting vibrations) with direct electromagnetic/proximity sensing (magnetic sensors detecting shaft position). This substitution transitions from mechanical vibration analysis to direct positional measurement, dramatically improving diagnostic accuracy while maintaining installation simplicity through non-contact sensing.
2Measurement precision
If direct monitoring of motor shaft is implemented, then the diagnostic accuracy improves, but the device complexity increases
Solution Approach 1:
The patent combines multiple sensing functions (radial position sensing, axial position sensing, angular position sensing) into a single integrated sensor assembly that mounts to the motor shaft adapter. This merging of multiple sensors and functions into one compact unit reduces overall system complexity while providing comprehensive direct monitoring capabilities.
Solution Approach 2:
The sensor assembly is designed with multi-functionality, capable of measuring radial position, axial position, and angular position simultaneously. This universal design allows a single assembly to perform multiple diagnostic functions, reducing the need for separate sensor systems and thereby reducing overall device complexity.
3Ease of operation
If existing sensor assemblies are used in subsea environments, then the installation is straightforward, but the reliability deteriorates due to harsh environmental conditions
Solution Approach 1:
The patent employs magnetic sensors that operate based on magnetic field parameters rather than mechanical contact. This parameter change from mechanical to magnetic sensing allows the system to withstand harsh subsea environmental conditions (high pressure, corrosion, moisture) while maintaining installation simplicity and improving reliability through non-contact measurement.
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
These sensor assemblies provide accurate and timely monitoring of subsea equipment health, enabling early detection of issues and preventing equipment failures, thus ensuring reliable operation and maintaining production in harsh subsea environments.
Implementation Method 1
Proximity sensors typically actively emit RF (radio-frequency) radiation, light, sound, or other types of energy, and detect changes in the electromagnetic field or return signal.
Data Source
AI summary
Integrated penetrator and proximity sensor probe assemblies are provided for monitoring a position of a rotating target within a subsea rotating device such as subsea motors and pumps. The integrated penetrator and proximity sensor probe assemblies are configured to communicate information related to the position of the rotating target through a wall of the device housing, and can be inserted through an opening in the wall of the device housing and mounted to the wall of the device to position a proximity sensor tip assembly adjacent the rotating target. The proximity sensor probe assemblies are pressure-compensated and configured to withstand subsea pressures and conditions.