Wireless ESP Sensor Flow Estimation for Accurate Downhole Rates
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Solution Overview
Problem
Conventional methods for determining downhole fluid flow rates in oil and gas wells are prone to errors due to surface measurements and inaccurate ESP stage performance, leading to inefficient operation and hydrocarbon allocation issues.
Innovation Solution
A system using wireless sensors in a discharge sub and suction sub coupled to an ESP to transmit monitoring data to a monitoring sub, which is then analyzed by a downhole flow rate analyzer to determine accurate fluid flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If surface flow meters are used to determine downhole fluid flow rates, then flow rate measurement is achieved, but measurement precision deteriorates due to errors from pressure and temperature corrections
Solution Approach 1:
The patent replaces conventional surface mechanical flow meters with downhole electronic sensors that directly measure pressure, temperature, and flow parameters at the wellbore. This substitution eliminates the need for pressure and temperature corrections that introduce errors in surface measurements, thereby improving measurement precision and preventing information loss.
Solution Approach 2:
The patent introduces wireless communication modules as intermediaries between downhole sensors and surface monitoring systems. These modules enable direct transmission of raw sensor data without physical hydraulic lines, maintaining data integrity while eliminating the complexity of hydraulic connections and associated measurement errors.
2Measurement precision
If factory tested ESP stage performance curves are used to estimate downhole flow rates, then flow rate estimation is achieved, but measurement precision deteriorates due to stage performance deterioration from erosion or corrosion
Solution Approach 1:
The patent implements real-time feedback through downhole sensors that continuously monitor actual pressure, temperature, and flow conditions. This feedback mechanism allows the system to detect deviations from factory performance curves caused by erosion or corrosion, enabling continuous calibration and maintaining measurement precision despite changing ESP stage conditions.
Solution Approach 2:
The patent performs preliminary calibration by comparing initial sensor readings with factory performance curves to establish baseline conditions. This preliminary action creates a reference framework that accounts for specific installation conditions, allowing the system to maintain accurate flow rate measurements even as ESP stage performance deteriorates over time.
3Loss of information
If conventional surface measurement methods are used, then flow rate data is obtained, but device complexity increases due to hydraulic lines and correction systems
Solution Approach 1:
The patent extracts the measurement function from the complex surface hydraulic system and relocates it to simple downhole electronic sensors. By taking out the measurement capability from the cumbersome hydraulic line infrastructure and placing it directly at the wellbore, the system achieves high data quality while dramatically reducing overall device complexity.
Solution Approach 2:
The patent replaces mechanical hydraulic lines with wireless electronic communication systems. This substitution eliminates the physical infrastructure complexity of hydraulic connections, pressure transducers, and temperature correction systems, while maintaining or improving flow rate data quality through direct downhole measurements.
4Productivity
If surface flow measurement with corrections is used, then flow rate is determined, but productivity decreases due to operational inefficiencies and inaccurate hydrocarbon allocation
Solution Approach 1:
The patent implements real-time feedback loops where downhole sensor data is continuously transmitted to surface monitoring systems, enabling immediate detection of flow rate changes, equipment performance degradation, or operational anomalies. This real-time feedback improves productivity by allowing prompt operational adjustments and accurate hydrocarbon allocation based on actual downhole conditions rather than delayed or corrected surface measurements.
Data Source
AI summary
A method to determine downhole fluid flow rate of a wellbore. The method includes generating, using sensors of a discharge sub and a suction sub coupled to an electrical submersible pump (ESP), monitoring data of the ESP that is suspended in the wellbore via a production tubing to facilitate well fluid flow to the Earth's surface through the production tubing, wirelessly transmitting, using wireless transmitters of the discharge sub and the suction sub, the monitoring data to a monitoring sub coupled to an electrical motor of the ESP, transmitting, by the monitoring sub to a downhole flow rate analyzer at the Earth's surface, monitoring data wirelessly received from the discharge sub and the suction sub, and determining, by the downhole flow rate analyzer, the downhole flow rate of the well fluid by analyzing the monitoring data.