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Electrical submersible pump monitoring and failure prediction

  • US 10,571,590 B2
  • Filed: 07/08/2019
  • Issued: 02/25/2020
  • Est. Priority Date: 12/13/2011
  • Status: Active Grant
First Claim
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1. An apparatus for monitoring and operating an electrical submersible pump disposed in a hydrocarbon well, the apparatus comprising:

  • a logging system configured to record pump motor electrical current logs of the operating electrical power provided to a pump motor of the electrical submersible pump during pumping of well fluids;

    a conditioning circuit configured to convert the pump motor electrical current logs to a format for processing;

    a frequency spectrum analyzer configured to generate, based on the pump motor electrical current logs, measures of energy density present during pumping of the well fluids in individual frequency ranges of a frequency spectrum of the pump motor electrical current;

    a wavelet analyzer configured to generate, based on the pump motor electrical current logs, measures of variations in signal time shift and frequency characteristics of the pump motor electrical current during pumping of the well fluids to identify variations of the pump motor dynamic behavior as functions of time, the wavelet analyzer configured to apply an adjustable wavelet to a pump motor electrical current waveform based on the pump motor electrical current logs to identify additional load on the pump motor during pumping of the well fluids;

    a dynamic behavior analyzer module, comprising;

    a signal embedding module configured to, based on the pump motor electrical current logs, superimpose a set of added time series signals of different characteristic frequencies into the pump motor electrical current logs to identify dynamic behavior performance changes of the pump motor during pumping of the well fluids from changes in the pump motor electrical current logs; and

    a phase diagram reconstruction module configured to, based on the pump motor electrical current with the superimposed time series signals, sample the received pump motor electrical current with the superimposed time series signals at different time intervals and form a measure of the identified dynamic behavior performance changes of the pump motor based on fluctuations in the pump motor electrical current during pumping of the well fluids;

    an interface module configured to generate pump motor diagnostic information for monitoring the behavior and performance of the pump motor to detect disturbances in performance of the pump motor during pumping of the well fluids, the pump motor diagnostic information comprising;

    (a) characteristic frequencies and amplitude peaks as a function of frequency in the frequency spectrum of the pump motor electrical current measures generated by the frequency spectrum analyzer;

    (b) variations of signal time shift and frequency characteristics of the pump motor electrical current identifying variations of the pump motor dynamic behavior from the measures generated by the wavelet analyzer; and

    (c) phase diagrams of the dynamic behavior performance changes of the pump motor formed by the phase diagram reconstruction module; and

    a diagnostic system configured to;

    predict, based on the pump motor diagnostic information, a failure of the pump motor; and

    reduce, in response to predicting the failure of the pump motor, an operating speed of the pump motor.

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