This invention relates in general to electrical submersible well pump assemblies containing sealed fluids and in particular to sensors for detecting well fluid contamination in the sealed fluids.
Electrical submersible pump assemblies are commonly used in hydrocarbon producing wells to pump well fluid. These assemblies include a rotary pump driven by an electrical motor. A seal section coupled between the pump and motor reduces a pressure differential between well fluid and motor oil or lubricant contained in the motor and part of the seal section. Usually, a string of production tubing supports the submersible pump assembly in the well. A chive shaft extends from the motor through the seal section to the pump. At least one shaft seal seals around the shaft to block the entry of well fluid into the motor and seal section. The well fluid often contains a high percentage of water, which is damaging to internal component so the motor.
Shaft seals are known to leak eventually, thus many submersible pump assemblies fail due to the entry of well fluid into the motor. The failure could be within a few months or years after installation. When a failure occurs, the operator has to retrieve the pump assembly for replacement or repair. Retrieval of a pump assembly suspended on production tubing requires pulling the production tubing, an expensive and time consuming task. Often, the operator will not know whether the failure resulted from encroaching well fluid into the motor or for some other reason.
One solution to reducing the cost of replacing a submersible pump assembly is to suspend two pump assemblies on a Y-tool secured into the production tubing. Each pump assembly has a rotary pump, seal section, and motor. One of the pump assemblies becomes the primary pump assembly, and it is operated initially. The secondary pump assembly will not be operated until the first pump assembly fails. A valve and an intake plug block well fluid from entering the secondary pump until needed, because the well fluid can be corrosive. The secondary pump would be filled with a non corrosive buffer fluid. At startup, the valve opens and the plug is dissolved or discharged to expel the buffer fluid and allow the well fluid to enter the secondary pump.
Also, the secondary pump could be a different type and/or one that produces more efficiently at a lower flow rate than the primary pump. The secondary pump would be employed possibly before the primary pump fails, but when lower well fluid flow into the well justifies using the secondary pump and shutting down the primary pump.
A problem with installing a secondary, non operating pump would occur if the well fluid began leaking into contact with the buffer fluid. By the time the operator wants to start the secondary pump, corrosive well fluid could have entered the secondary pump and damaged the components.
A well pump assembly has a rotary pump and an electrical motor operably connected to the pump. A seal section connects between the motor and the pump for reducing a pressure differential between motor oil in the motor and well fluid in the well. A sealed fluid is contained in the well pump assembly. At least one sensor is mounted to the well pump assembly to detect contamination of the sealed fluid by well fluid encroaching into contact with the sealed fluid.
In one embodiment, at least one sensor is mounted in the motor, and the sealed fluid comprises motor oil located in the motor and in the seal section. One of the sensors may also be mounted in the seal section in contact with motor oil located within the seal section.
The seal section comprises a housing having a chamber with a well fluid entry port. A flexible element may be located in the chamber, having a motor oil side in fluid communication with the motor oil and a well fluid side for contact with and sealing the well fluid in the chamber from the motor oil. At least one of the sensors may be located in the chamber on the well fluid side of the flexible element. Further, the seal section may have a labyrinth chamber. At least one of the sensor may be located in the labyrinth chamber.
The installation may include a first sensor and a second sensor mounted to the submersible well pump assembly at an axial distance from the first sensor. The system may include an instrument panel that receives signals from the first and second sensors and identifies a delay between receiving signals indicating a presence of well fluid encroachment into the sealed fluid from the first sensor and from the second sensor.
The installation may include a primary well pump assembly and a secondary well pump assembly, the secondary well pump assembly adapted to be suspended in the well along with the primary well pump assembly, but initially in a non operating mode. The secondary well pump assembly has a barrier to prevent entry of well fluid into the pump during the non operating mode. The sealed fluid comprises a buffer fluid located in the pump of the secondary well pump assembly while in the non operating mode. At least one of the sensors is mounted in the pump of the secondary well pump assembly to monitor the buffer fluid.
One type of sensor may have a light source and a photo detector mounted opposite the light source. The light source emits a light beam that passes through part of the sealed fluid. A circuit determines attenuation of the light beam, which is indicative of the presence of well fluid in the sealed fluid.
Referring to
Seal section 21 may be a variety of types, and in
Bag chamber 35 includes an elastomeric bag 39. Alternately, bag 39 could be a bellows having a corrugated side wall formed of metal. Bag 39 separates well fluid 38 from motor oil 40 and expands and contracts to reduce a pressure differential between motor oil 40 contained in motor 19 (
One or more labyrinth tubes 47 are located in labyrinth chamber 37 to define a serpentine flow path for any well fluid 38 migrating through motor oil 40 toward motor 19. The labyrinth tube 47 shown has an upper end that attaches to a passage (not shown) leading from the interior of bag chamber guide tube 43. The lower end of labyrinth tube 47 is spaced a short distance above a lower end of labyrinth chamber 37. A mechanical seal 49 separates labyrinth chamber 37 from interior of bag 39, preventing motor oil 40 within guide tube 43 from flowing directly into a guide tube 51 in labyrinth chamber 37. Guide tube 51 has ports 53 near its upper end and surrounds shaft 31. Motor oil 40 contained in labyrinth chamber 37 is in fluid communication with the motor oil in motor 19 via guide tube ports 53 and the interior of guide tube 51.
Prior to installing pump assembly 11 in cased well 15, motor oil 40 is pumped into a lower end of motor 19, filling motor 19, guide tube 51, labyrinth chamber 37, guide tube 43, and the interior of bag 39. When lowered into well 15, well fluid 38 enters port 41 and applies hydrostatic pressure to motor oil 40 via the contraction of bag 39. That increase in pressure is applied to motor oil 40 in labyrinth chamber 37 and in motor 19. When motor 19 is energized, it generates heat, which causes motor oil 40 to expand in volume. The volume increase causes bag 39 to expand. When motor 19 is turned off, motor oil 40 cools and decreases in volume, causing bag 39 to contract. Motor oil 40 may be considered to be a sealed fluid isolated from well fluid 38. However, over time, well fluid 38 may enter into contact with motor oil 40 through leakage of mechanical seals 32, 49 and bag 39. Well fluid 38 is principally water, which is heavier than motor oil. The higher density retards well fluid 38 from flowing upward in bag 39 through guide tube port 45 and down guide tube 43 to labyrinth tube 47. The higher density also retards any water that may enter labyrinth chamber 37 from flowing upward to ports 53 and down the annular passages in guide tubes 51 toward motor 19. Nevertheless, well fluid can migrate downward, particularly in wells that are inclined.
At least one sensor 55 is mounted in seal section 21 to detect the contamination of motor oil 40 with well fluid 38. Preferably, sensor 55 is in a location to give an earliest indication of well fluid 38 entry into contact with motor oil 40. In the drawing of
First sensor 55 would normally provide an indication of well fluid encroachment into motor oil 40 before second sensor 57 because of the closer proximity of first sensor 55 to upper mechanical seal 32. Instrument panel 56 may have a microprocessor or other circuitry to record a time that elapses between receiving a well fluid encroachment signal from first sensor 55 and from second sensor 57. The time delay would be indicative of how fast well fluid is leaking into seal section 21. Instrument panel 56 could be programmed to provide an estimate to an operator of the amount of time before retrieving well pump assembly 11 for repair or replacement should occur.
Sensors 55, 57 may be an opacity sensor, fluid density sensor, conductivity sensor, ph sensor, absorption spectroscopy sensor, an opacity sensor, a fluorescent fiber sensor, a fiber optic sensor, or any other sensor suitable for differentiating between motor oil 40 and well fluid 38. Sensors 55, 57 may be electronically powered or receive light from fiber optic lines leading to instrument panel 56, and may be of known types. As another example, one suitable fiber optic sensor operates on a principle of total internal reflection. Light propagated down the fiber core hits angled end of the fiber. Light is reflected based on the index of refraction of the sealed fluid into which the angled end of the fiber is placed. The index of refraction varies in response to whether it contains water within the sealed liquid.
Another type of fiber optic sensor employs fluorescent material on the probe. The fluorescent signal is captured by the same fiber and directed back to an output demodulator. The returning signal can be proportional to viscosity and water droplet content. The well fluid normally would have a different viscosity that the sealed fluid being monitored, thus a measurement of viscosity correlates to well fluid encroachment in the sealed liquid.
A variety of telemetry techniques are known for communicating sensed parameters of well pump assemblies, such as pressure and temperature. These techniques include superimposing a sensor signal onto the power cable leading to the motor, or sing a separate instrument wire or fiber optic line leading to instrument panel 56. These techniques may be used for transmitting signals from sensors 55, 57.
Referring to
Primary well pump assembly 89 has an electrical motor 95 connected to a seal section 97, which in turn connects to an optional gas separator 99. A pump 101, which in this example, is a centrifugal pump, connects to the upper end of gas separator 99; if one is employed. Intake 103 is located at the base of gas separator 99; or if not employed, intake 103 will be at the base of pump 101.
Secondary pump assembly 93 is illustrated as being a progressive cavity type, rather than centrifugal, but it could be centrifugal. Secondary pump assembly 93 has a progressive cavity pump 105, which has a helical rotor rotated in a double helical elastomeric stator (not shown). The rotor orbits and connects to a flex shaft section 107 that accommodates the orbital movement at an upper end and has an axially restrained rotational bearing at its lower end. Intake ports 109 are located in flex shaft section 107. A seal section 111 of a type similar to seal section 97 connects to the lower end of flex shaft section 17. Because a progressive cavity pumps rotates much slower than a centrifugal pump, a gear reducer 113 is connected between the shaft portion in flex shaft section 107 and an electrical motor 115.
Secondary pump assembly 93 is initially in an off or non operating mode with no power being supplied to motor 115 while power is being supplied to motor 95 of primary pump assembly 89. At a later date, secondary pump assembly 93 will be turned on, and primary pump assembly 89 optionally may be turned off. That date could occur when primary pump assembly 89 fails, thus could be months or even years later. If intake 109 is open, well fluid 38 would completely fill pump 105 and portions of seal section 111. To avoid deterioration of the internal components due to the immersion in well fluid 38, pump 105 and the well fluid part of seal section 111 are filled with a protective buffer fluid 116, as shown in
Temporary plugs 117 are placed in intake ports 109 to separate buffer fluid 116 from external well fluid. The discharge of pump 105 may be sealed by the valve or another plug in Y-connector 87. To retard leakage, buffer fluid 116 is kept at approximately the same hydrostatic pressure as well fluid 38. Maintaining the pressure may be performed by a surface pump 119 (
A well fluid sensor 123 is mounted within a portion of secondary pump assembly 93 containing buffer fluid 116. Well fluid sensor 123 is illustrated as being mounted within flex shaft section 107 adjacent intake ports 109. If buffer fluid 116 had a lighter specific gravity than well fluid 38, well fluid sensor 123 may be mounted at an upper end of secondary pump 105. Well fluid sensor 123 will be connected to wires or fiber optic lines for conveying a signal to a surface panel at wellhead 92. Well fluid sensor 123 may be a same type as sensors 55, 57, 73, 75 and 79 for detecting well fluid, principally water, in buffer fluid 116. An optional pressure sensor 125 provides a signal to the surface panel of the pressure of buffer fluid 116. Sensors for detecting well fluid contamination in the motor oil of primary and secondary pump assemblies 89, 93 may also be used.
While primary pump assembly 89 is operating and secondary pump assembly 93 turned off, plugs 117 will seal buffer fluid 116 in secondary pump 105. Well fluid sensor 123 provides signals indicating whether or not any well fluid 38 has contaminated buffer fluid 116. If well fluid 38 is detected, the operator may choose to circulate uncontaminated buffer fluid 116 into pump 105 with surface pump 119. Alternately, the operator may choose to place secondary pump 105 in immediate operation by removing plugs 117 and turning on surface pump 105. The operator may remove plugs 117 at any time by increasing pressure of buffer fluid 116 with surface pump 119. Plugs 117 could alternately be of a type soluble in a solvent that the operator pumps down lines 121.
While the invention has been shown in only a few of its forms, it should be apparent to those skilled in the art that it is not so limited but is susceptible to various changes without departing from the scope of the disclosure.
This application claims priority to provisional application 61/709,797, filed Oct. 4, 2012.
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