Electrical Signature Analysis
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Maximizing ESP Uptime With Electrical Signature Analysis
Electric submersible pumps (ESPs) are indispensable systems in the oil industry, efficiently lifting significant volumes of fluids from wellbores to the surface. Capable of operating at depths beyond 3,000 feet and with a pumping capacity of between 500 and 50,000 barrels per day, ESPs are engineered for performance and durability.
The challenge production engineers face is optimizing ESP output and fine-tuning the trade-off between output and wear and tear. ESPs will fail, and when they do, it is a problem, triggering a costly and time-consuming process to replace them. Operators can benefit from smart monitoring systems with sensor data, enabling them to make informed decisions to better manage pump longevity and productivity.
ESPs typically have a service life of two to five years, significantly shorter than the 15-plus-year life span of surface equipment. This disparity is primarily due to the harsh conditions under which ESPs operate: extreme pressures that can reach hundreds of bars, high temperatures and the constantly changing consistency of the pumped medium.
Electrical signature analysis (ESA) has emerged as a solution to some of the challenges associated with operating ESPs. Unlike conventional monitoring technologies, ESA does not rely on downhole sensors. Instead, it analyzes high-frequency electrical data recorded inside the motor control cabinet at the surface. Modern ESA systems incorporate machine learning algorithms to provide continuous surveillance and adeptly detect mechanical and electrical issues in the motor, pump and power cabling before they result in ESP failure. This information allows production engineers and operators to reduce unplanned downtime. For example, they can act to mobilize a workover rig in advance of any failure.
How the Water Industry Is Transforming Submersible Pump Maintenance With AI
A technology called electrical signature analysis (ESA) makes reliable, remote monitoring of submerged pumps possible. ESA measures the current and voltage being supplied to the motor driving the pump. Because it captures the electrical signals, ESA sensors are current and voltage probes that are installed in the motor control cabinet. This bypasses the need to install sensors on, or even near, submerged pumps.
One solution utility operators are increasingly deploying to improve the energy efficiency of pumps are variable frequency drives (VFDs). VFDs are a type of motor controller that drive an electric motor by varying the supply frequency. By matching fluctuating load and demand requirements, organizations can operate pumps more efficiently, saving energy and extending their lifetime.