Abstract: A system for determining whether a motor in an electrical submersible pump is backspinning is described herein. The system comprises a sensor mounted in a well bore proximate to a ground surface, the sensor outputting a backspin signal; a communication link connected to the sensor, the communications link communicating the backspin signal; and a controller receiving the backspin signal from the communications link and processing the backspin signal to determine whether the motor is backspinning.

Abstract: A system for detecting a backspin condition of a motor in an electrical submersible pump is disclosed herein. The system comprises a sensor mounted proximate to the motor, the sensor outputting a signal, a power cable connected between a motor and a controller, the power cable supplying a three phase AC voltage to the motor, one phase of the three phase signal having a control signal thereon; electronics connected to the sensor, the electronics receiving the signal and propagating the signal to the controller; and a computer defining the controller, the controller having a non-transitory memory, a computer processor, and a computer program product stored on the memory and executable by the processor, the computer program product performing a process of controlling the variable speed drive of the motor and a process of monitoring the signal from the sensor to determine if the motor is backspinning.

Abstract: Systems and methods for controlling an electrical drive such as is used with electric submersible pumps used in downhole oil production, wherein the drive automatically determines the proper phasing to drive the pump motor in a forward direction. In one embodiment, a method includes generating a drive signal having an initial phasing and driving the pump to establish a column of fluid in the borehole. The drive signal is then discontinued, allowing the column of fluid to fall through the pump and cause the pump to backspin and generate a signal having phasing corresponding to the reverse rotational direction. The forward phasing is then determined to be the opposite of the phasing corresponding to the reverse rotational direction. The pump can be restarted in the forward direction, or an operator can be notified of the proper phasing to produce forward rotation of the pump.

Abstract: A device and method can detect, and also break, an occurrence of gas lock in an electrical submersible pump assembly in a well bore based upon surface or downhole data without the need for operator intervention. To detect an occurrence of gas lock, an instantaneous value is monitored using a sensor. Then a controller compares the instantaneous value to a threshold value over a predetermined duration to thereby detect the occurrence of gas lock in the electrical submersible pump assembly. Sensors can include, for example, a differential pressure gauge, a pressure gage located in a pump stage located toward the inlet, a fluid temperature sensor located toward the discharge, a free gas detector located near the pump discharge, an electrical resistivity gage, a flow meter located within surface production tubing, and a vibration sensor attached to a tubing string to measure a vibration signature.

Abstract: Systems and methods for providing electrical power and to downhole oil production equipment such as electrical submersible pumps, wherein the outputs of multiple power modules are individually filtered before being added together to obtain a high voltage output that is provided to the downhole equipment. In one embodiment, an electrical drive system includes multiple power modules and corresponding filters. Each of the power modules is configured to receive an input power signal and to provide a corresponding pulse width modulated or stepped intermediate signal. The signal output by each power module is individually filtered to remove at least a portion of high-frequency components in the signal. The power modules and filters are coupled together in a configuration in which the filtered signals of the power modules are added to produce an output drive signal that is used to drive equipment such as an electrical submersible pump.

Abstract: Systems and methods for using variable speed drives to restart downhole submersible pump motors. In one embodiment, a downhole pump is controlled using a variable speed drive that includes a control system configured to detect interruptions in the operation of the pump system. After an interruption that requires the restart of the pump motor, the control system determines the reverse rotational speed of the pump motor and restarts the motor when this speed is sufficiently low. The control system may be configured to reduce the output voltage of the variable speed drive and sweep through a range of output frequencies to determine the frequency at which the current drawn by the motor is lowest. This is the frequency at which the drive's output matches the speed of the motor and the apparent impedance of the motor is highest. When the speed is low enough, the motor is restarted.

Abstract: A multiphase flow meter used in conjunction with an electrical submersible pump system in a well bore includes sensors to determine and transmit well bore pressure measurements, including tubing and down hole pressure measurements. The multiphase flow meter also includes at least one artificial neural network device to be used for outputting flow characteristics of the well bore. The artificial neural network device is trained to output tubing and downhole flow characteristics responsive to multiphase-flow pressure gradient calculations and pump and reservoir models, combined with standard down-hole pressure, tubing surface pressure readings, and the frequency applied to the electrical submersible pump motor.

Abstract: A system for detecting a backspin condition of a motor in an electrical submersible pump is disclosed herein. The system comprises a sensor mounted proximate to the motor, the sensor outputting a signal, a power cable connected between a motor and a controller, the power cable supplying a three phase AC voltage to the motor, one phase of the three phase signal having a control signal thereon; electronics connected to the sensor, the electronics receiving the signal and propagating the signal to the controller; and a computer defining the controller, the controller having a non-transitory memory, a computer processor, and a computer program product stored on the memory and executable by the processor, the computer program product performing a process of controlling the variable speed drive of the motor and a process of monitoring the signal from the sensor to determine if the motor is backspinning.

Abstract: A system for determining whether a motor in an electrical submersible pump is backspinning is described herein. The system comprises a sensor mounted in a well bore proximate to a ground surface, the sensor outputting a backspin signal; a communication link connected to the sensor, the communications link communicating the backspin signal; and a controller receiving the backspin signal from the communications link and processing the backspin signal to determine whether the motor is backspinning.

Abstract: Systems and methods for controlling an electrical drive such as is used with electric submersible pumps used in downhole oil production, wherein the drive automatically determines the proper phasing to drive the pump motor in a forward direction. In one embodiment, a method includes generating a drive signal having an initial phasing and driving the pump to establish a column of fluid in the borehole. The drive signal is then discontinued, allowing the column of fluid to fall through the pump and cause the pump to backspin and generate a signal having phasing corresponding to the reverse rotational direction. The forward phasing is then determined to be the opposite of the phasing corresponding to the reverse rotational direction. The pump can be restarted in the forward direction, or an operator can be notified of the proper phasing to produce forward rotation of the pump.

Abstract: Systems and methods for reducing harmonic distortion in a power system resulting from non-linear loading on the power system. The power at an interface with a power source is measured, and then distortion in the waveforms of the supplied power is identified. Cancellation signals which cancel all or part of the distortion are then generated and injected at the interface. In one embodiment, the power is sampled to determine the waveform, and then a Fast Fourier Transform is performed on the waveform to convert it to the frequency domain. Harmonics of the fundamental frequency can then be identified, and conjugates of the harmonics generated. An inverse Fast Fourier Transform is performed on the conjugates to generate a signal which is amplified to produce the cancellation signal.

Abstract: A device, method, and program product detect and break an occurrence of gas lock in an electrical submersible pump assembly in a well bore based upon surface or downhole data without the need for operator intervention. The system provides the ability to flush the pump and return the system back to production without requiring system shutdown. In addition, the system provides an algorithm for controlling a pump operating speed of the electrical submersible pump assembly to maximize production from the well bore.

Abstract: Systems and methods for providing electrical power and to downhole oil production equipment such as electrical submersible pumps, wherein the outputs of multiple power modules are individually filtered before being added together to obtain a high voltage output that is provided to the downhole equipment. In one embodiment, an electrical drive system includes multiple power modules and corresponding filters. Each of the power modules is configured to receive an input power signal and to provide a corresponding pulse width modulated or stepped intermediate signal. The signal output by each power module is individually filtered to remove at least a portion of high-frequency components in the signal. The power modules and filters are coupled together in a configuration in which the filtered signals of the power modules are added to produce an output drive signal that is used to drive equipment such as an electrical submersible pump.

Abstract: Systems and methods for providing ride-through for interruptions in the power supplied to drives that are used to control equipment such as downhole submersible pumps. In one embodiment, a variable speed drive includes converter and inverter sections, a capacitor bank and a control system. The drive shuts down the converter section upon detecting a disruption in the AC input power and continues to generate output power by drawing on the energy stored in the capacitor bank. When the AC input power returns (or begins to return) to normal, the drive resumes operation of the converter section in a controlled manner (e.g., by presetting the firing angle of the SCR's in the converter to match the voltage across the capacitor bank.) The drive thereby limits the current that recharges the capacitor bank and prevents sudden inrushes of current that could damage the drive.

Abstract: A device and method can detect, and also break, an occurrence of gas lock in an electrical submersible pump assembly in a well bore based upon surface or downhole data without the need for operator intervention. To detect an occurrence of gas lock, an instantaneous value is monitored using a sensor. Then a controller compares the instantaneous value to a threshold value over a predetermined duration to thereby detect the occurrence of gas lock in the electrical submersible pump assembly. Sensors can include, for example, a differential pressure gauge, a pressure gage located in a pump stage located toward the inlet, a fluid temperature sensor located toward the discharge, a free gas detector located near the pump discharge, an electrical resistivity gage, a flow meter located within surface production tubing, and a vibration sensor attached to a tubing string to measure a vibration signature.

Abstract: Systems and methods for reducing harmonic distortion in a power system resulting from non-linear loading on the power system. The power at an interface with a power source is measured, and then distortion in the waveforms of the supplied power is identified. Cancellation signals which cancel all or part of the distortion are then generated and injected at the interface. In one embodiment, the power is sampled to determine the waveform, and then a Fast Fourier Transform is performed on the waveform to convert it to the frequency domain. Harmonics of the fundamental frequency can then be identified, and conjugates of the harmonics generated. An inverse Fast Fourier Transform is performed on the conjugates to generate a signal which is amplified to produce the cancellation signal.

Abstract: A motor controller for an electrical submersible pump production system is coupled to a real-time software model using known correlations and algorithms to model the performance of the production system, including the production equipment and the well, and executes separately from any modeling used to compute operating parameters from downhole measurements for use by the motor controller. The real-time software model receives operating parameter measurements from a data acquisition subsystem and compares the measurements with projected operating parameter values according to the model. Differences between measured and projected values are analyzed to identify operating problems or non-optimal operating conditions, with automatic corrections and/or notifications being triggered.

Abstract: A device, method, and program product detect and break an occurrence of gas lock in an electrical submersible pump assembly in a well bore based upon surface or downhole data without the need for operator intervention. The system provides the ability to flush the pump and return the system back to production without requiring system shutdown. In addition, the system provides an algorithm for controlling a pump operating speed of the electrical submersible pump assembly to maximize production from the well bore.

Abstract: A multiphase flow meter used in conjunction with an electrical submersible pump system in a well bore includes sensors to determine and transmit well bore pressure measurements, including tubing and down hole pressure measurements. The multiphase flow meter also includes at least one artificial neural network device to be used for outputting flow characteristics of the well bore. The artificial neural network device is trained to output tubing and downhole flow characteristics responsive to multiphase-flow pressure gradient calculations and pump and reservoir models, combined with standard down-hole pressure, tubing surface pressure readings, and the frequency applied to the electrical submersible pump motor.

Abstract: Systems and methods for using variable speed drives to restart downhole submersible pump motors. In one embodiment, a downhole pump is controlled using a variable speed drive that includes a control system configured to detect interruptions in the operation of the pump system. After an interruption that requires the restart of the pump motor, the control system determines the reverse rotational speed of the pump motor and restarts the motor when this speed is sufficiently low. The control system may be configured to reduce the output voltage of the variable speed drive and sweep through a range of output frequencies to determine the frequency at which the current drawn by the motor is lowest. This is the frequency at which the drive's output matches the speed of the motor and the apparent impedance of the motor is highest. When the speed is low enough, the motor is restarted.