Systems and methods of prediction and management of scaling on components
Systems and methods provided herein relate to a well site or other plant. Systems and methods are employed to determine fouling and/or reduce maintenance and down time associated with equipment that is subject to fouling conditions due to their operating environments in some embodiments. Fouling can include but is not limited to scale formation due to mechanical, thermal, chemical or combinations of such phenomenon. These phenomenon are initiated and progressively exacerbated as the equipment interacts with gaseous, solids and/or liquids from the operating environment. The equipment includes stationary and rotary equipment including but not limited to pump systems, valves, piping, heat exchangers, and plumbing utilized to move fluid in a well in a subterranean environment.
1 . A pump system for a pump disposed within a well, the pump system comprising:
a controller comprising an optimizer configured to receive constraints and provide activations to the pump to maximize production and lifetime or minimize cost, stress or maintenance; and
an estimator configured to estimate an estimated factor in response to measured parameters from the pump, the estimated factor comprising skin temperature, wherein the optimizer is configured to receive the estimated factor, and wherein the controller is configured to operate the pump using the activations.
2 . The system of claim 1 , wherein the pump comprises an electric motor and the constraints comprise one or more of: a maximum temperature of a motor winding of the motor, a maximum temperature of a motor housing of the motor, or equipment ratings.
3 . The system of claim 1 , wherein the pump comprises an electric motor and the constraints comprise: a maximum temperature of a motor winding of the motor, a maximum temperature of a motor housing of the motor, and equipment ratings.
4 . The system of claim 1 , wherein the activations comprising a cooling mass flow, a drive frequency, and a choke position.
5 . The system of claim 1 , wherein the measured parameters comprise a pressure, a motor voltage, or a motor current.
6 . The system of claim 1 , wherein the activations comprising a cooling mass flow.
7 . The system of claim 1 , wherein the activations are provided to the pump to maximize production.
8 . The system of claim 1 , wherein the estimator comprises a digital twin configured to estimate the skin temperature and to detect scaling thickness in the pump system, wherein the digital twin comprises a thermal model, and a motor model for providing data so that the scaling thickness and the skin temperature can be provided.
9 . The system of claim 8 , wherein the motor model comprises a reduced order model.
10 . A pump system for a pump disposed within a well, wherein the pump comprises an electric motor, the pump system comprising:
a controller comprising an optimizer configured to receive constraints and provide activations to the pump to maximize production and lifetime or minimize cost, stress or maintenance; and
an estimator configured to estimate an estimated factor in response to measured parameters from the pump using a thermal model and a motor model, the estimated factor comprising skin temperature, wherein the optimizer is configured to receive the estimated factor, and wherein the controller is configured to operate the pump using the activations.
11 . The system of claim 10 , wherein the activations comprising a cooling mass flow.
12 . The system of claim 10 , wherein the activations are provided to the pump to maximize production.
13 . The system of claim 10 , wherein the estimator comprises a digital twin configured to estimate the skin temperature.
14 . The system of claim 13 , wherein the digital twin comprises a motor model for providing data so that scaling thickness and the skin temperature can be provided.
15 . The system of claim 10 , wherein the motor model comprises a reduced order model.
16 . The system of claim 10 , wherein the thermal model comprises a reduced order model.
17 . A pump system for an electric subsurface pump disposed within a well, the pump system comprising:
a controller comprising an optimizer configured to receive constraints and provide activations to the pump to maximize production and lifetime or minimize cost, stress or maintenance; and
an estimator configured to estimate an estimated factor in response to measured parameters from the pump using a thermal model and a motor model, the estimated factor comprising skin temperature, wherein the optimizer is configured to receive the estimated factor, and wherein the controller is configured to operate the pump using the activations.
18 . The pump system of claim 17 , wherein the controller is configured to maximize efficiency of injected scaling inhibitor, to maximize efficiency of injected cleaning fluid for cleaning cycles, or to maximize efficiency of injected cooling fluid to lowering operating temperatures.
19 . The pump system of claim 18 , wherein the controller is configured to manage rate of scale buildup over time to maximize useful life.
20 . The pump system of claim 18 , wherein the thermal model comprises a reduced order model.