Demonstration of Advanced Magnetic Technologies for a Highly Reliable and Retrievable Electric Submersible Pump Topology

2021 ◽  
Author(s):  
Patrick McMullen ◽  
David Biddick
Keyword(s):  
High Speed ◽  
Magnetic Bearing ◽  
Free Fluid ◽  
Submersible Pump ◽  
Rotor Vibration ◽  
Operating Life ◽  
Element Analysis ◽  
Operational Life ◽  
Electric Submersible Pump ◽  
Bearing System

Abstract This effort designs, builds and tests key enabling technology components of the magnetic drive system (MDS) electric submersible pump (ESP) concept, an advanced high speed ESP that differs from conventional ESP topologies in using magnetic technologies to increase reliability and retrievability. The enabling components include a radial passive magnetic bearing (PMB) system, allowing for a contact-less bearing system and remote removal of rotating components, and magnetic vibration sensors (MVS), enabling prognostics for higher reliability. An MDS ESP preliminary design has been developed through a DeepStar program, from which the size and integration requirements of the PMB and MVS have been defined. These requirements guide the analysis, design and testing of the full-scale components. Empirical analysis tools are used for initial iterations in size and performance of the PMB and MVS, followed by detailed magnetic finite element analysis (FEA) using commercial validated tools for the final performance prediction. With analytical validation of performance, detail designs are developed and hardware fabricated. Hardware testing is done to validate performance predictions and alignment with system requirements. The PMB performance results include testing of stiffness capability. These characteristics are used to validate the integration requirements for load capability and deflection during static load events, all in relation to validating performance for use in the MDS system. This test data is used to validate the analysis approach used as well as to finalize the integration size of the PMB to meet the performance requirements of the MDS system. To identify rotor operating speed and rotor vibration magnitude and frequencies, the MVS is tested for sensing rotor motion rate and frequency, including sub-synchronous and super synchronous frequencies. Identifying data reduction needs, i.e. how data is compiled and presented to focus on specific areas of interest, is also critical to determine the vibration characteristic of specific events happening in the ESP, such as bearing wear or dynamic fluid changes. Testing also includes variations in tubing materials to assess performance impact. These technologies offer bearing and sensor technologies that enhance ESP reliability and active performance monitoring. The PMBs offer a contact-less bearing system that does not require lubrication, can operate with large clearances to allow free fluid flow, and has no operating life limits. The compact MVS offers rotor vibration diagnostics throughout the ESP, including between pump stages, for monitoring performance, detecting ESP mechanical issues or process fluid variations allowing immediately response to increase operational life.

Development of a Passive Magnetic Radial Bearing System for Electric Submersible Pumps ESPs

2021 ◽  
Author(s):  
Patrick McMullen ◽  
David Biddick ◽  
Herman Artinian
Keyword(s):  
Magnetic Fields ◽  
High Speed ◽  
Phase 1 ◽  
Magnetic Bearing ◽  
Full Scale ◽  
Physical Contact ◽  
Free Fluid ◽  
Preliminary Design ◽  
Radial Bearing ◽  
Bearing System

Abstract This development is the result of a DeepStar program to build and test a new radial passive magnetic bearing system (PMB) for downhole tools. While slated for the Magnetic Drive System (MDS) ESP, an advanced high-speed ESP that uses magnetic fields to increase performance, reliability and retrievability, this technology is applicable to conventional ESPs. The PMB supports the motor rotor across large clearances with no physical contact via magnetic fields in the ESP. An MDS ESP preliminary design was developed, from which the size and integration requirements of the PMB were defined. These requirements guided the analysis, design and testing of the full-scale components. Empirical analysis tools were used for initial iterations in size and performance of the PMB, followed by detailed magnetic finite element analysis (FEA) using commercial validated tools for the final performance prediction. With analytical validation of performance, detail designs were developed and hardware fabricated. Hardware testing was done to validate performance predictions and alignment with system requirements. The feasibility, preliminary design and analysis of the PMB were conducted in Phase 1 of the DeepStar Program and has continued with the full-scale design, build and test results of Phase 2. PMB performance results include load capability and deflection during static load events, all in relation to validating performance for use in the MDS system. This test data is used to validate the analysis approach used as well as to finalize the integration size of the PMB to meet the performance requirements of the MDS system. With the PMB large (>14mm) clearance between rotor and stator magnets, testing also includes variations in axial and radial position of the rotor in relation to the stator to account for installation variations in the MDS as well as use of sealing materials on both the rotor and stator. Integration is planned for use of the PMB in the MDS, so integration testing is planned to validate performance for each of these areas. This technology offers a radial bearing that can greatly enhance ESP performance and reliability. The PMB is a contact-less bearing system that does not require lubrication, can operate with large clearances to allow free fluid flow, is easily fully sealed from the environment, has virtually no bearing rotating losses, and has no operating life limits.

Multi-State Transient Rotor Vibration Control Using Sampled Harmonics

2002 ◽  
Vol 124 (2) ◽  
pp. 186-197 ◽  
Author(s):  
P. S. Keogh ◽  
M. O. T. Cole ◽  
C. R. Burrows
Keyword(s):  
Magnetic Bearing ◽  
Measured Data ◽  
Rapid Decrease ◽  
Flexible Rotor ◽  
Rotor Vibration ◽  
Transient Vibration ◽  
Stability Boundaries ◽  
Vibration Attenuation ◽  
Harmonic Components ◽  
Bearing System

A technique is introduced to achieve transient vibration attenuation in a multi-input, multi-output flexible rotor/magnetic bearing system. The strategy employs feedback control of measured harmonic components of rotor vibration. Whereas previous harmonic controllers have been based only on steady state vibration characteristics, the new controller also incorporates the transient dynamics. The controller may still be designed from measured data and is determined from target transient vibrational responses arising from step changes in particular disturbances. Account is taken of delays arising from evaluation of harmonic components. Furthermore, stability boundaries for the controller are shown to have significant tolerance to measurement error. The controller is validated experimentally in a flexible rotor/magnetic bearing system and mass loss tests are used to demonstrate rapid decrease in vibration levels with near elimination of transient overshoot.

Performance of a Foil-Magnetic Hybrid Bearing

2000 ◽  
Author(s):  
Erik E. Swanson ◽  
Hooshang Heshmat ◽  
James Walton
Keyword(s):  
High Speed ◽  
Load Capacity ◽  
Magnetic Bearing ◽  
Experimental Program ◽  
Turbine Engine ◽  
Foil Bearing ◽  
Speed Performance ◽  
Hybrid Bearing ◽  
High Load Capacity ◽  
Bearing System

To meet the advanced bearing needs of modern turbomachinery, a hybrid foil-magnetic hybrid bearing system was designed, fabricated and tested in a test rig designed to simulate the rotor dynamics of a small gas turbine engine (31 kN to 53 kN thrust class). This oil-free bearing system combines the excellent low and zero-speed capabilities of the magnetic bearing with the high load capacity and high speed performance of the compliant foil bearing. An experimental program is described which documents the capabilities of the bearing system for sharing load during operation at up to 30,000 RPM and the foil bearing component’s ability to function as a back-up in case of magnetic bearing failure. At an operating speed of 22,000 RPM, loads exceeding 5300 N were carried by the system. This load sharing could be manipulated by an especially designed electronic control algorithm. In all tests, rotor excursions were small and stable. During deliberately staged magnetic bearing malfunctions, the foil bearing proved capable of supporting the rotor during continued operation at full load and speed, as well as allowing a safe rotor coast-down. The hybrid system tripled the load capacity of the magnetic bearing alone and can offer a significant reduction in total bearing weight compared to a comparable magnetic bearing.

Structure and Finite Element Analysis for a Permanent Magnet Bias Axial Magnetic Bearing

2011 ◽  
Vol 383-390 ◽  
pp. 4803-4809
Author(s):  
Xu Sheng Zhao ◽  
Zhi Quan Deng ◽  
Bo Wang ◽  
Chun Hua
Keyword(s):  
Finite Element ◽  
Permanent Magnet ◽  
High Speed ◽  
Magnetic Bearing ◽  
Magnetic Suspension ◽  
Low Loss ◽  
Theory Analysis ◽  
Element Analysis ◽  
Finite Element Software ◽  
Magnetic Field Simulation

A new permanent magnet bias axial magnetic bearing (PMAB) is introduced, then the structure and operation principle are analyzed. The equivalent magnetic circuit is established to deduce the mathematic expression. The parameter design and calculation of the magnetic bearing are presented including available area of magnetic pole, ampere - turns of control coils etc. The parameters of the proposed prototype are also given. The 3-D magnetic field simulation is performed by using the Finite Element software. The theory analysis and the simulation show that the maximum suspension magnetic force satisfies the design requirement. The magnetic suspension forces have better linearity and symmetry around the balanced position. Therefore, the proposed PMAB is suitable for the high speed or low loss occasions.

THE IMPROVEMENT OF WHEEL TREAD REPROFILING PROCESS

2017 ◽  
pp. 120-128
Author(s):  
Igor Ivanov ◽  
Dmitriy Kononov ◽  
Sergey Urushev
Keyword(s):  
High Speed ◽  
Performance Enhancement ◽  
Practical Knowledge ◽  
Practical Importance ◽  
Rolling Stock ◽  
Speed Profile ◽  
Operating Life ◽  
Operational Life ◽  
High Speed Grinding ◽  
Process Solutions

Object: To show the lack of wheelset operating life efficiency use in case traditional methods of wheel tread reprofiling were used in the process of repair works. To consider the possibilities of further improvement of this process on the basis of new reprofiling technologies, using the deep and high-speed grinding. Methods: The methods of wheel tread reprofiling were analyzed, the effective process solutions, based on theoretical conclusions and current practical knowledge, were studied. Results: Wheel set wastage in case of using the traditional ways of reprofiling was estimated. Preliminary parameters of wheelset reprofiling modes using high-speed grinding were estimated, providing for the increase in wheel set operational life and reprofiling performance enhancement. Practical importance: The appropriateness of rolling stock wheel tread reprofiling, by using the method of infeed high-speed profile grinding, was presented. The obtained results may be applied in the development of requirements specification for wheel tread reprofiling machine at repair facilities of the Russian Railways.

scholarly journals Design and Implementation of a Fault-Tolerant Magnetic Bearing System for MSCMG

2013 ◽  
Vol 2013 ◽  
pp. 1-12 ◽  
Author(s):  
Enqiong Tang ◽  
Bangcheng Han
Keyword(s):  
High Speed ◽  
Fault Tolerant ◽  
Control Strategies ◽  
Load Capacity ◽  
Maximum Load ◽  
Magnetic Bearing ◽  
Before And After ◽  
Key Factor ◽  
Gyroscopic Coupling ◽  
Bearing System

The magnetically suspended control moment gyros (MSCMGs) are complex system with multivariable, nonlinear, and strongly gyroscopic coupling. Therefore, its reliability is a key factor to determine whether it can be widely used in spacecraft. Fault-tolerant magnetic bearing systems have been proposed so that the system can operate normally in spite of some faults in the system. However, the conventional magnetic bearing and fault-tolerant control strategies are not suitable for the MSCMGs because of the moving-gimbal effects and requirement of the maximum load capacity after failure. A novel fault-tolerant magnetic bearing system which has low power loss and good robust performances to reject the moving-gimbal effects is presented in this paper. Moreover, its maximum load capacity is unchanged before and after failure. In addition, the compensation filters are designed to improve the bandwidth of the amplifiers so that the nutation stability of the high-speed rotor cannot be affected by the increasing of the coil currents. The experimental results show the effectiveness and superiority of the proposed fault-tolerant system.

Finite Element Analysis and Dynamics Charateristic Study for High-Speed Magnetic Suspension Motorized Spindle of CNC Machine Tools

2011 ◽  
Vol 317-319 ◽  
pp. 595-599
Author(s):  
Yu Xin Sun ◽  
Ling Ding ◽  
Tao Shi ◽  
Xian Xing Liu
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Induction Motor ◽  
High Speed ◽  
Magnetic Bearing ◽  
Magnetic Suspension ◽  
Distinct Advantage ◽  
Motorized Spindle ◽  
Element Analysis ◽  
Spindle System

According to magnetic suspension motorized spindle system, high speed motorized spindle system based on bearingless induction motor is presented in this paper. The prototype of high speed motorized spindle system with bearingless induction motor is studied and analyzed by using finite element analysis software Ansoft/Maxwell and Riccati transfer matrix method, and compared with high speed motorized spindle system supported by Active Magnetic Bearing (AMB). The results show that high speed motorized spindle system with bearingless induction motor has distinct advantage of simple and compact structure, which is easier to realize high speed and extra-high speed operation.

Fault Tolerant Magnetic Bearings

1999 ◽  
Vol 121 (3) ◽  
pp. 504-508 ◽  
Author(s):  
E. H. Maslen ◽  
C. K. Sortore ◽  
G. T. Gillies ◽  
R. D. Williams ◽  
S. J. Fedigan ◽  
...  
Keyword(s):  
Fault Tolerance ◽  
High Speed ◽  
Fault Tolerant ◽  
High Capacity ◽  
Magnetic Bearing ◽  
Magnetic Bearings ◽  
Flexible Rotor ◽  
Variable Reluctance ◽  
Modular Redundancy ◽  
Bearing System

A fault tolerant magnetic bearing system was developed and demonstrated on a large flexible-rotor test rig. The bearing system comprises a high speed, fault tolerant digital controller, three high capacity radial magnetic bearings, one thrust bearing, conventional variable reluctance position sensors, and an array of commercial switching amplifiers. Controller fault tolerance is achieved through a very high speed voting mechanism which implements triple modular redundancy with a powered spare CPU, thereby permitting failure of up to three CPU modules without system failure. Amplifier/cabling/coil fault tolerance is achieved by using a separate power amplifier for each bearing coil and permitting amplifier reconfiguration by the controller upon detection of faults. This allows hot replacement of failed amplifiers without any system degradation and without providing any excess amplifier kVA capacity over the nominal system requirement. Implemented on a large (2440 mm in length) flexible rotor, the system shows excellent rejection of faults including the failure of three CPUs as well as failure of two adjacent amplifiers (or cabling) controlling an entire stator quadrant.

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