EP3538741A1

EP3538741A1 - Electrical submersible pump flow meter

Info

Publication number: EP3538741A1
Application number: EP17804744.5A
Authority: EP
Inventors: Jinjiang Xiao; Randall Alan SHEPLER
Original assignee: Saudi Arabian Oil Co
Current assignee: Saudi Arabian Oil Co
Priority date: 2016-11-11
Filing date: 2017-11-09
Publication date: 2019-09-18
Also published as: CA3043857A1; WO2018089576A1

Abstract

An apparatus for metering fluid in a subterranean well 10 includes an electric submersible pump 12 having a motor, a seal section and a pump assembly and a metering assembly. The metering assembly includes an upper pipe section 36 with an outer diameter, the upper pipe section 36 having an upper pressure sensing means, and a lower pipe section 40 with an outer diameter smaller than the outer diameter of the upper pipe section 36, the lower pipe section 40 having a lower pressure sensing means. A power cable 26 is in electronic communication with the electric submersible pump 12 and with the metering assembly 34.

Description

PCT PATENT APPLICATION

ELECTRICAL SUBMERSIBLE PUMP FLOW METER

Inventors: Jinjiang XIAO

Randall Alan SHEPLER

BACKGROUND OF THE INVENTION

1. Cross-Reference to Related Application

[0001] This application is a continuation in part of and claims priority to and the benefit of co-pending U.S. Patent Application Serial No. 13/546,694, filed July 11^th, 2012, which claimed priority from U.S. Provisional Application Serial No. 61/540,639, filed September 29, 2011, the full disclosures of which are incorporated by reference herein in their entireties and for all purposes.

2. Field of the Invention

[0001] The present invention relates to electrical submersible pumps. More specifically, the invention relates a flow meter used in conjunction with an electrical submersible pump.

3. Description of the Related Art

[0002] In hydrocarbon developments, it is common practice to use electric submersible pumping systems (ESPs) as a primary form of artificial lift. ESPs often use downhole monitoring tools to supply both temperature and pressure readings from different locations on the ESP. For example, intake pressure, discharge pressure, and motor temperature, as well as other readings may be taken on the ESP.

[0003] If wells are producing below bubble point pressure, the liberated gas, at the surface, may not allow the surface meters to provide accurate flow rates. To replace the surface single phase meters with multi-phase meters can cost tens of thousands of dollars per well. Downhole at the ESP a significant percentage of wells are producing with intake pressures well above the bubble point pressure. Therefore, being able to measure flow rate down hole at the ESP would allow for an accurate flow meter that will assist immensely in extending the life of the ESPs. Therefore, a low cost and accurate flow meter that will assist immensely in extending the life of the ESPs that incorporates these theories would be desirable.

SUMMARY OF THE INVENTION

[0004] Disclosed herein is an example of an apparatus for monitoring a flow of fluid in a subterranean well, and that includes a first pipe section selectively disposed in the flow of fluid, a first pressure sensor on the first pipe section that measures a first pressure loss of the flow of fluid along at least a portion of the first pipe section, the first pressure loss made up of first gravitational losses and first frictional losses, a second pipe section spaced axially away from the first pipe section and that is selectively disposed in the flow of fluid, a second pressure sensor on the second pipe section that measures a second pressure loss of the flow of fluid along at least a portion of the second pipe section and that is made up of second gravitational losses and second frictional losses, the second pipe section having an outer diameter that is less than an outer diameter of the first pipe section so that the second frictional losses are negligible with respect to the second gravitational losses, a controller in communication with the first and second pressure sensors and that calculates a pressure gradient along a portion of the second pipe section based on the equation PG = (g)(p_m)/((g_c)(144)), and a communication media in communication with the controller and with the first and second pressure sensors, so that signals representing the first and second pressure losses are communicated to the controller. In an embodiment, the first and second pressure sensors each have sensor systems having axially spaced apart sensors that measure a pressure gradient. The apparatus can further have pressure transmitters in communication with the first and second sensors and the communication media. The first and second pipe sections can be coupled together to define a metering assembly, and wherein an end of the metering assembly can be attached to an electrical submersible pump. In an example, a power source is included that is in communication with the electrical submersible pump. Alternatively, a power cable provides electrical communication between the power source and the electrical submersible pump, and wherein signals between the first and second pressure sensors are transmitted to the controller along the power cable. In an example, the flow of fluid travels along a path that passes inside of the first and second pipe sections. Alternatively, the flow of fluid travels along a path that passes through an annular space between the first and second pipe sections and a sidewall of the well.

[0005] Also disclosed herein is another example of an apparatus for monitoring a flow of fluid in a subterranean well, and that includes an upper pipe section selectively disposed in the flow of fluid, an upper pressure sensor on the upper pipe section that measures an upper pressure loss of the flow of fluid along at least a portion of the upper pipe section, the upper pressure loss made up of upper gravitational losses and upper frictional losses, a lower pipe section selectively disposed in the flow of fluid, a lower pressure sensor on the lower pipe section that measures a lower pressure loss of the flow of fluid along at least a portion of the lower pipe section, the lower pressure loss made up of lower gravitational losses and lower frictional losses, the lower pipe section having an outer diameter that is less than an outer diameter of the upper pipe section so that the lower frictional losses are negligible with respect to the lower gravitational losses, and a controller in communication with the upper and lower pressure sensors and that calculates a flowrate of the flow of fluid based on upper and lower gravitational losses, upper frictional losses, and that ignores the lower frictional losses. In an example, the upper pipe sections, the lower pipe sections, the upper pressure sensor, and the lower pressure sensor define a metering assembly. In one alternative, an end of the metering assembly is coupled to an electrical submersible pump that pressurizes fluid from the flow of fluid, and wherein the flowrate calculated by the controller is substantially the same as a flowrate of a flow of fluid that is being pressurized by the electrical submersible pump. In one embodiment, the upper pressure sensor includes pressure sensors that are axially spaced apart on the upper pipe section. The lower pressure sensor can include pressure sensors that are axially spaced apart on the lower pipe section. In an example, the controller estimates a pressure gradient ("PG") along a portion of the lower pipe section with the equation: PG = (g)(p_m)/((g_c)(144)). The controller can estimate a water cut percentage of the flow of fluid based on the equation. In an alternate example, the controller estimates the flowrate of the flow of fluid based on a relationship where a pressure gradient difference between the upper and lower pipe sections is: ( p_mv² _m)/(24g_cD_¾). A production string can be included that is in fluid communication with the upper and lower pipe sections.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] So that the manner in which the above-recited features, aspects and advantages of the invention, as well as others that will become apparent, are attained and can be understood in detail, a more particular description of the invention briefly summarized above may be had by reference to the embodiments thereof that are illustrated in the drawings that form a part of this specification. It is to be noted, however, that the appended drawings illustrate only preferred embodiments of the invention and are, therefore, not to be considered limiting of the invention's scope, for the invention may admit to other equally effective embodiments.

[0007] Figure 1 is an elevational view of an electrical submersible pump with a flow meter of an embodiment of the current application.

[0008] Figure 2 is an elevational view of an electrical submersible pump with a flow meter of an alternative embodiment of the current application.

[0009] Figure 3 is a side sectional view of an alternate embodiment of the electrical submersible pump and flow meter of Figure 1.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

[0010] The method and system of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments are shown. The method and system of the present disclosure may be in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. Like numbers refer to like elements throughout. In an embodiment, usage of the term "about" includes +/- 5% of the cited magnitude. In an embodiment, usage of the term "substantially" includes +/- 5% of the cited magnitude.

[0011] It is to be further understood that the scope of the present disclosure is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. In the drawings and specification, there have been disclosed illustrative embodiments and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation.

[0012] Shown in a side sectional view in Figure 1 is an example of a well 10 having one embodiment of an electric submersible pump ("ESP") 12 disposed therein. As shown, ESP 12 depends from an end of a tubing string 14 disposed in the well 10. In the illustrated example, well 10 has in internal bore 11 with a diameter 13. Included with the example of the ESP 12 is an electric motor 16 with a seal section 18 disposed adjacent motor 16. In an example, seal section 18 equalizes pressure within ESP 12 with ambient pressure to reduce pressure differentials on fluid seals in the ESP 12 and thereby prevent well fluid from entering motor 16. ESP 12 also includes a pump section comprising pump assembly 20 located on an end of seal section 18 distal from motor 16. Examples exist where the pump assembly 20 includes a pump such as a centrifugal pump. Pump assembly 20 could alternatively include a progressing cavity pump, which has a helical rotor that rotates within an elastomeric stator. An ESP monitoring tool 22 is located below electric motor 16. In the illustrated example, monitoring tool 22 monitors various pressures, temperatures, and vibrations associated with the ESP 12. In the example of Figure 1, ESP 12 lifts well fluids from within the well 10 to the surface. Fluid inlets 24 located on pump assembly 20 define an entry way for fluid to enter into ESP 12. [0013] In the embodiment of Figure 1, a power cable 26 extends alongside production tubing 14, terminating in a splice or connector 28 that electrically couples cable 26 to a second power cable, or motor lead 30. An end of motor lead 30 distal from power cable 26 connects to a pothead connector 32 that electrically connects and secures motor lead 30 to electric motor 16. Coupled with ESP 12 on an end distal from tubing string 14 is an example of a metering assembly 34. Metering assembly 34 includes an upper pipe section 36 shown mounted to monitoring tool 22 of ESP 12. In the illustrated example, upper pipe section 36 is an elongated member having a curved outer periphery thereby having a cylinder like outer surface. Upper pipe section 36 has an external diameter 38. Metering assembly 34 also includes a lower pipe section 40 located on a side of upper pipe section 36 distal from motor 16. Lower pipe section 40 is also elongated with a curved outer periphery to have a generally cylindrically shaped outer surface. External diameter 42 of lower pipe section 40 has a magnitude less than that of the external diameter 38 of upper pipe section 36. A tapered intermediate pipe section 44 mates the upper pipe section 36 to lower pipe section 40. The intermediate pipe section 44 is tapered or swaged in such a manner to create a smooth transition between larger diameter upper pipe section 36 to the smaller diameter lower pipe section 40 to minimize the sudden flow disturbance and pressure losses within bore 11.

[0014] As an example, each of upper pipe section 36 and lower pipe section 40 may have a length of 15 to 20 feet. For a metering assembly 34 deployed inside a well 10 with an internal diameter of 7 inches, which may be, for example, the internal diameter of the casing completion, the external diameter 42 of lower pipe section 40 may be 3.5 inches or smaller and the external diameter 38 of upper pipe section 36 my be 5.5 inches. As a second example, for a metering assembly 34 deployed inside a well 10 with an internal diameter of 9 5/8 inches, which may be, for example, the internal diameter of the casing completion, the external diameter 42 of lower pipe section 40 may be 4.5 inches or smaller and the external diameter 38 of upper pipe section 36 my be 7 inches.

[0015] As described, the external diameters 38, 42 of upper and lower pipe sections 36, 40 are smaller than the internal diameter 13 of the bore 11 of well 10. The annular spaces between external diameters 38, 42 and bore 11 create an annular flow path 46 for the passage of fluids within the well 10 as the fluid flows towards fluid inlets 24 of pump assembly 20. A pressure sensing means is located on upper pipe section 36 and lower pipe section 40. In the illustrated example, the upper pressure sensing means includes two upper flow pressure sensors 48, 50 located on upper pipe section 36. The upper sensors 48, 50 as shown are located at an upper distance 52 apart from each other and selectively collect data from fluid flowing exterior to the upper and lower pipe sections 36, 40 in the annular flow path 46. Embodiments exist where upper distance 52 ranges from around 10 to 15 feet, and all distances within this range. Alternatively, a single pressure differential sensor may be used to measure the pressure difference between the two upper locations. As illustrated, the lower pressure sensing means includes two lower flow pressure sensors 54, 56 located on lower pipe section 40. The lower sensors 54, 56 are located at a lower distance 58 apart from each other. In one example lower distance 58 ranges from around 10 feet to around 15 feet, and all distances within this range. In an alternative, a single pressure differential sensor is used to measure the pressure difference between the two lower locations.

[0016] Because of the differences in the outer diameter 38 of upper pipe section of upper pipe section 36 and outer diameter 42 of lower pipe section 40, two distinctive flow regimes are created along the annulus flow path 46. One distinctive flow regime extends along lower distance 58 and another distinctive flow regime extends along upper distance 52. In a non- limiting example of operation, a first pressure loss is measured over lower distance 58. In this example, the first pressure loss is determined by measuring a pressure with first lower sensor 56 and second lower sensor 54 and finding the difference between the two pressure readings. Alternatively, a single pressure differential sensor measures the first pressure loss. While the first pressure loss includes both gravitational and frictional losses, the gravitational losses exceed the frictional losses by an amount such that a sufficiently accurate estimate of the first pressure loss is calculated by ignoring the frictional losses. For the purposes of discussion herein, an example of a sufficiently accurate estimate includes calculation results that are within a margin of error so that a difference between calculations or other evaluations using the sufficiently accurate estimate are within an acceptable margin from calculations that account for the frictional losses. In one example, an acceptable margin would mean that a calculated size of something being designed to accommodate the flow fluid is substantially the same when accounting for frictional losses or not accounting for frictional losses. As such, in an example of evaluating the first pressure loss the frictional losses between sensors 54, 56 are ignored and only the gravitational losses considered.

[0017] In one non-limiting example of operation the second pressure loss is determined by measuring a pressure in the fluid with first upper sensor 50 and second upper sensor 48 and finding the difference between the two pressure readings. In an alternative a single pressure differential sensor measures the second pressure loss. Because of the relatively larger external diameter 38 of upper pipe section 36, the second pressure loss is made up of substantial amounts of both gravitational loss and frictional loss, so that an accurate estimate of the second pressure includes both gravitational and frictional pressure losses. In the illustrated example, the pressure loss data collected by sensors 48, 50, 54, and 56 is transmitted to surface along the power cable 26, which is in communication with the metering assembly 34 through ESP monitoring tool 22. In an embodiment, the flow rate of the fluids within well 10 and the water cut of such fluids is calculated with this pressure loss data using hydraulic equations as further describe herein. More specifically in this example, the first pressure loss estimated via the first and second lower sensors 56, 54 (or with a single pressure differential sensor) is used to calculate oil-water mixture density and the production water cut. Further in this example, the second pressure loss, calculated with data from first upper sensor 50 and second upper sensor 48 (or with a single pressure differential sensor) is used to calculate oil-water mixture flowrate.

[0018] Referring now to Figure 2, shown in a side partial sectional view is an alternate embodiment of ESP 12 having an electric motor 16, seal section 18 adjacent motor 16, and pump assembly 20 on a side of seal section 18 distal from motor 16. In this example metering assembly 34 is disposed adjacent a side of pump assembly 20 distal from seal section 18 with lower pipe section 40 mounted to a discharge end of pump assembly 20. ESP monitoring tool 22 is shown adjacent electric motor 16 and distal from seal section 18. Fluid inlets 24 on pump assembly 20 define a passage for receiving fluid into ESP 12. The fluids then continue upwards within lower pipe section 40 and upper pipe section 36, and then discharged into tubing string 14, where tubing string couples to an end of upper pipe section 36 distal from lower pipe section 40. As shown, lower pipe section 40 has an internal diameter 42 which is smaller than the internal diameter 38 of upper pipe section 36. A tapered intermediate pipe section 44 mates the upper pipe section 36 to lower pipe section 40. The intermediate pipe section 44 is tapered in such a manner to create a smooth transition between upper pipe section 36 to lower pipe section 40 to minimize the sudden flow disturbance and pressure losses in fluid flowing along this flow path.

[0019] As an example, each of upper pipe section 36 and lower pipe section 40 have lengths that range from about 15 feet to about to 20 feet, and all distances within this range. For a metering assembly 34 deployed inside a well 10 with an internal diameter of 7 inches, which may be, for example, the internal diameter of the casing completion, the internal diameter 42 of lower pipe section 40 ranges up to about 3.5 inches, and the internal diameter 38 of upper pipe section 36 ranges up to about 5.5 inches.

[0020] As described, the internal diameters 38, 42 of upper and lower pipe sections 36, 40 are smaller than the internal diameter 13 of the bore 11 of well 10. An example of a packer 60 is depicted sealingly engaged between upper pipe section 36 and the bore 11. Packer 60 blocks flow path 46 so that fluids are diverted into fluid inlets 24, to be pressured by pump assembly 20 and then transported to the surface through tubing string 14.

[0021] Examples of a upper and lower pressure sensing means are located on upper pipe section 36 and lower pipe section 40. The upper pressure sensing means as shown includes two upper flow pressure sensors 48, 50 located on upper pipe section 36. The upper sensors 48, 50 are located at an upper distance 52 apart from each other. In an embodiment, upper distance 52 ranges from about 10 feet to about 15 feet, and all distances within this range. Alternatively, a single pressure differential sensor measures the pressure difference between the two upper locations. The lower pressure sensing means is illustrated as having two lower flow pressure sensors 54, 56 located on lower pipe section 40. The lower sensors 54, 56 are located at a lower distance 58 apart from each other. Lower distance 58 optionally ranges from about 10 feet to about 15 feet, and all distances within this range. Alternatively, a single pressure differential sensor measures the pressure difference between the two lower locations. The sensor means of Figure 2 selectively collects data from fluid flowing inside of lower pipe section 40 and upper pipe section 36

[0022] Because of the differences in the inner diameter 38 of upper pipe section 36 and inner diameter 42 of lower pipe section 40, two distinctive flow regimes are created, one along lower distance 58 and another along upper distance 52. In one non-limiting example, a pressure loss is measured over lower distance 58. The pressure loss is determined by measuring a pressure with first lower sensor 56 and second lower sensor 54 and finding the difference between the two pressure readings. Alternatively, a single pressure differential sensor can measure the pressure loss. Because of the relatively smaller internal diameter 42 of lower pipe section 40, gravitational losses and friction losses both significantly contribute to the pressure loss so that a precise estimate of the pressure loss requires that each of these types of losses be considered and neither can be ignored.

[0023] Further in this example, another pressure loss is measured over upper distance 52. This pressure loss is determined by measuring a pressure with first upper sensor 50 and second upper sensor 48 and finding the difference between the two pressure readings. Alternatively, a single pressure differential sensor can measure this pressure loss. Because of the relatively larger internal diameter 38 of upper pipe section 36 and lower flow velocity in this region, gravitational losses of the fluid between the first and second upper sensors 50, 48 are the primary losses contributing to this pressure loss. Accordingly, a precise value of pressure losses in the fluid flowing between the first and second upper sensors 50, 48 can be estimated by ignoring the frictional losses of the fluid flowing in this region.

[0024] In a non-limiting example of operation, pressure loss data collected by sensors 48, 50, 54, and 56 is transmitted to surface for evaluation. In an alternative, the data is transmitted along power cable 26 (Figure 1), which is in communication with metering assembly 34 through the ESP monitoring tool 22. Further in this example, the flow rate of the fluids within well 10, the fluid density, and the water cut of such fluids is calculated with this pressure loss data using hydraulic equations as further described herein. More specifically, the first pressure loss is calculated with data from the first upper sensor 48 and second upper sensor 50 (or with a single pressure differential sensor), the first pressure loss is also used to calculate oil-water mixture density and the production water cut. The second pressure loss is calculated with data from first lower sensor 54 and second lower sensor 56 (or with a single pressure differential sensor) is used to calculate oil- water mixture flowrate.

[0025] In the embodiment of Figure 1 , the water cut is calculated by first finding the pressure gradient (psi/ft) over lower distance 58, i.e. DPi/Li. As the gravitational loss is the major contributor to pressure loss over lower distance 58, in an example embodiment the frictional loss is ignored when estimating this pressure gradient. Ignoring frictional loss results in a relationship for pressure gradient that is illustrated by Equation 1 below:

PG = ( )(p_m)/((g_c)(144)) Equation 1

[0026] Where g is the gravitational acceleration, 32.2 ft/sec², g_c is a unit conversion factor, 32.2 lbm-ft/lbf-sec², and p_m is the oil-water mixture density in lbm/ft³. After determining p_m from Equation 1, production water cut can be calculated. A similar analysis could be performed over upper distance 52 of the embodiment of Figure 2 because this pressure loss is affected primarily by gravitational loss such that the frictional losses of fluid flowing in this region are sufficiently negligible that they can be ignored without impacting the precision of the resulting calculation. [0027] Returning to the embodiment of Figure 1, a pressure gradient (psi/ft) over upper distance 52 is estimated and expressed as DP₂/L₂. Here, the respective values of gravitational losses and frictional losses have magnitudes that are sufficiently high in relation to one another so that ignoring either the gravitational or frictional loss would produce inaccurate hydraulic calculations for the fluid flowing along upper distance 52. For this region of fluid flow the frictional pressure gradient results in the relationship of Equation 2 below:

PG₂ - PGi = (fp_mv²m)/(24g_cO_h) Equation 2

[0028] Where v_m is the oil-water mixture velocity in ft/sec in upper distance 52, D_¾ is the hydraulic diameter for the annulus in inches, calculated as internal diameter 13 minus external diameter 38, and /is the friction factor. A similar analysis would also apply to the lower distance 58 of the embodiment of Figure 2 where the pressure loss is dominated by both gravitational and friction losses.

[0029] The friction factor is a function of Reynolds number and roughness, and can be determined from Moody's chart or empirical correlations. Equation 2 can be used iteratively to obtain the mixture velocity and the total oil-water flowrate. With water cut calculated previously, the individual oil and water rates can be easily calculated.

[0030] Referring now to Figure 3, shown in a side sectional view is an alternate example of the ESP 12A and metering assembly 34A of Figure 1. As shown, an end of the tubing 14A distal from pump assembly 20A couples with a wellhead assembly 70A shown mounted on surface 71 A and above an opening of the well 10A. In the illustrated example, fluid F flows into well 10A from perforations 72A that project radially outward from well 10A. The perforations 72 A extend through casing 74A that lines the well 10A, and into formation 76A that surrounds well 10A. The fluid F produced from the formation 76A is pressurized in pump assembly 20A after being drawn into pump assembly 20A via fluid inlets 24A. The pressurized fluid is discharged into the tubing string 14A and routed to the wellhead assembly 70A for distribution to storage and/or process facilities (not shown). Further illustrated in Figure 3 is the power cable 26A extending generally parallel with the tubing 14A between the motor lead 30A and the wellhead assembly 70A. At the wellhead assembly 70A, the power cable 26A is routed through a passage 78A, which has an end that intersects a surface of the wellhead assembly 70A that faces the well 10A. An opposite end of the passage 78A intersects a surface of wellhead assembly 70A outside of the well 10A and above surface 71 A. After exiting the end of the passage 78 A above surface 71 A, the power cable 26A connects to a power supply 80A shown on surface 71 A. Examples of the power supply 80A include an electrical grid, a transformer, a generator, any other means of providing electricity, and combinations thereof. Electricity from the power supply 80A is selectively conducted via power cable 26A to ESP 12A for powering pump assembly 20A. Optionally, a variable frequency generator and controls (not shown) are included in the power supply 80A.

[0031] Further in the example of Figure 3, pressure transmitters 82Ai_₄ are shown connected respectfully to pressure sensors 48A, 50A, 54A, 56A. Here, pressure transmitters 82i_₄ send signals to a controller 84A shown on surface 71 A and outside of well 10A, where the signals communicated by pressure transmitters 82i_₄ represent ambient conditions of fluid F in the well 10A that are sensed by pressure sensors 48A, 50A, 54A, 56A. In an example, the controller 84 A includes an information handling system ("IHS"); embodiments exist where the IHS includes a processor, memory accessible by the processor, nonvolatile storage area accessible by the processor, and logics for performing each of the steps above described. Controller 84A receives the signals and translates the signals into a form, such as data or information, that is recognizable by the controller 84A, and performs operations based on the recognized data/information. In an example, the controller 84A recognizes the data/information as having a magnitude or value and calculates results based on the magnitude/value.

[0032] In one example of the system illustrated in Figure 3, communication links connect to and provide communication between the pressure transmitters 82Ai_₄ and the controller 84A, and which provide a way for the signals sent by the pressure transmitters to be delivered to the controller 84A. Optionally, the communication links 86Ai_₄ are formed from a signal transmission medium, such as a conductive metal, composites, fiber optics, and combinations thereof. In an embodiment, the communication links 86Ai_₄ include waves, such as radio waves, light waves, and other electromagnetic waves, sonic waves, acoustic waves, and combinations thereof. While the communication links 86Ai_₄ are illustrated as following a dedicated path separate from the motor lead 30A and power cable 26A, in one example communication links 86Ai_₄ are included within the motor lead 30A and/or power cable 26A. Optionally, the signals communicated between sensors 48A, 50A, 54A, 56A, pressure transmitters 82Ai_₄, and controller 84A are transmitted via the motor lead 30A and/or power cable 26 A.

[0033] Further in the example of Figure 3, as the fluid F flows past the sensors 48A, 50A, 54A, 56A, pressure of the fluid F adjacent the sensors 48A, 50A, 54A, 56A is monitored by the sensors 48A, 50A, 54A, 56A. Signals are generated and sent to the controller 84A from the sensors 48A, 50A, 54A, 56A along the pressure transmitters 82Ai_₄ and communication links 86Ai_4. In one non-limiting example of operation, at least one or more of a flow rate of the flow of fluid F, water cut, production cut, and fluid density is estimated by the controller 84A. Optionally, operation of the controller 84A is in accordance with the relationships of Equations 1 and 2, and per the steps described above. In an example, these values estimated by the controller 84A are based on pressure differentials between the sensors 48A, 50A, 54A, 56A.

[0034] Still referring to Figure 3, a passage 88A, similar to passage 78A, is shown formed through wellhead assembly 70A, and which provides a pathway for the placement of communication links 86Ai_₄ through the wellhead assembly 70A. A packer 90A is also illustrated that is sealingly disposed in the annular space between pump assembly 20A and inner surface of casing 74A and which blocks the flow of fluid F past ESP 12A and forces the fluid F into inlets 24A so that the fluid can be pressurized for transport to the wellhead assembly 70A.

[0035] Although the present invention has been described in detail, it should be understood that various changes, substitutions, and alterations can be made hereupon without departing from the principle and scope of the invention. Accordingly, the scope of the present invention should be determined by the following claims and their appropriate legal equivalents.

[0036] The singular forms "a", "an" and "the" include plural referents, unless the context clearly dictates otherwise. Optional or optionally means that the subsequently described event or circumstances may or may not occur. The description includes instances where the event or circumstance occurs and instances where it does not occur. Ranges may be expressed herein as from about one particular value, and/or to about another particular value. When such a range is expressed, it is to be understood that another embodiment is from the one particular value and/or to the other particular value, along with all combinations within said range.

[0037] Throughout this application, where patents or publications are referenced, the disclosures of these references in their entireties are intended to be incorporated by reference into this application, in order to more fully describe the state of the art to which the invention pertains, except when these reference contradict the statements made herein. [0038] The present invention described herein, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While a presently preferred embodiment of the invention has been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present invention disclosed herein and the scope of the appended claims.

Claims

CLAIMS What is claimed is:

1. An apparatus for monitoring a flow of fluid in a subterranean well 10 comprising: a first pipe section 36 selectively disposed in the flow of fluid;

a first pressure sensor 48, 50 on the first pipe section 36 that measures a first pressure loss of the flow of fluid along at least a portion of the first pipe section 36, the first pressure loss comprising first gravitational losses and first frictional losses;

a second pipe section 40 spaced axially away from the first pipe section 36 and that is selectively disposed in the flow of fluid;

characterized by,

a second pressure sensor 54, 56 on the second pipe section 40 that measures a second pressure loss of the flow of fluid along at least a portion of the second pipe section 40 and that comprises second gravitational losses and second frictional losses, the second pipe section 40 having an outer diameter that is less than an outer diameter of the first pipe section 36 so that the second frictional losses are negligible with respect to the second gravitational losses;

a controller in communication with the first pressure sensor 48, 50 and second pressure sensor 54, 56 and that calculates a pressure gradient along a portion of the second pipe section 40 based on the equation PG = (g)(p_m)/((g_c)(144)); and

a communication media 86 in communication with the controller 84 and with the first pressure sensor 48, 50 and second pressure sensor 54, 56, so that signals representing the first and second pressure losses are communicated to the controller 84.

2. The apparatus of Claim 1, characterized in that the first pressure sensor 48, 50 and second pressure sensor 54, 56 each comprise sensor systems having axially spaced apart sensors that measure a pressure gradient.

3. The apparatus of Claims 1 or 2, further characterized by pressure transmitters 82 in communication with the first pressure sensor 48, 50, second pressure sensor 54, 56 and the communication media 86.

4. The apparatus of any of Claims 1 - 3, characterized in that the first pipe section 36 and second pipe section 40 are coupled together to define a metering assembly 34, and wherein an end of the metering assembly 34 is attached to an electrical submersible pump 12.

5. The apparatus of Claim 4, further characterized by a power source 80 in communication with the electrical submersible pump 12.

6. The apparatus of Claim 5, characterized in that a power cable 26 provides electrical communication between the power source 80 and the electrical submersible pump 12, and wherein signals between the first pressure sensor 48, 50 and second pressure sensor 54, 56 are transmitted to the controller 84 along the power cable 26.

7. The apparatus of any of Claims 1 - 6, characterized in that the flow of fluid travels along a path that passes inside of the first pipe section 36 and second pipe section 40.

8. The apparatus of any of Claims 1 - 7, characterized in that the flow of fluid travels along a path that passes through an annular space between the first pipe section 36 and second pipe section 40 and a sidewall of the well 10.

9. An apparatus for monitoring a flow of fluid in a subterranean well 10 comprising: an upper pipe section 36 selectively disposed in the flow of fluid;

characterized by,

an upper pressure sensor on the upper pipe section 36 that measures an upper pressure loss of the flow of fluid along at least a portion of the upper pipe section 36, the upper pressure loss comprising upper gravitational losses and upper frictional losses;

a lower pipe section 40 selectively disposed in the flow of fluid;

a lower pressure sensor on the lower pipe section 40 that measures a lower pressure loss of the flow of fluid along at least a portion of the lower pipe section 40, the lower pressure loss comprising lower gravitational losses and lower frictional losses, the lower pipe section 40 having an outer diameter that is less than an outer diameter of the upper pipe section 36 so that the lower frictional losses are negligible with respect to the lower gravitational losses; and

a controller 84 in communication with the upper pressure sensor and lower pressure sensor and that calculates a flowrate of the flow of fluid based on upper and lower gravitational losses, upper frictional losses, and that ignores the lower frictional losses.

10. The apparatus of Claim 9, characterized in that the upper pipe section 36, the lower pipe section 40, the upper pressure sensor 48, 50, and the lower pressure sensor define a metering assembly.

11. The apparatus of Claim 10, characterized in that an end of the metering assembly is coupled to an electrical submersible pump 12 that pressurizes fluid from the flow of fluid, and wherein the flowrate calculated by the controller 84 is substantially the same as a flowrate of a flow of fluid that is being pressurized by the electrical submersible pump 12.

12. The apparatus of any of Claims 9 - 11, characterized in that the upper pressure sensor comprises pressure sensors 48, 50 that are axially spaced apart on the upper pipe section 36.

13. The apparatus of any of Claims 9 - 12, characterized in that the lower pressure sensor comprises pressure sensors 54, 56 that are axially spaced apart on the lower pipe section 40.

14. The apparatus of any of Claims 9 - 12, characterized in that the controller 84 estimates a pressure gradient ("PG") along a portion of the lower pipe section 40 with the equation: PG = (g)(p_m)/((g_c)(144)).

15. The apparatus of Claim 14, characterized in that the controller 84 estimates a water cut percentage of the flow of fluid based on the equation.

16. The apparatus of Claim 15, characterized in that the controller 84 estimates the flowrate of the flow of fluid based on a relationship where a pressure gradient difference between the upper pipe section 36 and lower pipe section 40 is: (/p_mv²m)/(24g_cD_¾).

17. The apparatus of any of Claims 9 - 16, further characterized by a production string 14 in fluid communication with the upper pipe section 36 and lower pipe section 40.