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.

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.

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.

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.

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.

scholarly journals Adaptive Spindle Balancing Using Magnetically Levitated Bearings

1999 ◽  
Author(s):  
Patrick Barney ◽  
James Lauffer ◽  
James Redmond ◽  
William Sullivan ◽  
Rebecca Petteys
Keyword(s):  
High Speed ◽  
System Analysis ◽  
High Vacuum ◽  
Magnetic Bearing ◽  
Active Magnetic Bearing ◽  
Physical Contact ◽  
Frictional Drag ◽  
Experimental Implementation ◽  
Amb System ◽  
Differential Control

Abstract A technological break through for supporting rotating shafts is the active magnetic bearing (AMB). Active magnetic bearings offer some important advantages over conventional ball, roller or journal bearings such as reduced frictional drag, no physical contact in the bearing, no need for lubricants, compatibility with high vacuum and ultra-clean environments, and ability to control shaft position within the bearing. The disadvantages of the AMB system are the increased cost and complexity, reduced bearing stiffness and the need for a controller. Still, there are certain applications, such as high speed machining, biomedical devices, and gyroscopes, where the additional cost of an AMB system can be justified. The inherent actuator capabilities of the AMB offer the potential for active balancing of spindles and micro-shaping capabilities for machine tools. The work presented in this paper concentrates on an AMB test program that utilizes the actuator capability to dynamically balance a spindle. In this study, an unbalanced AMB spindle system was enhanced with an LMS (Least Mean Squares) algorithm combined with an existing PID (proportional, integral, differential) control. This enhanced controller significantly improved the concentricity of an intentionally unbalanced shaft. The study included dynamic system analysis, test validation, control design and simulation, as well as experimental implementation using a digital LMS controller.

Effects of the Magnetic Damper Locations on Dynamic Characteristics of the Active Magnetic Bearing System in Manufacturing Engineering

2012 ◽  
Vol 252 ◽  
pp. 51-55
Author(s):  
Zhen Yu Xie ◽  
Hong Kai Zhou ◽  
Xiao Wang
Keyword(s):  
Dynamic Characteristics ◽  
High Speed ◽  
Magnetic Bearing ◽  
Magnetic Bearings ◽  
Active Magnetic Bearing ◽  
Active Magnetic Bearings ◽  
Actual Operation ◽  
And Control ◽  
System Operating ◽  
Bearing System

The magnetic damper was introduced into the high speed rotating machinery to restrain the vibration of the rotor supported by active magnetic bearings. The experimental setup, which was made up of one rotor, two radial active magnetic bearings, one axial active magnetic bearing, one magnetic damper and control system, was built to investigate the effects of the magnetic damper locations on dynamic characteristics of the system by theoretical analysis, experimental modal analysis and actual operation of the system. The results show that the vibration of the active magnetic bearing system operating at the modal frequency can be reduced more effectively if the magnetic damper is located far from the nodes of the corresponding mode shape.

Investigation of Magnetic Journal Bearing Instability Issues in Supercritical CO2 Turbomachinery

2019 ◽  
Author(s):  
Dokyu Kim ◽  
SeungJoon Baik ◽  
Jeong Ik Lee
Keyword(s):  
Supercritical Co2 ◽  
High Speed ◽  
Magnetic Bearing ◽  
Operating Conditions ◽  
Physical Contact ◽  
Analysis Model ◽  
Rotating Shaft ◽  
Power Cycles ◽  
Power Cycle ◽  
Lubrication Performance

Abstract With the increasing emphasis on reducing the CO2 emission while improving power generation efficiency, new power cycles are being developed. One of those promising power cycles is a supercritical CO2 (S-CO2) power cycle. To generate over 10MW electricity with S-CO2 power cycle, a magnetic bearing can be a good option for the hermetic type turbomachinery. However, from several studies on the magnetic bearing, the instability issues under high density fluid and high speed operating conditions were repeatedly mentioned. The instability in the magnetic bearing was observed to be related to the fluid conditions, mostly pressure and density. Because of this issue, the magnetic bearing sometimes cannot maintain enough clearance for the rotor leading to physical contact and consequently damaging the system. Thus, these instability issues should be thoroughly studied and be resolved for the successful and steady operation of the power system. The instability due to fluid force around the rotating shaft can be modeled with the Reynolds lubrication equation. The steady lubrication force analysis model is developed based on this equation. The model results imply that the lubrication performance is quite sensitive to the thermal condition of the CO2 especially density gradient around the shaft. Based on the modeling results, an experimental system is designed to investigate the issue. To study the instability issues experimentally, an impeller of the operating S-CO2 compressor is removed and the discharge line is blocked. Therefore, the main instability factor in this experiment will be the interaction between the rotor and the bearing only. The shaft position can be measured with inductive sensors. The forces exerted from the electromagnet is calculated from the electric current data which is applied by the controller. From these experimental data, the lubrication force is calculated. These results are compared with the analytical lubrication model to verify the model. From this study, it is expected that it will be possible to define the unstable operating conditions and suggest the required magnetic bearing performance for S-CO2 conditions.

Floating Shock Platform Testing of a Magnetic Bearing Supported Chiller Compressor: Measurements and Simulation Results

2018 ◽  
Author(s):  
Lawrence Hawkins ◽  
Zhiyang Wang ◽  
Koman Nambiar
Keyword(s):  
High Speed ◽  
Dynamic Models ◽  
Magnetic Bearing ◽  
Magnetic Bearings ◽  
Direct Drive ◽  
Structural Dynamic ◽  
Shock Testing ◽  
Shock Impacts ◽  
Standby Mode ◽  
Bearing System

Qualification shock testing has been completed for a new chilled water plant developed for the US Navy. The variable speed compressor at the heart of the chiller system includes a direct drive, high-speed permanent magnet (PM) motor, PM bias active magnetic bearings, and a backup bearing system. For MIL-S-901D shock certification, the chiller was mounted on a Navy floating shock platform (barge) and subjected to a standard sequence of four different shock impacts generated from high explosive charges from varying angles and standoff distances. The chiller was fully operational during three blasts and in standby mode for the fourth blast. In the standby mode, the shaft is de levitated and stationary on the backup bearings and the chiller secured. The backup bearing system of the motor absorbed the response to the shock impacts and the magnetic bearings subsequently recovered levitation as designed. The shock testing was simulated using a transient, nonlinear rotordynamic analysis including the magnetic bearing control and saturation features, backup bearings with resilient mounts and associated clearances, and structural dynamic models of the rotor and housing. Compressor/motor housing acceleration measured during the testing was used as the driving input into the simulation. Some rotor position data recorded during shock testing, the simulation approach and comparisons are reported and discussed.

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