Method and system for improving pump efficiency and productivity under power disturbance conditions

• US 20050283277A1
• Filed: 06/17/2005
• Published: 12/22/2005
• Est. Priority Date: 06/18/2004
• Status: Active Grant

• Current Assignee: Unico, LLC (Regal Rexnord Corp.)
• Original Assignee: Unico, Inc.
• Inventors: Schulz, Harry W.
• Granted Patent: US 7,330,779 B2
• Time in Patent Office: Days
• US Class Current: 700/282
• CPC Class Codes: E21B 41/0021 Safety devices, e.g. for preventing small objects from falling into the borehole
• CPC Class Codes: E21B 43/126 Adaptations of down-hole pump systems powered by drives outside the borehole, e.g. by a rotary or oscillating drive powered by fluid E21B43/129
• CPC Class Codes: E21B 43/128 Adaptation of pump systems with down-hole electric drives
• CPC Class Codes: F04B 49/06 Control using electricity regulating by means of floats actuating electric switches F04B49/04
• CPC Class Codes: F04C 13/008 Pumps for submersible use, i.e. down-hole pumping
• CPC Class Codes: F04C 14/28 Safety arrangements; Monitoring
• CPC Class Codes: F04C 15/0061 Means for transmitting movement from the prime mover to driven parts of the pump, e.g. clutches, couplings, transmissions
• CPC Class Codes: F04C 2/1073 where one member is stationary while the other member rotates and orbits
• CPC Class Codes: F04C 2270/72 preventing reverse rotation
• CPC Class Codes: Y02P 80/10 Efficient use of energy, e.g. using compressed air or pressurized fluid as energy carrier

Abstract

A system for controlling operation of a progressing cavity pump to maintain the motor operating under power disturbance conditions. For a blackout condition, a backspin controller uses regenerative power to provide controlled deceleration of the pump, counteracting backspin and preventing backspinning freely. For a brownout condition, a power dip controller weakens the motor field to maximize pump production consistent with reduced input power availability. For a phase loss or voltage imbalance condition, a phase loss controller reduces motor power output to keep drive system output power at or below single phase capacity.

Claims

1. A method for controlling the operation of a pump for optimizing pump efficiency and productivity under electrical power disturbance conditions, wherein the pump is driven by an AC electrical motor having a motor drive;

said method comprising the steps of;

detecting the occurrence of an electrical power disturbance;

determining when the electrical power disturbance condition is a phase loss condition or a voltage imbalance condition; and

using a phase loss controller to provide controlled operation of the motor when the electrical power disturbance condition is determined to be a phase loss condition or voltage imbalance condition, including reducing motor power output to maintain a drive power output at or below that for a single phase capacity or voltage imbalance power capacity during the phase loss condition or voltage imbalance condition.

2. The method according to claim 1, wherein the step of determining that the electrical power disturbance condition is a phase loss condition or voltage imbalance condition includes the step of detecting an increase in bus ripple current, and responding to a change in bus ripple current relative to a setpoint value for rated bus ripple current to adjust an output torque command provided by the motor drive whenever the setpoint value is exceeded during said portion of the power disturbance.

3. The method according to claim 2, including reducing output torque whenever the bus ripple current exceeds the setpoint value.

4. The method according to claim 1, wherein the step of providing controlled operation of the motor includes the steps of monitoring bus ripple current, and responding to a change in the bus ripple current relative to a rated value of the bus ripple current to adjust motor speed to maintain the bus ripple current at the rated value and to maintain motor torque equal to load torque.

5. A method for controlling the operation of a pump for optimizing pump efficiency and productivity under electrical power disturbance conditions, wherein the pump is driven by an AC electrical motor having a motor drive energized by a voltage derived from a bus voltage;

said method comprising the steps of;

monitoring the bus voltage to obtain an indication of bus ripple current;

detecting the occurrence of an electrical power disturbance condition by determining when the amplitude of the bus ripple current increases to a value above a setpoint value for rated bus ripple current, indicative of a phase loss condition or a voltage imbalance condition; and

providing controlled operation of the motor under a phase loss condition or voltage imbalance condition by reducing motor power output to maintain a drive power output at or below that for a single phase capacity or voltage imbalance power capacity during the phase loss condition or voltage imbalance condition.

6. The method according to claim 5, wherein the step of providing controlled operation of the motor includes the steps of responding to a change in bus ripple current relative to the setpoint value for rated bus ripple current to adjust an output torque command provided by the motor drive whenever the setpoint value is exceeded, and reducing the output torque whenever the bus ripple current exceeds the setpoint value.

7. The method according to claim 6, including reducing the output torque for the motor whenever the bus ripple current exceeds the setpoint value.

8. The method according to claim 6, wherein the step of providing controlled operation of the motor further includes the step of responding to a change in the bus ripple current relative to a rated value of the bus ripple current to adjust motor speed to maintain the bus ripple current at the rated value and to maintain motor torque equal to load torque.

9. A system for controlling the operation of a pump for optimizing pump efficiency and productivity under electrical power disturbance conditions, wherein the pump is driven by an AC electrical motor having a motor drive;

said system comprising;

a monitor for providing an output signal indicative of the amplitude of bus ripple current; and

a phase loss controller responsive to the output signal provided by said monitor and a further signal indicative of speed of the motor for providing controlled operation of the motor whenever the electrical power disturbance condition is a phase loss condition or voltage imbalance condition, the phase loss controller reducing motor power output to maintain a drive power output for the motor drive at a level at or below that for a single phase or voltage imbalance power capacity during the phase loss condition or voltage imbalance condition.

10. The system according to claim 9, wherein the phase loss controller is responsive to a change in the bus ripple current relative to a setpoint value for rated bus ripple current, to adjust motor speed to maintain the bus ripple current at the rated value for bus ripple current and to maintain motor torque equal to load torque.

11. The system according to claim 9, wherein the phase loss controller responds to a change in the amplitude of bus ripple current relative to a setpoint value for rated bus ripple current to adjust the torque command for the motor drive whenever rated bus ripple current is exceeded, to thereby reduce the output torque whenever the bus ripple current exceeds the setpoint value for bus ripple current.

12. The system according to claim 11, wherein the phase loss controller includes a proportional integral function that responds to a change in bus ripple current to adjust the torque command whenever the set point value for bus ripple current is exceeded.

13. The system according to claim 12, wherein the phase loss controller further includes a torque limiter that limits the output of the phase loss controller to plus torque and zero torque limits.