Control system for centrifugal pumps

• US 7,117,120 B2
• Filed: 09/05/2003
• Issued: 10/03/2006
• Est. Priority Date: 09/27/2002
• Status: Expired due to Term

• Current Assignee: Unico, LLC (Regal Rexnord Corp.)
• Original Assignee: Unico, Inc.
• Inventors: Anderson, Robb G., Olson, Steven J., Beck, Thomas L.
• Primary Examiner(s): NGHIEM, MICHAEL P
• Application Number:
  US10/656,091
• Publication Number:
  US 20040064292A1
• Time in Patent Office: 1,124 Days
• Field of Search: 702/182
• US Class Current: 702/182
• CPC Class Codes: F04B 2203/0201 Current
• CPC Class Codes: F04B 2203/0202 Voltage
• CPC Class Codes: F04B 2203/0207 Torque
• CPC Class Codes: F04B 2203/0208 Power
• CPC Class Codes: F04B 2205/00 Fluid parameters
• CPC Class Codes: F04B 2205/05 Pressure after the pump outlet
• CPC Class Codes: F04B 47/02 the driving mechanisms being situated at ground level F04B47/12 takes precedence
• CPC Class Codes: F04B 49/065 and making use of computers
• CPC Class Codes: F04D 13/10 adapted for use in mining bore holes
• CPC Class Codes: F04D 15/0066 by changing the speed, e.g. of the driving engine
• CPC Class Codes: F04D 15/0088 Testing machines

Abstract

A control system for the operation of a centrifugal pump which may be used for production of gas and/or oil from a well. The control system includes vector feedback model to derive values of torque and speed from signals indicative of instantaneous current and voltage drawn by the pump motor, a pump model which derives values of the fluid flow rate and the head pressure for the pump from torque and speed inputs, a pumping system model that derives from the estimated values of the pump operating parameters an estimated value of a pumping system parameter and controllers responsive to the estimated values of the pumping system parameters to control the pump to maintain fluid level at the pump input near an optimum level.

Claims

1. A method of controlling a centrifugal pump for transferring fluid within a fluid system, the method comprising the steps of:

determining a value of speed input to the centrifugal pump;

determining a value of pump flow rate;

using the value of speed input and the value of pump flow rate to calculate one or more values representing the performance of the centrifugal pump;

using the centrifugal pump performance values to produce one or more command signals, including the steps of selecting a centrifugal pump performance parameter to control, determining a setpoint for the selected centrifugal pump performance parameter, calculating a control signal using the setpoint value of the selected centrifugal pump performance parameter, and calculating the one or more command signals from the control signal; and

using the one or more command signals to control the speed of the centrifugal pump,

wherein the selected centrifugal pump performance parameter is the pump flow rate and the step of using the one or more command signals to control the speed of the centrifugal pump includes repetitively switching the speed of the centrifugal pump between a set pump speed for a portion of a cycle period and zero speed for the remainder of the cycle period to achieve an average pump flow rate equal to the setpoint value of the pump flow rate.

2. A method of controlling a centrifugal pump for transferring fluid within a fluid system, wherein the centrifugal pump is coupled to an electric motor, the method comprising the steps of:

determining a value of speed input to the centrifugal pump, including the steps of measuring values of electrical voltages applied to the motor and currents drawn by the motor, and using the measured values of electrical voltages applied to the motor and currents drawn by the motor to calculate a value for the motor speed;

determining a value of pump flow rate;

using the value of speed input and the value of pump flow rate to calculate one or more values representing the performance of the centrifugal pump;

using the centrifugal pump performance values to produce one or more command signals, including the steps of selecting a centrifugal pump performance parameter to control, determining a setpoint for the selected centrifugal pump performance parameter, calculating a control signal using the setpoint value of the selected centrifugal pump performance parameter, and calculating the one or more command signals from the control signal; and

using the one or more command signals to control the speed of the centrifugal pump,

wherein the selected centrifugal pump performance parameter is the pump flow rate and the step of using the one or more command signals to control the speed of the centrifugal pump includes repetitively switching the speed of the centrifugal pump between a set pump speed for a portion of a cycle period and zero speed for the remainder of the cycle period to achieve an average pump flow rate equal to the setpoint value of the pump flow rate.

3. A method of controlling a centrifugal pump for transferring fluid within a fluid system, the method comprising the steps of:

determining a value of speed input to the centrifugal pump;

determining a value of pump flow rate;

using the value of speed input and the value of pump flow rate to calculate one or more values representing the performance of the centrifugal pump;

using the centrifugal pump performance values to produce one or more command signals; and

using the command signals to control the speed of the centrifugal pump,

wherein the values representing the performance of the pump comprise values representing pump mechanical input power limit and pump mechanical input power, and the step of using the one or more command signals to control the speed of the centrifugal pump includes the steps of;

comparing the pump mechanical input power limit and pump mechanical input power, and

reducing the speed of the centrifugal pump if the value of pump mechanical input power is greater than the pump mechanical input power limit.

4. The method of claim 3, wherein the step of using centrifugal pump performance values to produce command signals comprises the steps of:

selecting a centrifugal pump performance parameter to control;

determining a setpoint for the selected centrifugal pump performance parameter;

calculating a control signal using the setpoint value of the selected centrifugal pump performance parameter; and

calculating the command signals from the control signal.

5. The method of claim 4, wherein the selected centrifugal pump performance parameter is the pump head pressure.

6. The method of claim 3, wherein the centrifugal pump is coupled to an electric motor and the step of determining the speed input to the centrifugal pump comprises the steps of:

measuring values of electrical voltages applied to the motor and currents drawn by the motor; and

using the measured values of electrical voltages applied to the motor and currents drawn by the motor to calculate a value for the motor speed.

7. The method of claim 6, wherein the step of using centrifugal pump performance values to produce the one or more command signals comprises the steps of:

selecting a centrifugal pump performance parameter to control;

determining a setpoint for the selected centrifugal pump performance parameter;

calculating a control signal using the setpoint value of the selected centrifugal pump performance parameter; and

calculating the one or more command signals from the control signal.

8. The method of claim 7, wherein the selected centrifugal pump performance parameter is the pump head pressure.

9. A method of controlling a centrifugal pump for transferring fluid within a fluid system, the method comprising the steps of:

determining a value of speed input to the centrifugal pump;

determining a value of torque input to the centrifugal pump;

using the value of speed input and the value of torque input to calculate one or more values representing the performance of the centrifugal pump;

using the centrifugal pump performance values to produce one or more command signals, including the steps of selecting a centrifugal pump performance parameter to control, determining a setpoint for the selected centrifugal pump performance parameter, calculating a control signal using the setpoint value of the selected centrifugal pump performance parameter; and

calculating the one or more command signals from the control signal, and

using the one or more command signals to control the speed of the centrifugal pump,

wherein the selected centrifugal pump performance parameter is the pump flow rate and wherein the step of using the one or more command signals to control the speed the centrifugal pump includes repetitively switching the speed of the centrifugal pump between a set pump speed for a portion of a cycle period and zero speed for the remainder of the cycle period to achieve an average pump flow rate equal to the setpoint value of the pump flow rate.

10. A method of controlling a centrifugal pump for transferring fluid within a fluid system, wherein the centrifugal pump is coupled to an electric motor, the method comprising the steps of:

determining a value of speed input to the centrifugal pump and determining a value of torque input to the centrifugal pump, including measuring values of electrical voltages applied to the motor and currents drawn by the motor, and using the measured values of electrical voltages applied to the motor and currents drawn by the motor to calculate a value for at least one of the parameters selected from the group consisting of motor torque and the motor speed;

using the value of speed input and the value of torque input to calculate one or more values representing the performance of the centrifugal pump;

using the centrifugal pump performance values to produce one or more command signals, including the steps of selecting a centrifugal pump performance parameter to control, determining a setpoint for the selected centrifugal pump performance parameter, calculating a control signal using the setpoint value of the selected centrifugal pump performance parameter, and calculating the one or more command signals from the control signal; and

using the one or more command signals to control the speed of the centrifugal pump,

wherein the selected centrifugal pump performance parameter is the pump flow rate; and

wherein the step of using the one or more command signals to control the speed of the centrifugal pump includes repetitively switching the speed of the centrifugal pump between a set pump speed for a portion of a cycle period and zero speed for the remainder of the cycle period to achieve an average pump flow rate equal to the setpoint value of the pump flow rate.

11. A method of controlling a centrifugal pump for transferring fluid within a fluid system, the method comprising the steps of:

determining a value of speed input to the centrifugal pump;

determining a value of torque input to the centrifugal pump;

using the value of speed input and the value of torque input to calculate one or more values representing the performance of the centrifugal pump;

using the centrifugal pump performance values to produce one or more command signals; and

using the one or more command signals to control the speed of the centrifugal pump,

wherein the values representing the performance of the pump comprise values representing pump mechanical input power limit and pump mechanical input power, and the step of using the one or more command signals to control the speed of the centrifugal pump includes the steps of;

comparing the pump mechanical input power limit and pump mechanical input power; and

reducing the speed of the centrifugal pump if the value of pump mechanical input power is greater than the pump mechanical input power limit.

12. The method of claim 11, wherein the step of using centrifugal pump performance values to produce the one or more command signals comprises the steps of:

selecting a centrifugal pump performance parameter to control;

determining a setpoint for the selected centrifugal pump performance parameter;

calculating a control signal using the setpoint value of the selected centrifugal pump performance parameter; and

calculating the one or more command signals from the control signal.

13. The method of claim 12, wherein the selected centrifugal pump performance parameter is the pump flow rate.

14. The method of claim 12, wherein the selected centrifugal pump performance parameter is the pump head pressure.

15. The method of claim 11, wherein the centrifugal pump is coupled to an electric motor and the step of determining the speed input and the torque input to the centrifugal pump comprises the steps of:

measuring values of electrical voltages applied to the motor and currents drawn by the motor; and

using the measured values of electrical voltages applied to the motor and currents drawn by the motor to calculate a value for at least one of the parameters selected from the group consisting of motor torque and the motor speed.

16. The method of claim 15, wherein the step of using centrifugal pump performance values to produce the one or more command signals comprises the steps of:

selecting a centrifugal pump performance parameter to control;

determining a setpoint for the selected centrifugal pump performance parameter;

calculating a control signal using the setpoint value of the selected centrifugal pump performance parameter; and

calculating the one or more command signals from the control signal.

17. The method of claim 16, wherein the selected centrifugal pump performance parameter is the pump flow rate.

18. The method of claim 16, wherein the selected centrifugal pump performance parameter is the pump head pressure.

19. A method of controlling the performance of a fluid system wherein a centrifugal pump is used for transferring fluid within said fluid system, the method comprising the steps of:

determining values of torque and speed inputs to the centrifugal pump;

using the values of torque and speed inputs to calculate one or more values representing the performance of the centrifugal pump;

using the values representing the performance of the centrifugal pump to calculate values representing the performance of the fluid system;

using the system performance values to produce one or more command signals, including deriving a setpoint value for a fluid system performance parameter from a fluid level command, and using the setpoint value in calculating the one or more command signals; and

using the one or more command signals to control the speed of the centrifugal pump.

20. The method of claim 19, wherein the step of using fluid system performance values to produce the one or more command signals comprises the further steps of:

selecting a fluid system performance parameter to control;

the setpoint value being derived for the selected fluid system performance parameter;

calculating a control signal using the setpoint value of the selected fluid system performance parameter; and

calculating the one or more command signals from the control signal.

21. The method of claim 20, wherein the selected fluid system performance parameter to control is the pump suction pressure.

22. The method of claim 19 wherein the centrifugal pump is coupled to an electric motor and the step of determining the torque and speed inputs to the centrifugal pump comprises the steps of:

measuring values of electrical voltages applied to the motor and currents drawn by the motor; and

using the measured values of electrical voltages applied to the motor and currents drawn by the motor to calculate values for at least one of the parameters selected from the group consisting of motor torque and motor speed.

23. The method of claim 22, wherein the step of using fluid system performance values to produce one or more command signals comprises the further steps of:

selecting a fluid system performance parameter to control,

the setpoint value being derived for the selected fluid system performance parameter;

calculating a control signal using the selected fluid system performance parameter; and

calculating the one or more command signals from the control signal.

24. The method of claim 23, wherein the selected fluid system performance parameter to control is the pump suction pressure.

25. A method of controlling the performance of a fluid system wherein a centrifugal pump is used for transferring fluid within said fluid system, the method comprising the steps of:

determining values of torque and speed inputs to the centrifugal pump;

using the values of torque and speed inputs to calculate one or more values representing the performance of the centrifugal pump;

using the values representing the performance of the centrifugal pump to calculate values representing the performance of the fluid system;

using the system performance values to produce one or more command signals, including the steps of selecting a fluid system performance parameter to control, determining a setpoint for the selected fluid system performance parameter, calculating a control signal using the setpoint value of the selected fluid system performance parameter, and calculating the one or more command signals from the control signal, and

using the command signals to control the speed of the centrifugal pump,

wherein the selected fluid system performance parameter to control is the pump suction pressure and further comprising the step of deriving the setpoint value for pump suction pressure from a fluid level command.

26. The method of claim 25, further comprising the step of determining the fluid level command, said step of determining the fluid level command comprising the steps of:

defining a fluid system performance characteristic to optimize;

varying the fluid level incrementally through a range of values;

determining a value representing the fluid system performance characteristic for each value of fluid level;

determining for which value of fluid level the value representing the fluid system performance characteristic is optimized; and

setting the fluid level command at the level which produces the optimized value.

27. The method of claim 26, wherein the step of determining the fluid level command is automatically repeated at predetermined times.

28. The method of claim 26, further comprising the step of periodically determining the pump efficiency and repeating the step of determining the fluid level command when a decrease in pump efficiency relative to prior determinations of pump efficiency is detected.

29. The method of claim 26, wherein the fluid system is a gas well, further comprising the step of periodically determining the gas production and repeating the step of determining the fluid level command when a decrease in gas production relative to prior determinations of gas production is detected.

30. A method of controlling the performance of a fluid system wherein a centrifugal pump is used for transferring fluid within said fluid system, the method comprising the steps of:

determining values of torque and speed inputs to the centrifugal pump;

using the values of torque and speed inputs to calculate one or more values representing the performance of the centrifugal pump;

using the values representing the performance of the centrifugal pump to calculate values representing the performance of the fluid system;

using the system performance values to produce one or more command signals, including the steps of selecting a fluid system performance parameter to control;

determining a setpoint for the selected fluid system performance parameter;

calculating a control signal using the setpoint value of the selected fluid system performance parameter; and

calculating the one or more command signals from the control signal; and

using the command signals to control the speed of the centrifugal pump,

wherein the selected fluid system performance parameter to control is the pump suction pressure and wherein the step of using the one or more command signals to control the speed of the centrifugal pump includes repetitively performing the steps of

operating the centrifugal pump at a set speed until the pump suction pressure decreases to a value less than or equal to a pump suction pressure lower limit, said pump suction pressure lower limit equal to the pump suction pressure setpoint minus a tolerances, and

operating the centrifugal pump at zero speed until the pump suction pressure increases to a value greater than or equal to a pump suction pressure upper limit, said pump suction pressure upper limit equal to the pump suction pressure setpoint plus a tolerance.

31. A method of controlling the performance of a fluid system wherein a centrifugal pump is used for transferring fluid within said fluid system, wherein the centrifugal pump is coupled to an electric motor, the method comprising the steps of:

determining values of torque and speed inputs to the centrifugal pump, including the steps of measuring values of electrical voltages applied to the motor and currents drawn by the motor, and using the measured values of electrical voltages applied to the motor and currents drawn by the motor to calculate values for at least one of the parameters selected from the group consisting of motor torque and motor speed;

using the values of torque and speed inputs to calculate one or more values representing the performance of the centrifugal pump;

using the values representing the performance of the centrifugal pump to calculate values representing the performance of the fluid system;

using the system performance values to produce one or more command signals, including the steps of selecting a fluid system performance parameter to control, including the steps of determining a setpoint for the selected fluid system performance parameter, calculating a control signal using the selected fluid system performance parameter, and calculating the one or more command signals from the control signal; and

using the one or more command signals to control the speed of the centrifugal pump;

wherein the selected fluid system performance parameter to control is the pump suction pressure, and further comprising the step of deriving the setpoint value for pump suction pressure from a fluid level command.

32. The method of claim 31, further comprising the step of determining the fluid level command, said step of determining the fluid level command comprising the steps of:

defining a fluid system performance characteristic to optimize;

varying the fluid level incrementally through a range of values;

determining a value representing the fluid system performance characteristic for each value of fluid level;

determining for which value of fluid level the value representing the fluid system performance characteristic is optimized; and

setting the fluid level command at the level which produces the optimized value.

33. The method of claim 32, wherein the step of determining the fluid level command is automatically repeated at predetermined times.

34. The method of claim 32, further comprising the step of periodically determining the pump efficiency and repeating the step of determining the fluid level command when a decrease in pump efficiency relative to prior determinations of pump efficiency is detected.

35. The method of claim 32, wherein the system is a gas well, further comprising the step of periodically determining the gas production and repeating the step of determining the fluid level command when a decrease in gas production is detected.

36. A method of controlling the performance of a fluid system wherein a centrifugal pump is used for transferring fluid within said fluid system and wherein the centrifugal pump is coupled to an electric motor, the method comprising the steps of:

determining values of torque and speed inputs to the centrifugal pump, including the steps of measuring values of electrical voltages applied to the motor and currents drawn by the motor, and using the measured values of electrical voltages applied to the motor and currents drawn by the motor to calculate values for at least one of the parameters selected from the group consisting of motor torque and motor speed;

using the values of torque and speed inputs to calculate one or more values representing the performance of the centrifugal pump;

using the values representing the performance of the centrifugal pump to calculate values representing the performance of the fluid system;

using the system performance values to produce one or more command signals, including the steps of selecting a fluid system performance parameter to control, including the steps of determining a setpoint for the selected fluid system performance parameter, calculating a control signal using the selected fluid system performance parameter, and calculating the one or more command signals from the control signal; and

using the one or more command signals to control the speed of the centrifugal pump,

wherein the selected fluid system performance parameter to control is the pump suction pressure, and wherein the step of using the one or more command signals to control the speed of the centrifugal pump includes repetitively performing the steps of

operating the centrifugal pump at a set speed until the pump suction pressure decreases to a value less than or equal to a pump suction pressure lower limit, said pump suction pressure lower limit calculated as the pump suction pressure setpoint minus a tolerance; and

operating the centrifugal pump at zero speed until the pump suction pressure increases to a value greater than or equal to a pump suction pressure upper limit, said pump suction pressure upper limit calculated as the pump suction pressure setpoint plus a tolerance.

37. A method of controlling the performance of a fluid system wherein a centrifugal pump is used for transferring fluid within said fluid system, the method comprising the steps of:

determining a value of speed input to the centrifugal pump;

determining a value of pump flow rate;

using the value of speed input and the value of pump flow rate to calculate one or more values representing the performance of the centrifugal pump;

using the values representing the performance of the centrifugal pump to calculate values representing the performance of the fluid system;

using the system performance values to produce one or more command signals, including deriving a setpoint value for a fluid system performance parameter from a fluid level command, and using the setpoint value in calculating the one or more command signals; and

using the one or more command signals to control the speed of the centrifugal pump.

38. The method of claim 37, wherein the step of using fluid system performance values to produce command signals comprises the further steps of:

selecting a fluid system performance parameter to control;

the setpoint value being derived for the selected fluid system performance parameters;

calculating a control signal using the setpoint value of the selected fluid system performance parameter; and

calculating the one or more command signals from the control signal.

39. The method of claim 38, wherein the selected fluid system performance parameter to control is the pump suction pressure.

40. The method of claim 37 wherein the centrifugal pump is coupled to an electric motor and the step of determining the speed input to the centrifugal pump comprises the steps of:

measuring values of electrical voltages applied to the motor and currents drawn by the motor; and

using the measured values of electrical voltages applied to the motor and currents drawn by the motor to calculate a value for motor speed.

41. The method of claim 40, wherein the step of using fluid system performance values to produce command signals comprises the steps of:

selecting a fluid system performance parameter to control;

the setpoint being derived for the selected fluid system performance parameter;

calculating a control signal using the selected fluid system performance parameter; and

calculating the one or more command signals from the control signal.

42. The method of claim 41, wherein the selected fluid system performance parameter to control is the pump suction pressure.

43. A method of controlling the performance of a fluid system, wherein a centrifugal pump is used for transferring fluid within said fluid system, the method comprising the steps of:

determining a value of speed input to the centrifugal pump;

determining a value of pump flow rate;

using the value of speed input and the value of pump flow rate to calculate one or more values representing the performance of the centrifugal pump;

using the values representing the performance of the centrifugal pump to calculate values representing the performance of the fluid system;

using the system performance values to produce one or more command signals, including the steps of selecting a fluid system performance parameter to control, determining a setpoint for the selected fluid system performance parameter, calculating a control signal using the setpoint value of the selected fluid system performance parameter, and calculating the one or more command signals from the control signal; and

using the one or more command signals to control the speed of the centrifugal pump,

wherein the selected fluid system performance parameter to control is the pump suction pressure, and further comprising the step of deriving the setpoint value for pump suction pressure from a fluid level command.

44. The method of claim 43, further comprising the step of determining the fluid level command, said step of determining the fluid level command comprising the steps of:

defining a fluid system performance characteristic to optimize;

varying the fluid level incrementally through a range of values;

determining a value representing the fluid system performance characteristic for each value of fluid level;

determining for which value of fluid level the value representing the fluid system performance characteristic is optimized; and

setting the fluid level command at the level which produces the optimized value.

45. The method of claim 44, wherein the step of determining the fluid level command is automatically repeated at predetermined times.

46. The method of claim 44, further comprising the step of periodically determining the pump efficiency and repeating the step of determining the fluid level command when a decrease in pump efficiency relative to prior determinations of pump efficiency is detected.

47. The method of claim 44, wherein the fluid system is a gas well, further comprising the step of periodically determining the gas production and repeating the step of determining the fluid level command when a decrease in gas production relative to prior determinations of gas production is detected.

48. A method of controlling the performance of a fluid system, wherein a centrifugal pump is used for transferring fluid within said fluid system, the method comprising the steps of:

determining a value of speed input to the centrifugal pump;

determining a value of pump flow rate;

using the value of speed input and the value of pump flow rate to calculate one or more values representing the performance of the centrifugal pump;

using the values representing the performance of the centrifugal pump to calculate values representing the performance of the fluid system;

using the system performance values to produce one or more command signals, including the steps of selecting a fluid system performance parameter to control, determining a setpoint for the selected fluid system performance parameter, calculating a control signal using the setpoint value of the selected fluid system performance parameter, and calculating the one or more command signals from the control signal; and

using the command signals to control the speed of the centrifugal pump,

wherein the selected fluid system performance parameter to control is the pump suction pressure; and

wherein the step of using the command signals to control the speed of the centrifugal pump includes repetitively performing the steps of;

operating the centrifugal pump at a set speed until the pump suction pressure decreases to a value less than or equal to a pump suction pressure lower limit, said pump suction pressure lower limit calculated as the pump suction pressure setpoint minus a tolerance; and

operating the centrifugal pump at zero speed until the pump suction pressure increases to a value greater than or equal to a pump suction pressure upper limit, said pump suction pressure upper limit calculated as the pump suction pressure setpoint plus a tolerance.

49. A method of controlling the performance of a fluid system wherein a centrifugal pump is used for transferring fluid within said fluid system, and wherein the centrifugal pump is coupled to an electric motor, the method comprising the steps of:

determining a value of speed input to the centrifugal pump, including the steps of measuring values of electrical voltages applied to the motor and currents drawn by the motor, and using the measured values of electrical voltages applied to the motor and currents drawn by the motor to calculate a value for motor speed

determining a value of pump flow rate;

using the value of speed input and the value of pump flow rate to calculate one or more values representing the performance of the centrifugal pump;

using the values representing the performance of the centrifugal pump to calculate values representing the performance of the fluid system, including the steps of selecting a fluid system performance parameter to control, determining a setpoint for the selected fluid system performance parameter, calculating a control signal using the selected fluid system performance parameter, and calculating one or more command signals from the control signal;

using the system performance values to produce the one or more command signals; and

using the command signals to control the speed of the centrifugal pump,

wherein the selected fluid system performance parameter to control is the pump suction pressure, and further comprising the step of deriving the setpoint value for pump suction pressure from a fluid level command.

50. The method of claim 49, further comprising the step of determining the fluid level command, said step of determining the fluid level command comprising the steps of:

defining a fluid system performance characteristic to optimize;

varying the fluid level incrementally through a range of values;

determining a value representing the fluid system performance characteristic for each value of fluid level;

determining for which value of fluid level the value representing the fluid system performance characteristic is optimized; and

setting the fluid level command at the level which produces the optimized value.

51. The method of claim 50, wherein the step of determining the fluid level command is automatically repeated at predetermined times.

52. The method of claim 50, further comprising the step of periodically determining the pump efficiency and repeating the step of determining the fluid level command when a decrease in pump efficiency relative to prior determinations of pump efficiency is detected.

53. The method of claim 50, wherein the system is a gas well, further comprising the step of periodically determining the gas production and repeating the step of determining the fluid level command when a decrease in gas production is detected.

54. A method of controlling the performance of a fluid system wherein a centrifugal pump is used for transferring fluid within said fluid system, and wherein the centrifugal pump is coupled to an electric motor, the method comprising the steps of:

determining a value of speed input to the centrifugal pump, including the steps of measuring values of electrical voltages applied to the motor and currents drawn by the motor, and using the measured values of electrical voltages applied to the motor and currents drawn by the motor to calculate a value for motor speed;

determining a value of pump flow rate;

using the value of speed input and the value of pump flow rate to calculate one or more values representing the performance of the centrifugal pump;

using the values representing the performance of the centrifugal pump to calculate values representing the performance of the fluid system, including the steps of using the system performance values to produce one or more command signals;

selecting a fluid system performance parameter to control, determining a setpoint for the selected fluid system performance parameter;

calculating a control signal using the selected fluid system performance parameter; and

calculating the one or more command signals from the control signal; and

using the one or more command signals to control the speed of the centrifugal pump,

wherein the selected fluid system performance parameter to control is the pump suction pressure, and wherein the step of using the one or more command signals to control the speed of the centrifugal pump includes repetitively performing the method comprising the steps of

operating the centrifugal pump at a set speed until the pump suction pressure decreases to a value less than or equal to a pump suction pressure lower limit, said pump suction pressure lower limit calculated as the pump suction pressure setpoint minus a tolerance; and

operating the centrifugal pump at zero speed until the pump suction pressure increases to a value greater than or equal to a pump suction pressure upper limit, said pump suction pressure upper limit calculated as the pump suction pressure setpoint plus a tolerance.

55. A method of controlling the performance of a fluid system wherein at least first and second centrifugal pumps are connected in parallel and are used for transferring fluid within said fluid system and the first and second centrifugal pumps are coupled to first and second electric motors, respectively, the method comprising the steps of:

determining values of speed input to each of the centrifugal pumps, including the steps of measuring values of electrical voltages applied to the first and second motors and currents drawn by the first and second motors and using the measured values of electrical voltages applied to the first and second motors and currents drawn by the first and second motors to calculate for the first and second centrifugal pumps values for at least one of the parameters selected from the group consisting of motor torque and motor speed;

determining values of pump flow rate of each of the centrifugal pumps;

using the values of speed input and pump flow rate to calculate the efficiency of each centrifugal pump;

using efficiency and flow of each centrifugal pump to calculate the speed for each centrifugal pump which would result in the most efficient operation of the fluid system;

using the calculated speed for each centrifugal pump to produce command signals; and

using the command signals to control the speed of each centrifugal pump.

56. The method of claim 55, wherein the step of determining the pump flow rate of each of the centrifugal pumps comprises the steps of:

determining values of torque input to each of the centrifugal pumps; and

using the values of torque inputs and speed inputs to the first and second motors and currents drawn by the first and second motors to calculate for the first and second centrifugal pumps values for pump flow rate.

57. A method of controlling the performance of a fluid system wherein a centrifugal pump is used for transferring fluid within said fluid system, the method comprising the steps of:

selecting a fluid system performance parameter to control;

determining a setpoint for the selected fluid system performance parameter;

determining values representing the performance of the centrifugal pump;

determining values representing the performance of the fluid system;

using the pump performance values and fluid system performance values to calculate a feedforward signal by predicting a value of mechanical input to the centrifugal pump when operating with the selected centrifugal pump performance value at the setpoint value;

using the feedforward signal to generate command signals; and

using the command signals to control the speed of the centrifugal pump.

58. The method of claim 57, wherein the selected fluid system performance parameter to control is the pump suction pressure.

59. The method of claim 58, further comprising the step of deriving the setpoint value for pump suction pressure from a fluid level command.

60. The method of claim 59, further comprising the step of determining the fluid level command, said step of determining the fluid level command comprising the steps of:

defining a fluid system performance characteristic to optimize;

varying the fluid level incrementally through a range of values;

determining a value representing the fluid system performance characteristic for each value of fluid level;

determining for which value of fluid level the value representing the fluid system performance characteristic is optimized; and

setting the fluid level command at the level which produces the optimized value.

61. The method of claim 60, wherein the step of determining the fluid level command is automatically repeated at predetermined times.

62. The method of claim 60, further comprising the step of periodically determining the pump efficiency and repeating the step of determining the fluid level command when a decrease in pump efficiency relative to prior determinations of pump efficiency is detected.

63. The method of claim 60, wherein the system is a gas well, further comprising the step of periodically determining the gas production and repeating the step of determining the fluid level command when a decrease in gas production is detected.

64. The method of claim 58, wherein the step of using the command signals to control the speed of the centrifugal pump includes repetitively performing the method comprising the steps of:

operating the centrifugal pump at a set speed until the pump suction pressure decreases to a value less than or equal to a pump suction pressure lower limit, said pump suction pressure lower limit calculated as the pump suction pressure setpoint minus a tolerance; and

operating the centrifugal pump at zero speed until the pump suction pressure increases to a value greater than or equal to a pump suction pressure upper limit, said pump suction pressure upper limit calculated as the pump suction pressure setpoint plus a tolerance.

65. A pump control system for controlling a centrifugal pump for transferring fluid within a wellbore, the pump control system comprising:

a plurality of sensors;

means responsive to the sensors for determining values of torque and speed input to the centrifugal pump;

means for using the values of torque and speed input to calculate one or more values representing the performance of the centrifugal pump; and

means for using the centrifugal pump performance values to produce one or more command signals for controlling the speed of the centrifugal pump, wherein none of the sensors are located within the wellbore, whereby the values of torque and speed input are derived using sensed values without requiring down hole sensors,

wherein said means using the centrifugal pump performance values to produce command signals includes means for calculating a feedback signal indicative of the difference between a current value of a selected centrifugal pump performance parameter and a setpoint value of the selected centrifugal pump performance parameters; and

means for calculating the command signals from the feedback signal.

66. The pump control system of claim 65, wherein the selected centrifugal pump performance parameter is the pump flow rate.

67. The pump control system of claim 66, including means for repetitively switching the speed of the centrifugal pump between a set pump speed for a portion of a cycle period and zero speed for the remainder of the cycle period to achieve an average pump flow rate equal to the setpoint value of the pump flow rate.

68. The pump control system of claim 65, wherein the selected centrifugal pump performance parameter is the pump head pressure.

69. A pump control system for controlling a centrifugal pump for transferring fluid within a wellbore, the pump control system comprising:

a plurality of sensors;

means responsive to the sensors for determining values of torque and speed input to the centrifugal pump;

means for using the values of torque and speed input to calculate one or more values representing the performance of the centrifugal pump; and

means for using the centrifugal pump performance values to produce one or more command signals for controlling the speed of the centrifugal pump, wherein none of the sensors are located within the wellbore, whereby the values of torque and speed input are derived using sensed values without requiring down hole sensors,

wherein said means using the centrifugal pump performance values to produce command signals includes means for calculating a feedforward signal by predicting a value of mechanical input to the centrifugal pump when operating with the selected centrifugal pump performance value at the setpoint value, and means for calculating the command signals from the feedforward signal.

70. A pump control system for controlling a centrifugal pump for transferring fluid within a fluid system, the pump control system comprising:

means for determining a value of speed input to the centrifugal pump;

means for determining a value of pump flow rate of the centrifugal pump;

means for using the values of pump flow rate and speed input to calculate one or more values representing the performance of the centrifugal pump; and

means for using the centrifugal pump performance values to produce one or more command signals for controlling the speed of the centrifugal pump;

means for calculating a feedforward signal by predicting a value of mechanical input to the centrifugal pump when operating with the selected centrifugal pump performance value at the setpoint value, and means for calculating the command signals from the feedforward signal.

71. The pump control system of claim 70, wherein said means for using the centrifugal pump performance values to produce command signals includes means for calculating a feedback signal indicative of the difference between a current value of a selected centrifugal pump performance parameter and a setpoint value of the selected centrifugal pump performance parameter, and means for calculating the command signals from the feedback signal.

72. The pump control system of claim 71, wherein the selected centrifugal pump performance parameter is the pump head pressure.

73. The pump control system of claim 71, wherein the selected centrifugal pump performance parameter is the pump flow rate, including means for repetitively switching the speed of the centrifugal pump between a set pump speed for a portion of a cycle period and zero speed for the remainder of the cycle period to achieve an average pump flow rate equal to the setpoint value of the pump flow rate.

74. The pump control system of claim 70, wherein said means for using the centrifugal pump performance values to produce command signals includes means for calculating a feedforward signal by predicting a value of mechanical input to the centrifugal pump when operating with the selected centrifugal pump performance value at the setpoint value, and means for calculating the command signals from the feedforward signal.

75. A pump control system for controlling a centrifugal pump for transferring fluid within a gas or oil well, the pump control system comprising:

means to calculate one or more values representing the performance of the centrifugal pump;

means for using the values representing the performance of the centrifugal pump to calculate values representing the performance of the well;

means for using at least one of the well performance values to calculate a feedforward signal; and

means responsive to at least one of the well performance values and to the feedforward signal to produce one or more command signals for controlling the speed of the centrifugal pump.

76. The pump control system of claim 75, wherein said means for using the performance values to produce command signals includes means for calculating a feedback signal indicative of the difference between a current value of the selected performance parameter and a setpoint value of the selected performance parameter;

and means for using the feedback signal to calculate the command signals.

77. The pump control system of claim 76, wherein the selected performance parameter is the pump suction pressure.

78. The pump control system of claim 77, wherein said means for using the performance values to produce command signals includes means for calculating the setpoint for pump suction pressure from a fluid level command.

79. The pump control system of claim 78, wherein said means for using the well performance values to produce command signals includes means for periodically determining gas or oil production and adjusting fluid level command in response to detection of a decrease in gas or oil production.

80. The pump control system of claim 77, wherein said means for using the command signals to control the speed of the centrifugal pump includes means for operating the centrifugal pump at a set speed until the pump suction pressure decreases to a value less than or equal to a pump suction pressure lower limit that is equal to the pump suction pressure setpoint minus a tolerance;

and means for operating the centrifugal pump at zero speed until the pump suction pressure increases to a value greater than or equal to a pump suction pressure upper limit that is equal to the pump suction pressure setpoint plus a tolerance.

81. The pump control system of claim 75, wherein said means for calculating the feedforward signal includes means for predicting a value of mechanical input to the centrifugal pump when operating with the selected pump performance value at the setpoint value.

82. A pump control system for controlling at least first and second centrifugal pumps connected in parallel for transferring fluid within a fluid system, the pump control system comprising:

means to determine values for the efficiency and flow of each centrifugal pump;

means for using the values of efficiency and flow of each centrifugal pump to calculate a speed for each centrifugal pump which would result in the most efficient operation of the fluid system;

means for using the calculated speed for each centrifugal pump to produce command signals; and

means for using the command signals to control the speed of each centrifugal pump,

wherein at least one centrifugal pump is coupled to an electric motor and the means for determining the efficiency and flow rate of at least one centrifugal pump coupled to an electric motor includes means for measuring the electrical voltages applied to the motor and currents drawn by the motor; and

means for using the measured values of electrical voltages applied to the motor and currents drawn by the motor to calculate at least one of the values selected from the group consisting of motor torque and motor speed.

83. A pump control system for controlling a centrifugal pump for transferring fluid within a fluid system, the pump control system comprising:

means for determining values representing the performance of the centrifugal pump;

means for using the values representing the performance of the centrifugal pump for determining values representing the performance of the fluid system;

means for using at least one of the fluid system performance values for calculating a feedforward signal by predicting a value of mechanical input to the centrifugal pump when operating with a selected centrifugal pump performance value at a setpoint value; and

means for calculating from the feedforward signal one or more command signals for controlling the speed of the centrifugal pump.

84. The pump control system of claim 83, wherein the selected performance parameter is the pump suction pressure.

85. The pump control system of claim 84, wherein said means for calculating a feedforward signal includes means for calculating the setpoint for pump suction pressure from a fluid level command.

86. The pump control system of claim 85, wherein said means for calculating a feedforward signal includes means for periodically determining gas or oil production and adjusting fluid level command in response to detection of a decrease in gas or oil production.

87. The pump control system of claim 84, wherein said means for using the command signals to control the speed of the centrifugal pump includes means for operating the centrifugal pump at a set speed until the pump suction pressure decreases to a value less than or equal to a pump suction pressure lower limit that is equal to the pump suction pressure setpoint minus a tolerance;

and means for operating the centrifugal pump at zero speed until the pump suction pressure increases to a value greater than or equal to a pump suction pressure upper limit that is equal to the pump suction pressure setpoint plus a tolerance.

88. A pump control system for controlling a centrifugal pump for transferring fluid within a gas or oil well, the pump control system comprising:

means for determining values representing the performance of the centrifugal pump;

means for using the values representing the performance of the centrifugal pump for determining values representing the performance of the well;

means for using at least one of the well performance values for calculating a feedforward signal by predicting a value of mechanical input to the centrifugal pump when operating with a selected centrifugal pump performance value at a setpoint value; and

means for calculating from the feedforward signal one or more command signals for controlling the speed of the centrifugal pump.

89. The pump control system of claim 88, wherein the selected performance parameter is the pump suction pressure.

90. The pump control system of claim 89, wherein said means for calculating a feedforward signal includes means for calculating the setpoint for pump suction pressure from a fluid level command.

91. The pump control system of claim 90, wherein said means for calculating a feedforward signal includes means for periodically determining gas or oil production and adjusting fluid level command in response to detection of a decrease in gas or oil production.

92. The pump control system of claim 89, wherein said means for using the command signals to control the speed of the centrifugal pump includes means for operating the centrifugal pump at a set speed until the pump suction pressure decreases to a value less than or equal to a pump suction pressure lower limit that is equal to the pump suction pressure setpoint minus a tolerance;

and means for operating the centrifugal pump at zero speed until the pump suction pressure increases to a value greater than or equal to a pump suction pressure upper limit that is equal to the pump suction pressure setpoint plus a tolerance.