System and method for controlling fluid pumps to achieve desired levels

• US 8,684,078 B2
• Filed: 09/08/2011
• Issued: 04/01/2014
• Est. Priority Date: 09/08/2010
• Status: Active Grant

• Current Assignee: Direct Drivehead Incorporated
• Original Assignee: Direct Drivehead Incorporated
• Inventors: Boyles, Greg, Snyder, Bob
• Primary Examiner(s): Wright, Giovanna
• Assistant Examiner(s): RUNYAN, RONALD R
• Application Number:
  US13/227,632
• Publication Number:
  US 20130133881A1
• Time in Patent Office: 936 Days
• Field of Search: 166/250.15, 166/113, 166/60, 166/61, 166/105, 166/62, 166/66, 700/1, 700/28, 700/78, 700/82, 700/87, 700/281, 700/282, 700/296
• US Class Current: 166/250.15
• CPC Class Codes: E21B 47/008 Monitoring of down-hole pump systems, e.g. for the detection of "pumped-off" conditions
• CPC Class Codes: F04D 13/08 for submerged use
• CPC Class Codes: F04D 15/0066 by changing the speed, e.g. of the driving engine

Abstract

A system for attaining and maintaining a pre-determined fluid level in a petroleum-producing well having a pump, such as a progressive-cavity pump, and a pump motor having a variable-frequency drive control using two sensors: a pump pressure sensor located at the pump depth and a casing pressure sensor located at the casinghead of the well. A programmable computer is connected to the first and second pressure sensors and the motor speed control so that the programmable computer controls the operation of the pump motor to attain and maintain a target fluid level in the well over a predetermined time interval for reaching the target fluid level in the well. The programmable computer computes an error signal to control a variable frequency drive motor, where the error signal is computed periodically from the difference between in the actual fluid level in the well and the target fluid level in the well according to a rate reference curve. In general, the rate reference curve is generated according to an exponential or hyperbolic function.

Claims

1. In a well having a pump and a pump motor having a motor speed control, a system for attaining and maintaining a pre-determined fluid level in the well, the system comprising:

a second pressure sensor that monitors pump pressure located at the pump depth;

a first pressure sensor that monitors casing pressure located at the casing head of the well;

a programmable computer connected to the first and second pressure sensors and the motor speed control, where;

the programmable computer controls the speed of the pump motor to attain and maintain a target fluid level in the well over a predetermined time interval for reaching the target fluid level in the well; and

,

where the programmable computer computes an error signal proportional to fluid level to control a variable frequency drive motor, where the error signal proportional to fluid level is computed periodically from the difference between the actual fluid level in the well and the target fluid level in the well according to a rate reference curve; and

,

where the rate reference curve is generated according to an exponential function.

2. The system of claim 1 where the programmable computer is configured to receive data from the pump pressure sensor and the casing pressure sensor to calculate the fluid level within the well.

3. The system of claim 2 where the programmable computer is further configured to receive user inputs for the desired fluid level in the well and the predetermined time interval for reaching the target level in the well.

4. The system of claim 1 where the programmable computer provides a user interface for entering a target fluid level in the well.

5. The system of claim 1 where the programmable computer provides a user interface for entering the predetermined time interval for reaching the target fluid level in the well.

6. The system of claim 1, where the pump is a progressive-cavity pump.

7. The system of claim 1, where the pump is a pump jack lifting a submersible pump.

8. The system of claim 1 where the programmable computer is remotely controlled through an internet connection.

9. In a well having a pump and a pump motor having a motor speed control, a method for attaining and maintaining a pre-determined fluid level in the well, the method comprising:

measuring the pressure in the well at the pump depth;

measuring the pressure at the casinghead of the well;

setting a predetermined time interval for reaching a target fluid level in the well;

calculating the fluid level in the well from the pressure at the pump and the pressure at the casinghead of the well;

calculating a rate reference curve for the target fluid level in the well over the predetermined time interval;

computing an error signal proportional to fluid level from the difference between the actual fluid level in the well and the target fluid level in the well according to the rate reference curve;

using the error signal proportional to fluid level to control a variable-frequency drive motor driving the pump to attain and maintain the target fluid level in the well.

10. The method of claim 9, where the rate reference curve is generated according to an exponential function.

11. The method of claim 9, where the rate reference curve is calculated at predetermined time intervals.

12. The method of claim 9, where the error signal is computed at predetermined time intervals.

13. The method of claim 9 further comprising logging pump speed versus volume output over time to detect pump wear.