Adaptive pump control for positive displacement pump failure modes

• US 9,243,628 B2
• Filed: 05/05/2014
• Issued: 01/26/2016
• Est. Priority Date: 07/18/2011
• Status: Expired due to Fees

• Current Assignee: Schlumberger Technology Corporation (Schlumberger NV)
• Original Assignee: Schlumberger Technology Corporation (Schlumberger NV)
• Inventors: Villareal, Steven, Pop, Julian J., Hoefel, Albert, Harms, Kent David
• Primary Examiner(s): Bertheaud, Peter J
• Assistant Examiner(s): Plakkoottam, Dominick L
• Application Number:
  US14/269,743
• Publication Number:
  US 20140244049A1
• Time in Patent Office: 631 Days
• Field of Search: 417/53, 417 56- 58, 417/63, 417/242, 417/386, 417/390, 417/401, 417/404, 417/555.1, 417/555.2, 166/68, 166/105, 166/108
• US Class Current: 1/1
• CPC Class Codes: E21B 43/121 Lifting well fluids monitoring of down-hole pump systems E21B47/008
• CPC Class Codes: E21B 44/005 Below-ground automatic control systems
• CPC Class Codes: E21B 47/06 Measuring temperature or pressure
• CPC Class Codes: E21B 49/10 using side-wall fluid samplers or testers
• CPC Class Codes: F04B 19/22 of reciprocating-piston type
• CPC Class Codes: F04B 2201/0201 Position of the piston
• CPC Class Codes: F04B 2201/0603 Valve wear
• CPC Class Codes: F04B 47/00 Pumps or pumping installations specially adapted for raising fluids from great depths, e.g. well pumps by using positive or negative pressurised fluid medium acting directly on the liquid to be pumped F04F1/00
• CPC Class Codes: F04B 47/02 the driving mechanisms being situated at ground level F04B47/12 takes precedence
• CPC Class Codes: F04B 49/00 Control , e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
• CPC Class Codes: F04B 49/022 by means of pressure
• CPC Class Codes: F04B 49/22 by means of valves F04B49/03 takes precedence
• CPC Class Codes: F04B 53/10 Valves; Arrangement of valves
• CPC Class Codes: F04B 53/14 Pistons, piston-rods or piston-rod connections
• CPC Class Codes: F04B 53/16 Casings; Cylinders; Cylinder liners or heads; Fluid connections

Abstract

Detecting a failure mode of a fluid flow controller configured to control fluid flow between first and second chambers of a downhole positive displacement pump and a flow line, wherein the positive displacement pump comprises a piston moving in an axial reciprocating motion, and subsequently adjusting operation of the downhole positive displacement pump based on the detected failure mode such that the downhole positive displacement pump piston operates differently in different axial directions.

Claims

1. An apparatus, comprising:

a positive displacement pump for a downhole tool, wherein the positive displacement pump is operable to produce fluid from a flow line of the downhole tool, and wherein the positive displacement pump comprises;

a first chamber disposed to receive a first volume of fluid during a first stroke of the positive displacement pump;

a second chamber disposed to receive a second volume of fluid during a second stroke of the positive displacement pump, wherein the second stroke is in a reverse direction relative to the first stroke, and a fluid flow controller operable to control fluid flow between the first and second chambers and the flow line; and

a processor operatively connected to the positive displacement pump and operable to;

detect a failure mode of the fluid flow controller, and apply compensation for the failure mode by adjusting at least one parameter of the positive displacement pump; and

wherein, during the failure mode, one but not both of the first and second chambers accumulates a volume of fluid from the flow line, resulting in an active stroke for the one of the first and second chambers and an inactive stroke for the other of the first and second chambers, and adjusting the at least one parameter comprises increasing an operating rate of the positive displacement pump for the inactive stroke.

2. The apparatus of claim 1 wherein the processor is operable to automatically detect the failure mode of the fluid flow controller.

3. The apparatus of claim 1 wherein the positive displacement pump is connected to a pipe string positioned in a borehole penetrating a subterranean formation.

4. The apparatus of claim 3 wherein the positive displacement pump produces fluid from the subterranean formation.

5. The apparatus of claim 1 wherein the fluid flow controller comprises a networked plurality of check valves.

6. The apparatus of claim 5 wherein the failure mode results from at least one of the networked plurality of check valves being clogged in an open position.

7. The apparatus of claim 1 further comprising a plurality of sensors each operatively connected to the processor and operable in the detection of the failure mode.

8. The apparatus of claim 7 wherein the plurality of sensors comprises a pressure sensor operable for measuring a pressure response to producing fluid from the flow line during the first and second strokes.

9. The apparatus of claim 8 wherein detecting the failure mode comprises observing a difference in the pressure response during the first and second strokes.

10. The apparatus of claim 7 wherein at least one of the plurality of sensors is operable for measuring at least one parameter selected from the group consisting of:

volumetric flow rate;

pump pressure;

fluid mobility;

applied torque; and

pump power.

11. The apparatus of claim 9 wherein the positive displacement pump comprises a piston, and wherein axial reciprocation of the piston defines the first and second strokes.

12. The apparatus of claim 11 wherein the piston comprises an electromechanically driven piston, a mechanically driven piston, or a hydraulically driven piston.

13. The apparatus of claim 9 further comprising a motor operable to apply torque to drive the positive displacement pump, wherein the processor is operable to monitor the torque applied by the motor to detect a load imbalance resulting from the failure mode.

14. The apparatus of claim 9 wherein the processor is operable to automatically apply the compensation by sending at least one command from a surface tool to the processor to control a pumping rate of the first and second strokes.

15. The apparatus of claim 9 wherein the apparatus is configured for conveyance in a borehole via a drill string.