Methods, apparatus and products useful in the operation of a sucker rod pump during the production of hydrocarbons

• US 20030065447A1
• Filed: 10/02/2001
• Published: 04/03/2003
• Est. Priority Date: 10/02/2001
• Status: Active Grant

• Current Assignee: Ravdos Holdings Inc.
• Original Assignee: Lufkin Industries Incorporated (Baker Hughes Company)
• Inventors: Dorado, Doneil M., Boyer, LeMoyne, Bramlett, Bobby R., Gibbs, Sam Gavin, Nolen, Kenneth Bernard
• Granted Patent: US 6,857,474 B2
• Time in Patent Office: Days
• US Class Current: 702/6
• CPC Class Codes: E21B 47/009 Monitoring of walking-beam pump systems

Abstract

Apparatus, methods and products for monitoring/controlling a reciprocating well producing hydrocarbons from a wellbore, which determine the surface card from a well operating characteristics, determine the downhole card, and display both at the same scale for position.

Claims

1. A system for controlling a reciprocating pump producing hydrocarbons from a wellbore extending from the surface into the subterranean, the system comprising:

(A) a data gathering system to monitor a surface operating characteristic of the pumping system;

(B) a processor in communication with the data gathering system, wherein the processor comprises software that when executed utilizes the operating characteristic to determine the surface card, determines the downhole card, and generates a graphics signal representative of at least one of the surface card or the downhole card, and wherein the processor further comprises software for generating a pump control signal; and

(C) an output system in communication with the processor, which upon receipt of the graphics signal from the processor provides a viewable graphical representation of the graphics signal.

2. The system of claim 1, wherein the pump control signal is provided directly or indirectly to the pump, or provided to a human operator for further processing.

3. The system of claim 1, wherein the graphics signal generated by the processor is representative of both the surface card and the downhole card.

4. The system of claim 3, wherein the viewable graphical representation of the graphics signal comprises an axis on the surface card representing position having the same scale as an axis on the downhole card representing position.

5. The system for monitoring of claim 4, wherein in near real time comprises within 12 hours.

6. The system for monitoring of claim 4, wherein in near real time comprises within 2 reciprocations of the pump.

41. The method of claim 5, wherein step (D) of generating a viewable graphical representation occurs in near real time, relative to step (A) of monitoring an operating characteristic.

42. The method of claim 6, wherein in near real time comprises within 24 hours.

43. The method of claim 6, wherein in near real time comprises within 10 reciprocations of the pump.

44. The method of claim 6, wherein in near real time comprises within 1 reciprocation of the pump.

45. The method of claim 1, further comprising:

(E) adjusting the operation of the pump if warranted based on the surface card and the downhole card.

80. The method of claim 44, further comprising:

(F) repeatedly repeating in sequence steps (A), (B), (C), (D), and (E).

7. A method of monitoring a reciprocating pump producing hydrocarbons from a wellbore extending from the surface into the subterranean, the method comprising:

(A) monitoring an operating characteristic of the well at the surface;

(B) generating at least one of the surface card or the downhole card utilizing the operating characteristic;

(C) generating a pump control signal based on at least one of the surface card, downhole card or operating characteristic; and

(D) providing a viewable graphical representation of the surface card or downhole card.

8. The method of claim 7, wherein steps (C) and (D) occur in near real time, relative to step (A) of monitoring an operating characteristic.

9. The method of claim 8, wherein in near real time comprises within 24 hours.

10. The method of claim 8, wherein in near real time comprises within 10 reciprocations of the pump.

11. The method of claim 8, wherein in near real time comprises within 1 reciprocation of the pump.

12. The method of claim 7, further comprising:

(E) providing the control signal directly or indirectly to the pump.

13. The method of claim 7, in which step (C) first comprises comparing the surface or downhole card to ideal cards.

14. The method of claim 13, further comprising:

(F) r epeatedly repeating steps (A), (B), (C), (D), and (E).

46. The method of claim 10, in which step (E) first comprises comparing the downhole card to ideal downhole cards.

47. The method for monitoring of claim 10, further comprising:

(F) repeatedly repeating in sequence steps (A),(B),(C), (D), and (E).

49. The system of claim 13, wherein instruction (C) of generate a viewable graphical representation occurs in near real time.

50. The system of claim 14, wherein in near real time comprises within 4 hours.

51. The system of claim 14, wherein in near real time comprises within 2 reciprocations of the pump.

52. The system of claim 14, wherein in near real time comprises within 1 reciprocation of the pump.

53. The system of claim 13, further comprising software that when executed instructs the system to:

(D) generate a signal to adjust the operation of the pump if warranted based on the surface card and the downhole card.

82. The system of claim 46, wherein instruction (C) of compare occurs in near real time.

83. The system of claim 47, wherein in near real time comprises within 24 hours.

84. The system of claim 47, wherein in near real time comprises within 10 reciprocations of the pump.

85. The system of claim 47, wherein in near real time comprises within 1 reciprocation of the pump.

86. The system of claim 47, wherein the comparison signal is provided to and alters the operation of the pump.

87. The system of claim 47, further comprising:

(D) generate a viewable graphical representation of both the surface card and the downhole card, wherein for the viewable graphical representation an axis on the surface card representing position is at the same scale as an axis on the downhole card representing position.

88. The system of claim 52, further comprising:

(F) repeatedly repeating in sequence instructions (A), (B), (C), (D), and (E).

15. A system for monitoring a reciprocating pump producing hydrocarbons from a wellbore extending from the surface into the subterranean, the system comprising a computer receiving data regarding an operating characteristic of the pump, and comprising software that when executed instruct the system to:

(A) monitor an operating characteristic of the well at the surface;

(B) generate at least one of the surface card or the downhole card utilizing the operating characteristic;

(C) generate a pump control signal based on at least one of the surface card, downhole card or operating characteristic; and

(D) provide a viewable graphical representation of the surface card or downhole card.

16. The system of claim 15, wherein instructions (C) and (D) occur in near real time, relative to instruction (A) of monitoring an operating characteristic.

17. The system of claim 16, wherein in near real time comprises within 24 hours.

18. The system of claim 16, wherein in near real time comprises within 10 reciprocations of the pump.

19. The system of claim 16, wherein in near real time comprises within 1 reciprocation of the pump.

20. The system of claim 15, further comprising software that when executed instructs the system to:

(E) provide the control signal directly or indirectly to the pump.

21. The system of claim 15, in which instruction (C) first comprises comparing the surface or downhole card to ideal cards.

22. The system of claim 21, further comprising software that when executed instructs the system to:

(F) repeatedly repeat steps (A),(B),(C), (D), and (E).

54. The system of claim 18, in which instruction (D) first comprises instructing the system to compare the downhole card to ideal downhole cards.

55. The system of claim 18, further comprising software that when executed instructs the system to:

(E) repeatedly repeat in sequence steps (A),(B),(C), and (D).

57. The medium of claim 21, wherein instruction (C) of generate a viewable graphical representation occurs in near real time.

58. The medium of claim 22, wherein in near real time comprises within 2 reciprocations of the pump.

59. The medium of claim 21, further comprising software that when executed instructs the system to:

(D) generate a signal to adjust the operation of the pump if warranted based on the surface card and the downhole card.

90. The medium of claim 54, wherein instruction (C) of compare occurs in near real time.

91. The medium of claim 55, wherein in near real time comprises within 24 hours.

92. The medium of claim 55, wherein in near real time comprises within 10 reciprocations of the pump.

93. The medium of claim 55, wherein in near real time comprises within 1 reciprocation of the pump.

94. The medium of claim 55, wherein the comparison signal is provided to and alters the operation of the pump.

95. The medium of claim 55, further comprising:

(D) generate a viewable graphical representation of both the surface card and the downhole card, wherein for the viewable graphical representation an axis on the surface card representing position is at the same scale as an axis on the downhole card representing position.

23. A computer-readable storage medium having stored thereon a plurality of instructions for controlling a reciprocating pump producing hydrocarbons from a wellbore extending from the surface into the subterranean, said instructions that when executed by a computer instruct the computer to:

(A) monitor an operating characteristic of the well at the surface;

(B) generate at least one of the surface card or the downhole card utilizing the operating characteristic;

(C) generate a pump control signal based on at least one of the surface card, downhole card or operating characteristic; and

(D) provide a viewable graphical representation of the surface card or downhole card.

24. The medium of claim 23, wherein instructions (C) and (D) occur in near real time, relative to instruction (A) of monitoring an operating characteristic.

25. The medium of claim 24, wherein in near real time comprises within 24 hours.

26. The medium of claim 24, wherein in near real time comprises within 10 reciprocations of the pump.

27. The medium of claim 24, wherein in near real time comprises within 1 reciprocation of the pump.

28. The medium of claim 23, further comprising software that when executed instructs the system to:

(E) provide the control signal directly or indirectly to the pump.

29. The medium of claim 23, in which instruction (C) first comprises comparing the surface or downhole card to ideal cards.

30. The medium of claim 29, further comprising software that when executed instructs the system to:

(F) repeatedly repeat steps (A),(B),(C), (D), and (E).

60. The medium of claim 24, in which instruction (D) first comprises instructing the system to compare the downhole card to ideal downhole cards.

61. The medium of claim 24, further comprising software that when executed instructs the system to:

(D) repeatedly repeat in sequence steps (A),(B),(C), and (D).

63. The signal of claim 27, wherein instruction (C) of generate a viewable graphical representation occurs in near real time.

64. The signal of claim 28, wherein in near real time comprises within 2 reciprocations of the pump.

65. The signal of claim 27, further comprising software that when executed instructs the system to:

(D) generate a signal to adjust the operation of the pump if warranted based on the surface card and the downhole card.

66. The signal of claim 30, in which instruction (D) first comprises instructing the system to compare the downhole card to ideal downhole cards.

67. The signal of claim 30, further comprising software that when executed instructs the system to:

(D) repeatedly repeat in sequence steps (A),(B),(C), and (D).

96. The medium of claim 60, further comprising:

(F) repeatedly repeating in sequence instructions (A), (B), (C), (D), and (E).

99. The signal of claim 63, wherein in near real time comprises within 24 hours.

100. The signal of claim 63, wherein in near real time comprises within 10 reciprocations of the pump.

101. The signal of claim 63, wherein in near real time comprises within 1 reciprocation of the pump.

102. The signal of claim 63, wherein the comparison signal is provided to and alters the operation of the pump.

103. The signal of claim 63, further comprising:

(D) generate a viewable graphical representation of both the surface card and the downhole card, wherein for the viewable graphical representation an axis on the surface card representing position is at the same scale as an axis on the downhole card representing position.

31. A propagated signal comprising a plurality of instructions for controlling a reciprocating pump producing hydrocarbons from a wellbore extending from the surface into the subterranean, said instructions that when executed by a computer instruct the computer to:

(A) monitor an operating characteristic of the well at the surface;

(B) generate at least one of the surface card or the downhole card utilizing the operating characteristic;

(C) generate a pump control signal based on at least one of the surface card, downhole card or operating characteristic; and

(D) provide a viewable graphical representation of the surface card or downhole card.

32. The signal of claim 31, wherein instructions (C) and (D) occur in near real time, relative to instruction (A) of monitoring an operating characteristic.

33. The signal of claim 32, wherein in near real time comprises within 24 hours.

34. The signal of claim 32, wherein in near real time comprises within 10 reciprocations of the pump.

35. The signal of claim 32, wherein in near real time comprises within 1 reciprocation of the pump.

36. The signal of claim 31, further comprising software that when executed instructs the system to:

(E) provide the control signal directly or indirectly to the pump.

37. The signal of claim 31, in which instruction (C) first comprises comparing the surface or downhole card to ideal cards.

38. The signal of claim 37, further comprising software that when executed instructs the system to:

(F) repeatedly repeat steps (A), (B),(C), (D), and (E).

74. The method of claim 38, wherein step (D) of comparing occurs in near real time, relative to step (A) of monitoring an operating characteristic.

78. The method of claim 38, wherein the comparison signal is provided to and alters the operation of the pump.

79. The method of claim 38, further comprising:

(E) generating a viewable graphical representation of both the surface card and the downhole card, wherein for the viewable graphical representation an axis on the surface card representing position is at the same scale as an axis on the downhole card representing position.

39. A system for monitoring a reciprocating pump producing hydrocarbons from a wellbore extending from the surface into the subterranean, the system comprising:

(A) a data gathering system to monitor a surface operating characteristic of the pumping system;

(B) a processor in communication with the data gathering system, wherein the processor comprises software that when executed utilizes the operating characteristic to determine the surface card, determines the downhole card, and generates a graphics signal representative of the surface card or the downhole card; and

(C) an output system in communication with the processor, which upon receipt of the graphics signal from the processor provides a viewable graphical representation of the graphics signal.

75. The method of claim 39, wherein in near real time comprises within 24 hours.

76. The method of claim 39, wherein in near real time comprises within 10 reciprocations of the pump.

77. The method of claim 39, wherein in near real time comprises within 1 reciprocation of the pump.

40. A method of monitoring a reciprocating pump producing hydrocarbons from a wellbore extending from the surface into the subterranean, the method comprising:

(A) monitoring an operating characteristic of the well at the surface;

(B) generating a surface card utilizing the operating characteristic;

(C) generating a downhole card;

(D) generating a viewable graphical representation of both the surface card and the downhole card, wherein for the viewable graphical representation an axis on the surface card representing position is at the same scale as an axis on the downhole card representing position.

48. A system for monitoring a reciprocating pump producing hydrocarbons from a wellbore extending from the surface into the subterranean, the system comprising a computer receiving data regarding an operating characteristic of the pump, and comprising software that when executed instruct the system to:

(A) generate a surface card utilizing the operating characteristic;

(B) generate a downhole card; and

(C) generate a viewable graphical representation of both the surface card and the downhole card, wherein for the viewable graphical representation an axis on the surface card representing position is at the same scale as an axis on the downhole card representing position.

56. A computer-readable storage medium having stored thereon a plurality of instructions for monitoring a reciprocating pump producing hydrocarbons from a wellbore extending from the surface into the subterranean, said instructions that when executed by a computer instruct the computer to:

(A) generate a surface card utilizing an operating characteristic of the pump;

(B) generate a downhole card; and

(C) generate a viewable graphical representation of both the surface card and the downhole card, wherein for the viewable graphical representation an axis on the surface card representing position is at the same scale as an axis on the downhole card representing position.

62. A propagated signal comprising a plurality of instructions for monitoring a reciprocating pump producing hydrocarbons from a wellbore extending from the surface into the subterranean, said instructions that when executed by a computer instruct the computer to:

(A) generate a surface card utilizing an operating characteristic of the pump;

(B) generate a downhole card; and

(C) generate a viewable graphical representation of both the surface card and the downhole card, wherein for the viewable graphical representation an axis on the surface card representing position is at the same scale as an axis on the downhole card representing position.

98. The signal of claim 62, wherein instruction (C) of compare occurs in near real time.

68. A system for controlling a reciprocating pump producing hydrocarbons from a wellbore extending from the surface into the subterranean, the system comprising:

(A) a data gathering system to monitor a surface operating characteristic of the pumping system;

(B) a database of ideal cards;

(C) a processor in communication with the data gathering system and the database, wherein the processor comprises software that when executed utilizes the operating characteristic to determine at least one of the surface card or downhole card, and wherein the processor further comprises software that when executed makes a comparison of the determined card against the database and generates a control signal dependent upon the comparison.

69. The system of claim 68, wherein the control signal is provided to and alters the operation of the pump.

70. The system of claim 69 wherein the processor generates the control signal in near real time.

71. The system for of claim 70, wherein in near real time comprises within 12 hours.

72. The system of claim 70, wherein in near real time comprises within 2 reciprocations of the pump.

104. The signal of claim 68, further comprising:

(F) repeatedly repeating in sequence instructions (A), (B), (C), (D), and (E).

73. A method of monitoring a reciprocating pump producing hydrocarbons from a wellbore extending from the surface into the subterranean, the method comprising:

(A) monitoring an operating characteristic of the well at the surface;

(B) generating a surface card utilizing the operating characteristic;

(C) generating a downhole card;

(D) comparing the downhole card to a database of ideal downhole cards, and generating a comparison signal based on the comparing.

81. A system for monitoring a reciprocating pump producing hydrocarbons from a wellbore extending from the surface into the subterranean, the system comprising a computer receiving data regarding an operating characteristic of the pump, and comprising software that when executed instruct the system to:

(A) generate a surface card utilizing the operating characteristic;

(B) generate a downhole card;

(C) compare the downhole card to a database of ideal downhole cards, and generating a comparison signal based on the comparing.

89. A computer-readable storage medium having stored thereon a plurality of instructions for monitoring a reciprocating pump producing hydrocarbons from a wellbore extending from the surface into the subterranean, said instructions that when executed by a computer instruct the computer to:

(A) generate a surface card utilizing the operating characteristic;

(B) generate a downhole card;

(C) compare the downhole card to a database of ideal downhole cards, and generating a comparison signal based on the comparing.

97. A propagated signal comprising a plurality of instructions for monitoring a reciprocating pump producing hydrocarbons from a wellbore extending from the surface into the subterranean, said instructions that when executed by a computer instruct the computer to:

(A) generate a surface card utilizing the operating characteristic;

(B) generate a downhole card;

(C) compare the downhole card to a database of ideal downhole cards, and generating a comparison signal based on the comparing.