Pump system and method for wellsite applications

Abstract

A pump system for a wellsite and a method of providing measurements to a controller are provided. Systems and methods provided herein relate to power systems, such as systems for electric machines. The digital acquisition unit is configured to receive a current sense signal associated with the electric machine and a phase voltage power signal associated with the electric machine. The data acquisition unit includes a module coupled to a first ground and an attenuator circuit coupled to a second ground. The first ground is isolated from the second ground. The phase voltage power signal is provided to the attenuator, and the attenuator provides a phase voltage sense signal to the module.

Description

Technical Field

[0001] The present application relates generally to monitoring and / or control equipment at a wellsite. Background Art

[0002] Various types of electrical equipment can be used at a well site (e.g., an oil field). As an example, a pump system can be used to move fluids in a well in an underground or surface environment. The pump system can include, but is not limited to, a downhole pump, a submersible pump, a donkey head pump, a jet pump, a centrifugal pump, a reciprocating plunger pump, a screw pump, a gear pump, a diaphragm pump, a metering pump, etc. Voltage sensors and transducers can be used to sense conditions associated with the pump system. However, the isolation requirements associated with monitoring such conditions require expensive components. For example, some conventional systems use special step-down power transformers for measurement isolation, or use transformer-isolated Hall effect sensors to obtain low voltage drive signals on the primary side of the main power transformer. Summary of the invention

[0003] One implementation of the present disclosure relates to a pump system for a well site. The pump system includes a data acquisition unit configured to receive a current sensing signal associated with a motor and a phase voltage and current signal associated with the motor. The data acquisition unit includes an attenuator circuit referenced to a first side of a first ground and referenced to a second ground. The first ground is isolated from the second ground. A phase voltage power signal is provided to the attenuator circuit, and the attenuator circuit provides a phase voltage sensing signal.

[0004] In some embodiments, the system further comprises an isolated power supply referenced to the first ground and the second ground, the isolated power supply being configured to provide separate power to the modules on each side. In some embodiments, the isolated power supply referenced to the second ground can be used to provide power to the electronic devices on the attenuator side.

[0005] In some embodiments, the attenuator includes an impedance network and provides a phase voltage power signal to the impedance network. In some embodiments, the attenuator includes an amplifier coupled to the impedance network. The amplifier is coupled to an analog-to-digital converter in the module. In some embodiments, the module includes an isolation circuit between the controller and the analog-to-digital converter. In some embodiments, the system also includes a current sensor configured to provide a current phase sensing signal.

[0006] Some embodiments relate to a pump system for a well site. The pump system includes a data acquisition unit configured to receive a current sensing signal associated with a motor and a phase voltage power sensing signal associated with the motor. The data acquisition unit includes an isolation circuit having a first side referenced to a first ground and a second side coupled to an attenuator circuit and referenced to a second ground, wherein the first ground is isolated from the second ground, wherein the phase voltage power signal is provided to the attenuator circuit, and wherein the attenuator circuit provides the phase voltage sensing signal. In some embodiments, the term "side" as used herein may refer to an electrical side and not necessarily a mechanical side. The side may refer to an electrical side of an isolation circuit.

[0007] Some embodiments relate to a digital acquisition unit for high voltage applications. The unit includes a first analog-to-digital converter configured to receive a current sensing signal associated with a phase voltage power signal. The first converter is coupled to a first ground, and in some embodiments, a single analog-to-digital converter processes both voltage and current. The unit may also include a second analog-to-digital converter configured to receive a voltage sensing signal. The second converter is also coupled to the first ground. The unit also includes an attenuator circuit coupled to the first ground on the analog side. The first ground is isolated from the second ground and provides the phase voltage power signal to the attenuator circuit. The attenuator circuit provides the phase voltage sensing signal to the first analog-to-digital converter. The ADC digital interface signal is coupled to the second ground via an isolation interface.

[0008] In some embodiments, the digital acquisition unit further comprises a separate isolated power supply coupled to the first ground and configured to provide the first power to the first analog-to-digital converter. In some embodiments, the first power supply is coupled to the second ground and configured to provide power to the circuit on the attenuator side.

[0009] In some embodiments, the digital acquisition unit further comprises an isolation circuit between the second analog-to-digital converter and the controller. In some embodiments, the attenuator circuit comprises an impedance network, and the phase voltage power signal is provided to the impedance network. In some embodiments, the attenuator circuit comprises an attenuator circuit, the attenuator circuit comprising an amplifier coupled to the impedance network. The amplifier is coupled to the second analog-to-digital converter. In some embodiments, the digital acquisition unit further comprises a current sensor configured to provide a current sensing signal.

[0010] Some embodiments relate to a method of providing measurements to a controller. The method includes receiving, by a data acquisition unit, a current sense signal associated with a motor, and receiving, by a data acquisition module, a phase voltage sense signal associated with a phase voltage power signal of the motor. An ADC analog input is coupled to a first ground and an attenuator circuit. The first ground is isolated from a second ground. The phase voltage power signal is provided to the attenuator circuit, and the attenuator circuit provides the phase voltage sense signal to the ADC.

[0011] In some embodiments, the method further comprises powering the module using an isolated power supply, the isolated power supply coupled to a first ground and configured to provide a first power to the module. In some embodiments, the method further comprises powering an attenuator side circuit using a first power supply, the first power supply coupled to a second ground and configured to provide a second power to the attenuator circuit. In some embodiments, the attenuator circuit comprises an amplifier coupled to an impedance network. In some embodiments, the amplifier is coupled to an analog-to-digital converter in the module.

[0012] This summary is illustrative only and is not intended to be limiting in any way.Other aspects, inventive features, and advantages of the devices or processes described herein will become apparent from the detailed description set forth herein, taken in conjunction with the accompanying drawings, wherein like reference numerals refer to like elements. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Various objects, aspects, features and advantages of the present disclosure will become more apparent and better understood by referring to the detailed description in conjunction with the accompanying drawings, in which the same reference numerals always identify corresponding elements. In the accompanying drawings, the same reference numerals generally represent the same, functionally similar and / or structurally similar elements.

[0014] Figure 1 is a schematic diagram of a well site including a pump according to some embodiments.

[0015] Figure 2 is a schematic diagram of a system including a pump disposed in a subterranean environment, according to some embodiments.

[0016] Figure 3 is a schematic diagram of an isolation system coupled to a sensor, a motor, and a driver according to some embodiments, the isolation system may be Figure 1 Well site as shown and / or Figure 2 used in the system shown.

[0017] Figure 4 According to some embodiments Figure 3 A more detailed schematic diagram of the isolation system is shown.

[0018] Figure 5 According to some embodiments Figure 3A more detailed schematic diagram of the isolation system is shown. DETAILED DESCRIPTION

[0019] Before turning to the drawings showing certain exemplary embodiments in detail, it should be understood that the present disclosure is not limited to the details or methods set forth in the specification or shown in the drawings. It should also be understood that the terminology used herein is for descriptive purposes only and should not be considered as limiting.

[0020] The present disclosure relates to pump systems, including but not limited to downhole pump systems, reciprocating pump systems such as rod pump systems, submersible pump systems, motors on well sites, and other electrical systems. In some embodiments, systems and methods are used to isolate higher power or higher voltage systems from lower power or lower voltage systems without bulky and expensive isolation components. In some embodiments, isolation for measurement and / or data acquisition equipment is achieved. In some embodiments, systems and methods avoid the potentially destructive saturation effects of coupling transformers with direct current (DC) content and / or high voltage frequency (volts / hertz (V / Hz)) ratios. In some embodiments, data acquisition uses an attenuator on the secondary high voltage side. The digital side of the data acquisition unit is not affected by voltage attenuation or transformer magnetizing current. Systems and methods enable better evaluation of the leakage of cables or motors to ground formed by zero-sequence voltage for quantitative symmetry of phase voltages to ground (e.g., earth).

[0021] In some embodiments, isolated systems and methods enable more types of measurements and more accurate measurements with less cost and without the risk of saturation associated with high V / Hz ratios or DC content. An apparatus provides a cost effective solution for proper high voltage isolation with little or no performance degradation over analog acquisition.

[0022] Reference Figure 1 , the well site 10 includes a pump 20, a controller 22, an electric transformer 24 and a wellhead 26. The produced fluid 12 is pumped to the wellhead 26 by the pump 20. The pump 20 can be one or more electric submersible pumps (ESP), each of which includes a motor controlled by a variable speed drive in the controller 22. The variable speed drive adjusts the output of the pump 20 by controlling the speed of the motor via a signal to the armature, rotor / stator or other windings of the motor. In some embodiments, the motor is a two-pole, three-phase induction motor. The controller 22 can also include a user interface or a computer to provide various settings for well site operations. Although shown as an underground pump, in some embodiments the pump 20 can be any type of pump or motor system.

[0023] The power transformer 24 provides power (e.g., voltage and current for a variable speed drive). The controller 22 includes circuits and components that can protect components of the well site 10 by cutting off power without maintaining normal operating limits. The power cable 32 provides electrical signals to one or more motors through an armored insulated conductor. The power cable 32 is circular except for a flat portion along one or more ESPSs and a motor protector (in some embodiments, where space is limited). In some embodiments, the motor protector connects the pump 20 to the motor and isolates the motor from the produced fluid and other well fluids. In some embodiments, the motor protector acts as an oil reservoir and balances the pressure between the wellbore and the well casing or pipe casing annulus 48 and allows for expansion and / or contraction of the motor oil.

[0024] In some embodiments, the pump housing 34 for the pump 20 includes a multi-stage rotating impeller and a fixed diffuser. The number of stages (e.g., centrifugal stages) is related to the rate, pressure, and power required, and can be any number from 1 to n, depending on the design criteria and well site parameters. A gas separator 42 can be used to separate some free gas from the produced fluid into the pipe casing annulus 48 by fluid reversal or a rotating centrifuge before the gas enters the pump 20. The inlet of the pump 20 allows the fluid to enter the pump 20 and can be part of the gas separator 42. In some embodiments, the well site 10 is used for cased wells or open wells. For example, a partially cased well can include one or more open well sections. An annular space can exist between the outer surface of the pipe casing annulus 48 and the pump 20.

[0025] Now refer to Figure 2 , shows a pump system 100 according to some embodiments. The pump system 100 can be used in a well site 10 ( Figure 1 ). The system 100 includes a pump assembly 101 driven by a pump drive system 104, which is operably coupled to a controller 122. For example, the pump assembly 101 and the drive system 104 can be arranged as a beam pump. In some embodiments, the system 100 also includes a walking beam 138 that reciprocates a rod string 144. The rod string 144 can include a light rod portion 146 that can move in a hole of a stuffing box 150 of a wellhead assembly, which includes a discharge port in fluid communication with a flow line 152. The rod string 144 can be suspended from the walking beam 138 via one or more cables 142 suspended from a donkey head 140 for actuating a downhole pump 110 of the pump assembly 101, wherein the downhole pump 110 is positioned in a well 102. For example, the well 102 can be in an underground environment, and the downhole pump 110 can be positioned near the bottom 112 of the well 102.

[0026] In some embodiments, well 102 may be a cased well or an open well. For example, a partially cased well may include one or more open well sections. Figure 2 As shown, the well 102 includes a casing 106 defining a casing bore, wherein a tubing 108 is disposed in the casing bore. An annular space may exist between an outer surface of the tubing 108 and an inner surface of the casing 106.

[0027] In some embodiments, the walking beam 138 is actuated by a link arm (or multiple link arms) that reciprocates through a crank arm (or multiple crank arms) 134 driven by a prime mover 130 (e.g., an electric motor, etc.). For example, the prime mover 130 can be coupled to the crank arm 134 through a gear reduction mechanism such as gears of a gearbox 132. In some cases, the prime mover 130 is a three-phase AC induction motor that can be controlled via a circuit system of a controller 122 that can be connected to a power source. The gearbox 132 of the pump drive system 104 can convert the motor torque into a low-speed, high-torque output for driving the crank arm 134. The crank arm 134 can be operably coupled to one or more counterweights that are used to balance the rod column 144 and other equipment suspended from the donkey head 140 of the walking beam 138. The balance can be provided by a cylinder, such as those on an air balance unit.

[0028] In some embodiments, the downhole pump 110 is a reciprocating type pump that includes a plunger 116 attached to the end of a rod string 144 and a pump barrel 114 that can be attached to the end of a pipe 108 in the well 102. The plunger 116 can include a traveling valve 118 and a fixed valve 120 located at or near the bottom of the pump barrel 114. During operation, for an upstroke in which the rod string 144 translates upward, the traveling valve 118 can close and lift the fluid (e.g., oil, water, etc.) above the plunger 116 to the top of the well 102, and the fixed valve 120 can open to allow additional fluid from a reservoir to flow into the pump barrel 114. On a downstroke in which the rod string 144 translates downward, the traveling valve 118 can open and the fixed valve 120 can close to prepare for a subsequent cycle. Operation of the downhole pump 110 may be controlled so that a fluid level is maintained in the pump barrel 114, wherein the fluid level may be sufficient to maintain the lower end of the rod string 144 in fluid throughout its stroke.

[0029] As an example, the prime mover can be an electric motor that provides power to the pumping unit. As an example, the prime mover can transmit high-speed, low-torque power to a gear reducer that converts the energy into low-speed, high-torque energy that is utilized by the surface pump. Figure 2 As shown, a beam pumping unit, beam pump system, or just beam pump, converts the rotary motion of a prime mover into a reciprocating vertical motion that raises and lowers a rod connected to a subsurface pump.

[0030] Reference Figure 3 , the system 300 may be a well site 10 ( Figure 1 ) or part of the pumping system 100. Although the system 300 is particularly advantageous when used with underground motors for pumps where sensor placement is more difficult, the system 300 can be used with motors that are placed above the ground, such as the motor in the system 100. The system 300 can be used in various oil processing systems, mines, industrial systems, etc. In some embodiments, the system 300 is used with water pumps, geothermal power generation and heating, etc. Downhole pumps in the water industry, waste treatment industry, mine dewatering, geothermal power plants, etc. can be used with the system 300.

[0031] System 300 includes an electric drive 302, a transformer 304, a current sensor system 306, a motor 308, and a data acquisition system 310. System 300 can be part of a lifting system. In some embodiments, system 300 is configured to provide isolation for electrical surface power measurement and perform condition monitoring. In some embodiments, system 300 provides analog signal acquisition (e.g., voltage and current measurement acquisition). In some embodiments, system 300 can be part of a Powerdaq and / or HCC2 controller manufactured by Sensia LLC. The HCC2 controller can include analog acquisition hardware and software.

[0032] The electric drive 302 is any type of power source for powering components associated with the system 300. The electric drive 302 can be a high voltage drive. In some embodiments, the drive 302 provides two-phase or three-phase alternating current (AC) power on a cable 322 (e.g., two or more conductor cables). In some embodiments, the cable 322 can be coupled to the motor 308. Electric drive can refer to a system that uses electricity to propel machinery or control various mechanical / electrical processes. The electric drive 302 can include power electronics, transformers, converters, energy storage, and control systems.

[0033] The electric drive 302 is coupled to a transformer 304. The transformer 304 is optional. The transformer 304 can be a step-up or step-down transformer. The transformer 304 receives power from the drive 302 and transforms the power to a different level on a cable 324 coupled to the motor 308. The cable 324 is similar to the cable 322. In some embodiments, the power from the transformer 304 is three-phase alternating current (AC). In some embodiments, the cable 322 is directly or indirectly coupled to the motor 308 without the transformer 304.

[0034] Cables 324 and 322 include a shield 312 coupled to an earth ground 316 (e.g., a structure coupled to the earth, a platform, a chassis, etc.). Impedance 318 is between the earth ground 316 and the shield 312 (e.g., an armor ground 313). In some embodiments, impedance 319 is between the earth ground 316 and the conductor 314 coupled to a digital ground or DGND 315. In some embodiments, the earth ground 316 is a contact point where a conductor coupled to DGND 15 and a cable coupled to armor ground 313 are connected. Impedances 318 and 319 generally represent nominal impedances associated with the connection to the earth ground 316. In some embodiments, the shield 312 is isolated from the conductor 314.

[0035] The motor 308 is any type of electrical device. The motor 308 can be a solenoid, an induction motor, an AC motor, a DC motor, a linear motor, or other devices for converting electrical energy into motion or force. In some embodiments, the motor 308 is a two-phase or three-phase motor. Depending on the system and application, the motor 308 can receive a signal with a specific voltage level, waveform, and frequency. In some embodiments, the voltage signal is a sinusoidal signal of 208 volts, 230 volts, 460 volts, and / or 575 volts. The selection of appropriate voltage depends on factors such as the power requirements of the motor, the type of driven machinery, and the overall electrical infrastructure. Lower voltage systems such as 208V and 230V systems are generally suitable for smaller motors and applications with medium power requirements, while higher voltage levels such as 460V and 575V are used for larger motors.

[0036] The current sensor system 306 includes one or more sensors configured to sense current provided through the cable 324 or the cable 322. In some embodiments, the current sensor system 306 includes three current isolation sensors for measuring the current I associated with the motor 308 in some embodiments. A ,I B and I C In some embodiments, the current isolation sensor is a current transformer (CT) sensor including a primary and a secondary to isolate the signal. Other types of sensors may be used for the current sensor system 306. The indicated current I is provided to the data acquisition system 310. A ,I B and I C The sensor signal, wherein in some embodiments, the current I A , I B and I C Indicates the three phases of the motor current.

[0037] In some embodiments, a current isolation sensor refers to any device that utilizes isolation to provide a signal related to the measurement of frequency and / or amplitude. In some embodiments, the current sensor system 306 measures and monitors current without direct electrical contact between the sensing element and the conductor carrying the current. Isolation can be achieved through various techniques such as magnetic coupling or optical isolation.

[0038] The data acquisition system 310 is configured to provide insulation or isolation for circuitry associated with capturing parameters in the environment of the system 300. The data acquisition system 310 includes circuitry for providing isolation and circuitry for receiving and / or processing measurements. In some embodiments, the circuitry associated with digitally processing measurements uses a voltage referenced to a digital ground (DGND) 315, which is provided using a conductor 314. In some embodiments, the circuitry associated with receiving measurements uses a voltage referenced to an armor ground 313. The data acquisition system 310 may include or be coupled to a computing device (e.g., an edge controller) for processing measurements and providing analysis and control, and may include or be coupled to a communication device for communicating with a user, cloud, network, or other server. In some embodiments, the data acquisition system 310 may be a digital system powered by an isolated power supply.

[0039] In some embodiments, the data acquisition system 310 is configured to monitor the electrical surface power quality, which may be an important task in oilfield applications. The measurements of the data acquisition system 310 can be used to determine the grid power quality and the integrity of the equipment. For example, the electrical load measurements associated with the operation of the motor 308 can provide valuable information of the overall system (e.g., the health and operating conditions of the motor and pump). The data acquisition system 310 provides high frequency (e.g., greater than 5khz) acquisition of all motor phase voltages and currents. Typically, regardless of the drive type of the drive 302, the sensor needs to withstand a root mean square (Vrms) phase-to-phase voltage of 5000 volts. In some embodiments, the data acquisition system 310 provides digital isolation for acquisition on the high voltage side without sacrificing performance or reducing range.

[0040] In some embodiments, the three-phase voltage signal V A 、V B and V CRepresents the three phases of voltage provided to the motor 308 (e.g., three motor phases via cables 324 and / or 322). In some embodiments, the measurement is floating relative to earth ground 316. The phase voltage relative to shield 312 (e.g., armor ground 313) is implicitly defined by the parasitic capacitance and leakage between the phase voltage signal and the shield 312. With symmetrical motors, cables, and other optional equipment, the phase voltage is symmetrical about the armor ground 313 associated with the shield 312. The shield 312 acts as a shield or isolator and is at the potential of the armor ground 313. In some embodiments, the potential of DGND 315 does not have to be completely isolated, and DGND 315 and armor ground 313 can share a reference point (e.g., earth ground 316). In some embodiments, the digital isolation low voltage (referenced to DGND potential) of the edge controller associated with the data acquisition system 310 and the driver or transformer housing (referenced to armor ground 313) are coupled to earth ground 316, except for negligible impedances 318 (e.g., Z1_earth) and 319 (Z2_earth). Isolation by the data acquisition system 310 prevents the high voltage phase voltage signal V A 、V B and V C A direct return current path through conductor 314 (DGND 315) back to earth ground 316. A high voltage isolator circuit, either alone or as part of the data acquisition system 310, can provide the isolation.

[0041] Various sensors may be provided as part of the system 200. In some embodiments, the sensors may be connected to or as part of the data acquisition system 310. Current, voltage, speed, torque, pressure, power, position, frequency, and load sensors may be provided in some embodiments. For example, the position sensor may include an inclinometer, a proximity switch (e.g., a Hall effect sensor), etc., and the load sensor may include a load sensor, a current sensor, and a beam transducer, etc. Such sensors may be operably coupled to the controller (e.g., via a wire and / or wirelessly through a wireless circuit system). As an example, the load sensor may be a loadable dynamometer attached to the light rod for acquiring dynamic data, which may be sent and / or otherwise accessed by one or more pieces of equipment. The controller may utilize the sensor data to calculate the rod load (e.g., ground conditions) and couple with various models (e.g., algorithms) to estimate downhole pump filling (e.g., downhole conditions). The sensed parameters enable diagnosis of various conditions including, but not limited to, gas disturbances, liquid fluid shock severity and gas disturbances, system leaks, stuck pumps, cracked rods, and various other abnormal or operating conditions using a dynamometer. The systems and methods described herein may provide an advantageous solution for providing isolation and improved accuracy of monitored variables for one-dimensional, two-dimensional, and / or three-dimensional models of the Gibbs wave equation.

[0042] The system 300 may implement one or more offline techniques and / or online or real-time techniques to control equipment at the wellsite 10 in response to monitored parameters. The system 300 may be configured to estimate or predict values ​​of relatively more difficult to measure variables such as gas content, inlet pressure, damping, etc. It should be understood that these specific variables are presented as examples and should not be construed as limiting.

[0043] Reference Figure 4 , System 300( Figure 3 ) includes a data acquisition system 310 coupled to a controller 417. The controller 417 includes digital hardware and a microprocessor or other computing device. The controller 417 can be an edge controller coupled to the DGND potential and can be part of the data acquisition system 310 or separate from the data acquisition system 310.

[0044] The data acquisition system 310 includes an attenuator circuit or attenuator 404, an analog-to-digital converter 406, a power isolation circuit 412, and a power isolation circuit 410. In some embodiments, the attenuator 404, the power isolation circuit 410, the power isolation circuit 412, and the converter 406 use a voltage referenced to the armor ground 313. In some embodiments, the controller 417, the power isolation circuit 410, and the power isolation circuit 412 use a voltage referenced to the armor ground 313. Figure 3 ) voltage.

[0045] Cable 322 or 324 receives one or more high voltage phase voltage signals V A 、V B and V C . The power isolation circuit 410 provides power to the current sensor system 306, the power isolation circuit 412, and the converter 406. The power isolation circuit 412 is coupled between the controller 417 and the converter 406. The converter 406 converts the analog current sensing signal from the current sensor system 306 into a current sensing signal in digital form. The current sensing signal in digital form is provided to the controller 417 through the power isolation circuit 412. In some embodiments, the current measurement is performed using full high voltage isolation. In some embodiments, the power isolation circuit 412 can be an optical isolation circuit.

[0046] In some embodiments, the attenuator 404 reduces the peak voltage isolation requirement. The attenuator 404 may be used to reduce the peak voltage isolation requirement associated with one or more high voltage phase voltage signals V A 、V B and V C In some embodiments, the attenuator 404 can include an impedance network. In some embodiments, the attenuator 404 prevents exposure to higher voltages due to single point failures in electrical insulation. For example, when the shield 312 ( Figure 3 ), the phase voltage is brought to armor potential or armor ground 313. In some embodiments, since even with respect to earth ground 316 ( Figure 3 )'s phase voltage potential changes, the phase-to-phase voltage remains the same, so the individual motors 308 can still operate without any optional integrated local downhole motor low voltage measurement.

[0047] Reference Figure 5 , the data acquisition unit or system 310 can be provided in a module. The data acquisition system 310 includes a converter 416, a power isolation circuit 410, an attenuator 404 and an isolation circuit 412. The isolation circuit 412 includes a reference armor ground 313 (relative to the driver 302 ( Figure 3 ) floating), and a second side 532 for receivers and transmitters and other circuitry referenced to DGND 315. An isolation circuit 536 (e.g., an optical or magnetic coupling type isolation device) separates the first side 530 from the second side 532. High voltage and current are prevented from going from the first side 530 to the second side 532.

[0048] The power isolation circuit 410 includes an isolated AC-DC power supply 510, an isolated low voltage power supply 512, and an isolated low voltage power supply 514. The isolated AC-DC power supply 510 provides power (e.g., 12 VDC, 5 VDC, etc.) to the sensor system 306 on conductor 506 referenced to armor ground 313, and the isolated low voltage power supply 512 provides power (e.g., 12 VDC, 5 VDC, etc.) to the converter 416 and the side 530 of the isolation circuit 412 on conductors 508 and 509 referenced to armor ground 313. The isolated low voltage power supply 514 provides power (e.g., 12 VDC, 5 VDC, etc.) to the controller 417 and the side 532 of the isolation circuit 412 on conductor 516 referenced to DGND.

[0049] The attenuator 404 includes a resistor or other impedance element, and an amplifier. The attenuator 404 provides the phase voltage sense signal from the amplifier as a differential signal. In some embodiments, the resistor and the amplifier (e.g., an operational amplifier) ​​are arranged close to the side 530 of the isolation circuit 412. The resistor in the attenuator 404 is used to reduce the difference with the high voltage phase voltage signal V A 、V B and V C The converter 416 operates on a high voltage potential referenced to the armor ground 313 , without such a potential crossing the isolation circuit 412 to the second side 532 .

[0050] In some embodiments, voltage isolation can be achieved by an analog isolation amplifier, where the converter 416 is located at a low voltage potential, thereby eliminating the need for digital isolation of the ADC, or the converter 416 is located at the armor ground 313, and then the ADC digital interface connected to the controller 417 and the digital hardware is isolated. The isolation circuit 412 can provide digital isolation. However, analog isolation amplifiers perform poorly in almost all performance aspects (gain accuracy, drift, frequency response, and noise). The controller can be used in an EDGE controller environment, but can also be used to some extent in other applications.

[0051] In some embodiments, the current and voltage measurements are synchronized. By using a converter 416 with simultaneous multi-channel acquisition, the current and voltage measurements can be synchronized. Therefore, even if the current sensor system 306 can also be directly connected to the low voltage DGND potential, the isolated current sensor signal is also acquired using the armor ground 313. In some embodiments, the armor ground 313 is coupled to the earth ground 316 as a reference point, and the DGND 315 is coupled to the earth ground 316 as a reference point. In some embodiments, the earth ground 316 does not carry any current. In some embodiments, the converter 416 is a pair of converters, one for current sensing signals and one for voltage sensing signals. Both converters are referenced to the armor ground 313.

[0052] Configuration of the exemplary embodiment

[0053] As used herein, the terms "approximately," "about," "substantially," and similar terms are intended to have a broad meaning consistent with the common and accepted usage by those of ordinary skill in the art to which the subject matter of the present disclosure belongs. It should be understood by those skilled in the art reading the present disclosure that these terms are intended to allow description of certain features described and claimed without limiting the scope of these features to the precise numerical ranges provided. Therefore, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or changes to the subject matter described and claimed are considered to be within the scope of the present disclosure set forth in the appended claims.

[0054] It should be noted that the term "exemplary" and variations thereof as used herein to describe various embodiments are intended to indicate that such embodiments are possible examples, representations, or illustrations of possible embodiments (and such terms are not intended to imply that such embodiments are necessarily unusual or best examples).

[0055] The term "coupling" and its variants used herein mean that two components are directly or indirectly engaged with each other. Such engagement can be immovable (i.e., permanent or fixed) or movable (i.e., removable or releasable). Such engagement can be achieved in the following ways: two components are directly coupled to each other, two components are coupled to each other using a separate intermediate component and any additional intermediate components that are coupled to each other, or two components are coupled to each other using an intermediate component that is integrally formed into a single integral body with one of the two components. If "coupling" or its variants are modified by additional terms (i.e., direct coupling), the general definition of "coupling" provided above is modified by the colloquial language meaning of the additional terms (i.e., "direct coupling" means that two components are engaged without any separate intermediate component), resulting in a narrower definition than the general definition of "coupling" provided above. Such coupling can be mechanical, electrical or fluid.

[0056] As used herein, the term "or" is used in its inclusive sense (rather than in its exclusive sense), such that when used to connect a list of elements, the term "or" means one, some, or all of the elements in the list. Unless otherwise specifically stated, connective language such as the phrase "at least one of X, Y, and Z" is understood to express that the element can be: any one of X, Y, Z; X and Y; X and Z; Y and Z; or X, Y, and Z (i.e., any combination of X, Y, and Z). Therefore, unless otherwise specified, such connective language is generally not intended to imply that certain embodiments require that at least one of X, at least one of Y, and at least one of Z each be present.

[0057] References herein to the position of elements (i.e., "top," "bottom," "above," "below") are only used to describe the orientation of the various elements in the drawings. It should be noted that according to other exemplary embodiments, the orientation of the various elements may be different, and such variations are intended to be encompassed by the present disclosure.

[0058] Although the drawings and description may illustrate a particular order of method steps, the order of such steps may differ from the order depicted and described, unless otherwise specified above. Two or more steps may also be performed simultaneously or partially simultaneously, unless otherwise specified above. Such variations may depend, for example, on the software and hardware systems selected and the designer's choice. All such variations are within the scope of the present disclosure.

[0059] It is important to note that the construction and arrangement of the devices shown in the various exemplary embodiments are illustrative only. In addition, any element disclosed in one embodiment may be combined or used with any other embodiment disclosed herein. Although only one example of an element from one embodiment that may be combined or used in another embodiment is described above, it should be appreciated that other elements of the various embodiments may be combined or used in any other embodiment disclosed herein.

[0060] Furthermore, the following configurations also fall within the technical scope of the present disclosure.

[0061] (1) A pump system for a well site, the pump system comprising:

[0062] A data acquisition unit configured to receive a current sensing signal associated with a motor and a phase voltage power sensing signal associated with the motor, the data acquisition unit comprising an isolation circuit having a first side referenced to a first ground and a second side coupled to an attenuator circuit and referenced to a second ground, wherein the first ground is isolated from the second ground, wherein the phase voltage power signal is provided to the attenuator circuit, and wherein the attenuator circuit provides the phase voltage sensing signal.

[0063] (2) The system of (1), further comprising an isolated power supply referenced to the first ground and configured to provide a first power to the first side.

[0064] (3) The system of (1), further comprising a first power source referenced to the second ground and configured to provide power to the second side.

[0065] (4) The system of (2), further comprising a first power source referenced to the second ground and configured to provide power to the second side.

[0066] (5) The system of (1), wherein the attenuator circuit includes an impedance network, and the phase voltage power signal is provided to the impedance network.

[0067] (6) The system of (5), wherein the attenuator circuit comprises an amplifier coupled to the impedance network, wherein the amplifier is coupled to an analog-to-digital converter.

[0068] (7) The system of (6), wherein the isolation circuit is provided between a controller and the analog-to-digital converter.

[0069] (8) The system according to (1), further comprising:

[0070] A current sensor is configured to provide the current sense signal, the current sensor being referenced to the second ground.

[0071] (9) A digital acquisition unit for high voltage applications, comprising:

[0072] a first analog-to-digital converter configured to receive a current sensing signal associated with the phase voltage power signal and coupled to a first ground;

[0073] a second analog-to-digital converter configured to receive a voltage sensing signal related to the phase voltage power signal and coupled to the first ground; and

[0074] an attenuator circuit coupled to the first ground, wherein the first ground is isolated from a second ground, wherein the phase voltage power signal is provided to the attenuator circuit, and wherein the attenuator circuit provides a phase voltage sense signal to the first analog-to-digital converter; and

[0075] An isolation circuit has a first side referenced to the first ground and a second side referenced to the second ground, wherein the second side is coupled to the first analog-to-digital converter and the second analog-to-digital converter.

[0076] (10) The digital acquisition unit according to (9), further comprising an isolated power supply coupled to the first ground and configured to provide the first power to the first analog-to-digital converter.

[0077] (11) According to the digital acquisition unit of (10), a first power supply is coupled to the second ground and is configured to provide power to the second side.

[0078] (12) The digital acquisition unit according to (9), wherein the first ground and the second ground are coupled to an earth ground.

[0079] (13) The digital acquisition unit according to (9), wherein the attenuator circuit includes an impedance network, and the phase voltage power signal is provided to the impedance network.

[0080] (14) The digital acquisition unit of (12), wherein the attenuator circuit comprises an amplifier coupled to an impedance network, wherein the amplifier is coupled to the second analog-to-digital converter.

[0081] (15) The digital acquisition unit according to (9), further comprising:

[0082] A current sensor is configured to provide the current sense signal.

[0083] (16) A method of providing measurements to a controller, the method comprising:

[0084] receiving, by a data acquisition unit, a current sensing signal associated with the motor; and

[0085] A phase voltage sensing signal associated with a phase voltage power signal for the motor is received by the data acquisition unit, the data acquisition unit comprising a module coupled to a first ground and an attenuator circuit coupled to a second ground, wherein the first ground is isolated from the second ground, wherein the phase voltage power signal is provided to the attenuator circuit, and wherein the attenuator circuit provides the phase voltage sensing signal to the module.

[0086] (17) The method according to (16), further comprising:

[0087] The module is powered using an isolated power supply coupled to the first ground and configured to provide a first power to the module.

[0088] (18) The method according to (16), further comprising:

[0089] An analog-to-digital converter coupled to receive the phase voltage sensing signal is powered using a first power supply, the first power supply being coupled to the second ground and configured to provide a second power to the analog-to-digital converter.

[0090] (19) The method according to (17), further comprising:

[0091] An analog-to-digital converter coupled to receive the phase voltage sensing signal is powered using a first power supply, the first power supply being coupled to the second ground and configured to provide a second power to the analog-to-digital converter.

[0092] (20) The method of (16), wherein the attenuator circuit comprises an amplifier coupled to an impedance network, wherein the amplifier is coupled to an analog-to-digital converter in the module.

Claims

1. A pump system for a well site, the pump system comprising: A data acquisition unit is configured to receive a current sensing signal associated with a motor and a phase voltage power signal associated with the motor, the data acquisition unit comprising a module coupled to a first ground and an attenuator circuit coupled to a second ground, wherein the first ground is isolated from the second ground, wherein the phase voltage power signal is provided to the attenuator circuit, and wherein the attenuator circuit provides the phase voltage sensing signal to the module. 2 . The system of claim 1 , further comprising an isolated power supply coupled to the first ground and configured to provide a first power to the module. 3 . The system of claim 1 , further comprising a first power supply coupled to the second ground and configured to provide power to the attenuator circuit. 4 . The system of claim 1 , further comprising a first power supply coupled to the second ground and configured to provide power to the attenuator circuit.

5. The system according to claim 1 or 2, wherein: The attenuator circuit includes an impedance network, and the phase voltage power signal is provided to the impedance network.

6. The system according to claim 5, wherein: The attenuator circuit includes an amplifier coupled to the impedance network, wherein the amplifier is coupled to an analog-to-digital converter in the module.

7. The system according to claim 6, wherein: The module includes isolation circuitry between a controller and the analog-to-digital converter.

8. The system according to claim 1 or 2, further comprising: A current sensor is configured to provide the current sense signal.

9. A method of providing measurements to a controller, the method comprising: receiving, by a data acquisition unit, a current sensing signal associated with the motor; as well as A phase voltage sensing signal associated with a phase voltage power signal for the motor is received by the data acquisition unit, wherein the data acquisition unit includes a module coupled to a first ground and an attenuator circuit coupled to a second ground, wherein the first ground is isolated from the second ground, wherein the phase voltage power signal is provided to the attenuator circuit, and wherein the attenuator circuit provides the phase voltage sensing signal to the module.

10. The method according to claim 9, further comprising: The module is powered using an isolated power supply coupled to the first ground and configured to provide a first power to the module.

Images