Adaptive Control for Surface Hydraulic Pumping Systems
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Solution Overview
Problem
Current artificial lift systems for oil and gas wells face challenges in optimizing production efficiency, durability, and safety due to difficulties in real-time control of rod lifting systems, which often require operator intervention and are prone to premature failure and high maintenance costs.
Innovation Solution
A surface-mounted hydraulic lift system with a closed-loop adaptive control system that uses a computer, sensors, and algorithms to continuously monitor and control the position, velocity, and acceleration of the rod lifting system, optimizing stroking length and speed, and mitigating hazardous conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional beam pump with fixed stroke length is used, then structural simplicity is maintained, but production efficiency cannot be optimized under varying well conditions
Solution Approach 1:
The patent applies dynamics by making the stroke length adjustable rather than fixed. The system dynamically adapts the stroke length based on real-time well conditions monitored by sensors, allowing optimization of production efficiency under varying reservoir pressure and fluid characteristics while maintaining manageable control complexity through automated adjustment mechanisms.
Solution Approach 2:
The patent implements parameter changes by varying the stroke length parameter in response to changing well conditions. Sensors monitor parameters such as reservoir pressure, fluid density, and flow rate, and the control system adjusts the stroke length parameter accordingly to maintain optimal pumping efficiency without requiring complex manual intervention.
2Productivity
If higher pumping speed is used to increase production, then productivity improves, but pumped off conditions cause equipment overstressing and premature failure
Solution Approach 1:
The patent applies feedback by using sensors to continuously monitor pumping conditions and system performance. The control system receives real-time data on fluid levels, pressure, and equipment stress, and automatically adjusts pumping speed and stroke length to maintain optimal production while preventing pumped off conditions that would cause equipment overstressing and premature failure.
Solution Approach 2:
The system dynamically adjusts pumping speed based on real-time well conditions rather than operating at a fixed high speed. This dynamic control allows the system to maximize production capacity when conditions permit while reducing speed to prevent equipment stress and ensure reliability when approaching operational limits.
3Productivity
If operator intervention is required to adjust pumping parameters, then system simplicity is maintained, but production optimization is limited and response time is delayed
Solution Approach 1:
The patent implements self-service by enabling the pumping system to automatically monitor and adjust its own operating parameters. Sensors continuously collect data on well conditions and equipment performance, and the control system autonomously optimizes pumping parameters without requiring operator intervention, thereby achieving production optimization with immediate response time.
Solution Approach 2:
The feedback mechanism enables the system to self-optimize by continuously monitoring performance and automatically adjusting parameters. Real-time data from sensors on fluid levels, pressure, and equipment status feeds back to the control system, which makes immediate adjustments to maximize production while eliminating the time loss associated with manual operator response.
4Adaptability or versatility
If fixed stroke length is used, then device complexity is minimized, but adaptability to changing well conditions is reduced
Solution Approach 1:
The system transitions from a fixed stroke length to a dynamic, adjustable stroke length that automatically adapts to changing well conditions. Sensors monitor reservoir pressure, fluid characteristics, and equipment status, and the control mechanism adjusts stroke length in real-time to maintain optimal pumping performance across varying conditions without requiring excessive complexity.
Solution Approach 2:
The patent implements adaptability by changing the stroke length parameter in response to varying well conditions. The control system monitors multiple parameters including reservoir pressure and fluid density, and automatically adjusts the stroke length parameter to optimize performance, providing versatility across different operating conditions while keeping the control mechanism relatively simple through automated parameter adjustment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution significantly increases production efficiency, extends equipment longevity, reduces power consumption, and minimizes operator intervention, enabling the system to adapt to changing well conditions and prevent damage, thus enhancing safety and reducing maintenance costs.
Implementation Method 1
a hydraulic pump that supplies hydraulic pressure and flow to a hydraulic cylinder
Implementation Method 2
sensors, including a position sensor that provides a signal corresponding to an instantaneous position of the cylinder piston rod
Implementation Method 3
velocity sensors that provide signals corresponding to velocities of the cylinder piston rod
Implementation Method 4
acceleration sensors that provide signals corresponding to accelerations of the cylinder piston rod
Implementation Method 5
a control unit that processes the sensor signals and controls operation of the hydraulic pump
Data Source
AI summary
The disclosed invention provides intelligent adaptive control for optimization of production output, energy efficiency and safety of a linear reciprocating long stroke hydraulic lift system, for use at the surface of oil and gas wells to extract fluids or gas after free flowing stopped due to natural decline of reservoir pressure.The hydraulic pump and its adaptive control system introduced in this invention are capable of optimizing its production capacity by varying multiple operating parameters, including its stroking length and speed characteristics continuously and instantaneously at any point. Merits and benefits of this invention include significant increase in production efficiency, improved durability and longevity of the pumping equipment, significant power consumption savings and an ability to adapt effectively to changing well conditions.