Programmable Battery Balancing Controller for Remote Pump Jacks
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Solution Overview
Problem
The challenge in oil well pump jacks is maintaining reliable battery service for chemical injection pumps, especially in remote locations with extended periods of low sunlight, which can lead to battery voltage issues and inefficient chemical injection, requiring frequent maintenance and increasing operational costs.
Innovation Solution
A programmable controller system that monitors battery performance, automatically switches between battery power sources, senses high voltages, and communicates potential failures via cell phone, extending battery and equipment life while reducing maintenance costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If solar powered systems are used to power chemical injection pumps, then operational autonomy is improved, but battery voltage reliability deteriorates during extended periods without sunlight
Solution Approach 1:
The system monitors battery voltage parameters and automatically adjusts system operation based on voltage thresholds. When voltage drops below acceptable levels during extended periods without sunlight, the system can alert operators or adjust operational parameters to maintain reliable chemical injection.
2Reliability
If routine maintenance is performed to assure battery performance, then battery reliability is improved, but operational costs and time consumption increase due to frequent travel to remote locations
Solution Approach 1:
The system continuously monitors battery voltage and provides feedback to remote operators via communication systems. This allows operators to respond to actual battery conditions rather than following fixed maintenance schedules, reducing unnecessary travel while ensuring timely intervention when problems arise.
Solution Approach 2:
The monitoring system enables the battery system to essentially monitor and report its own status without requiring constant human oversight. The automated detection and communication of battery issues allows the system to serve its own monitoring needs, reducing the burden of manual maintenance.
3Reliability
If operators periodically travel to test batteries, then battery failure is prevented, but operational costs increase
Solution Approach 1:
The automated monitoring system provides continuous feedback on battery status and communicates with remote operators, eliminating the need for periodic operator travel. This reduces operational costs while maintaining battery reliability through automated detection and alerting.
Solution Approach 2:
The system replaces the mechanical approach of operator travel with electronic monitoring and communication systems. Sensors and communication modules substitute for the physical presence of operators, reducing travel costs while maintaining or improving monitoring effectiveness.
4Loss of energy
If neglected batteries are allowed to fail, then maintenance costs are reduced, but chemical injection failure occurs with concomitant losses in production or efficiency
Solution Approach 1:
The monitoring system provides early warning feedback when batteries show signs of failure, allowing operators to intervene before complete failure occurs. This balances maintenance costs with productivity by addressing issues only when necessary, avoiding both over-maintenance and complete failure.
Data Source
AI summary
The present disclosure provides a programmable controller for monitoring battery performance and usage at a remote pump jack location. The disclosure provides an energy efficient controller and display system which allows the operator to quickly and accurately test batteries in an installation. It uses programmable logic to switch between system modes and decide which battery supplies power to the output. Further it will sense any high voltages at and disable the input from the faulty source. Further, the programmable logic is designed such that the mode selection process is automatic when the system is in operation. The purpose is to elongate battery and connected equipment life by preventing battery failure. The present disclosure also provides an easy and economical method of communicating potential battery failure and status to an operator via cell phone communication.