Beam Pump Diagnostics via Multi-Physics Sensor Fusion
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Solution Overview
Problem
Beam pumps in oil wells face inefficiencies and diagnostic challenges, leading to potential well shutdowns, lost production, and health, safety, and environmental issues due to delayed equipment diagnostics.
Innovation Solution
A method and system utilizing acoustic sensors, strain gauges, gyroscopes, and accelerometers to collect and analyze data from beam pump units, converting analog signals to digital and transmitting them for external processing to detect operational issues, employing machine learning algorithms to diagnose problems such as motor, gearbox, or polished rod issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional diagnostic methods are used for beam pumps, then device complexity is reduced, but diagnostic precision and reliability deteriorate leading to delayed issue detection
Solution Approach 1:
The patent combines multiple diagnostic sensors (acoustic, vibration, temperature, current) into an integrated monitoring system that collects data from multiple sources simultaneously. This merging of sensing capabilities enables comprehensive diagnostics without requiring separate standalone systems, thus improving diagnostic precision while managing complexity through integration.
Solution Approach 2:
The diagnostic system is designed to detect multiple types of operational issues (motor problems, gearbox failures, polished rod issues, operational conditions) using a single multi-functional platform. The system can identify various failure modes and operational states through unified data processing, eliminating the need for multiple specialized diagnostic devices.
2Productivity
If real-time monitoring is implemented, then productivity is improved through early issue detection, but loss of time for data processing and analysis increases
Solution Approach 1:
The system performs preliminary data processing and anomaly detection directly at the sensor level and edge computing devices. By pre-processing data locally and identifying patterns before full analysis, the system reduces the time required for centralized processing while maintaining real-time monitoring capabilities and enabling rapid response to issues.
Solution Approach 2:
The diagnostic system implements continuous feedback loops where detected anomalies trigger immediate alerts and automated responses. The system provides real-time feedback on pump health status, enabling operators to take corrective actions before minor issues escalate into major failures, thus maintaining productivity without excessive processing delays.
3Reliability
If multiple sensors are deployed for comprehensive monitoring, then reliability of diagnosis is improved, but device complexity and cost increase
Solution Approach 1:
The monitoring system is segmented into modular components distributed at different locations (sensors on motor, gearbox, polished rod; edge computing devices; centralized platform). Each segment performs specific functions independently, and results are aggregated for comprehensive diagnostics. This segmentation improves reliability through distributed sensing while managing complexity through modular architecture.
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
Enhances the ability to identify and address operational issues in beam pumps, reducing unplanned downtimes, increasing hydrocarbon production, and improving long-term oil well profitability by enabling real-time monitoring and predictive maintenance.
Implementation Method 1
A sensor system includes a first acoustic sensor coupled to a polished rod of a beam pump unit and configured to measure first acoustic signals
Implementation Method 2
The sensor system includes a strain gauge coupled to a polished rod of the beam pump unit and configured to measure strain data
Implementation Method 3
The sensor system includes a gyroscope coupled to a polished rod of the beam pump unit and configured to measure gyroscopic data
Implementation Method 4
The sensor system includes an accelerometer coupled to a polished rod of the beam pump unit and configured to measure acceleration data
Data Source
AI summary
A method includes receiving acoustic signals from one or more acoustic sensors that are coupled to a beam pump unit. The method also includes identifying a frequency of the beam pump unit in the acoustic signals. The method also includes detecting an outlier in the acoustic signals based at least partially upon the identified frequency. The outlier represents an operational issue with the beam pump unit.