Downhole Dynamometer Diagnostics for Automated Pump Fillage
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Solution Overview
Problem
Existing methods for determining pump fillage in reciprocating rod lift systems rely heavily on human interpretation of graphical dynamometer data, leading to inaccuracies and inefficiencies, especially when dealing with diverse well conditions and large numbers of wells, making it difficult to accurately monitor and control pump operations.
Innovation Solution
A method that involves measuring downhole data during a pump cycle, converting it into non-dimensional data points, calculating non-dimensional slope values, and using these values to determine pump fillage, thereby reducing reliance on human interpretation and improving accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If human interpretation of graphical dynamometer data is used to determine pump fillage, then flexibility in handling diverse well conditions is maintained, but accuracy and efficiency deteriorate due to subjectivity and time consumption
Solution Approach 1:
The patent replaces the manual visual interpretation method (mechanical human analysis) with an automated computer-based system that processes dynamometer card data through algorithms to determine pump fillage parameters, thereby eliminating subjectivity and reducing time loss
Solution Approach 2:
The system enables self-service by allowing the computer to automatically analyze the dynamometer card data and generate pump fillage determinations without requiring human intervention, making the process both faster and more consistent
2Measurement precision
If traditional dynamometer card analysis methods are used, then existing equipment can be utilized, but measurement precision deteriorates due to difficulty in predicting card shape, orientation, and span
Solution Approach 1:
The patent transforms the dynamometer card data into non-dimensional parameters, changing the representation from absolute values dependent on specific well conditions to normalized values that are universally comparable, thereby simplifying the detection and measurement process while improving precision
Solution Approach 2:
The automated computer-based analysis system replaces the difficult manual assessment of card shape, orientation, and span with algorithmic processing that objectively determines pump fillage parameters from the dynamometer card data
3Productivity
If manual methods are used to monitor and control pump operations, then system complexity remains low, but productivity deteriorates due to inefficiency in handling large numbers of wells
Solution Approach 1:
The patent creates a universal computer-based system that can handle multiple wells and various pump fillage conditions through a single automated platform, thereby dramatically improving productivity across large numbers of wells while the added complexity is justified by the scale of operation
Data Source
AI summary
Techniques and apparatus are provided for improved diagnostics of downhole dynamometer data for control and troubleshooting of reciprocating rod lift systems. A method for pump fillage determination for a reciprocating rod lift system is provided. The method generally includes measuring downhole data during a pump cycle, wherein the downhole data comprises a first plurality of data points associated with an upstroke of the pump cycle and a second plurality of data points associated with a downstroke of the pump cycle, each data point comprising a rod position value and an associated rod load value; converting the data points to non-dimensional data points, calculating non-dimensional slope values between non-dimensional data points; and determining pump fillage based, at least part, on the calculated non-dimensional slope values.