Downhole Pump Control System for Carbon Capture

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Solution Overview

Problem

Current artificial lift systems for oil and gas production are inefficient due to lack of real-time data analysis, leading to suboptimal pump performance, frequent failures, and environmental issues like natural gas flaring and venting, which compromise system efficiency and increase operating costs.

Innovation Solution

A novel system utilizing real-time data from wells to optimize reservoir performance by adjusting downhole flow regimes, reducing power requirements, and incorporating predictive maintenance, while minimizing gas flaring and venting through a cloud-connected control system that analyzes flow rates and pressures to optimize pump operation and carbon capture.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If intermittent timing cycles are used to operate the pump based on manual clock and timer inputs, then the pump operation can be controlled, but there is no feedback loop to optimize pump and well performance based on real-time data

Engineering Contradiction:
Improvepump operation controlVSAvoidreal-time data feedback
Core Design Contradiction:
Ease of operationVSLoss of information

Solution Approach 1:

The patent implements a feedback loop system that continuously monitors well performance parameters (pressure, temperature, flow rate) and pump operating conditions, then uses this real-time data to automatically adjust pump timing and operation. This resolves the contradiction by providing both ease of operation through automated control and real-time information feedback for optimization, eliminating the need for manual timing while maximizing efficiency.

Inventive Principle:
Principle #23Feedback

2Productivity

If gas enters the pump during production, then the pumping process continues, but pump efficiency decreases and pump life is reduced

Engineering Contradiction:
Improvepumping continuityVSAvoidpump efficiency and life
Core Design Contradiction:
ProductivityVSReliability

Solution Approach 1:

The patent employs dynamic control of pump timing cycles based on real-time monitoring of downhole conditions including gas presence. The system automatically adjusts pump start/stop times, run times, and intervals in response to changing flow regimes and gas conditions. This dynamic adjustment allows the pump to operate efficiently by avoiding gas ingestion when possible while maintaining productivity through continuous adaptive optimization of the pumping schedule.

Inventive Principle:
Principle #15Dynamics

3Object-generated harmful factors

If excess natural gas is vented and flared, then the gas handling problem is resolved, but environmental concerns arise and system efficiency is compromised

Engineering Contradiction:
Improvegas handlingVSAvoidenvironmental impact
Core Design Contradiction:
Object-generated harmful factorsVSObject-affected harmful factors

Solution Approach 1:

The patent converts the harmful effect of excess gas by using it beneficially through several mechanisms: (1) utilizing gas as energy source to power subsurface equipment, (2) injecting gas back into the reservoir to maintain pressure and enhance oil recovery, (3) controlling gas flow to optimize well performance. This approach eliminates the need for venting or flaring, converting what was previously a harmful waste product into a resource that benefits both production efficiency and environmental performance.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

4Productivity

If real-time data analysis is implemented to optimize well production, then pump efficiency and power system performance improve, but system complexity increases

Engineering Contradiction:
Improvewell production optimizationVSAvoiddata analysis system
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The patent implements a self-service control system where the pump and control apparatus autonomously monitor their own operating conditions and automatically adjust timing cycles based on real-time data without requiring external intervention or complex external control systems. The system self-diagnoses performance issues, self-optimizes operation parameters, and maintains efficient pumping through automated feedback loops, thereby achieving productivity improvement without proportionally increasing system complexity.

Inventive Principle:
Principle #25Self-service

Data Source

PatentUS11649705B2Oil and gas well carbon capture system and method
Publication Date: 2023.05.16 BERLAND ROBERT J
  • US11649705B2 patent drawing
  • US11649705B2 patent drawing
  • US11649705B2 patent drawing

AI summary

An oil and gas well carbon capture system includes a controller configured for minimizing or eliminating natural gas flaring and venting. A downhole pump is driven by a motor connected to the controller, which interactively operates a control valve. Controller inputs include gas pressures, pump motor speed and oil and gas delivery. The system is configured for separating production phases comprising oil, water and natural gas. A pressure transducer monitors output to gas sales, which can also be monitored with a digital flow meter. A carbon capture method for oil and gas production is also provided. The controls system maximizes downhole pump efficiency and oil and gas production by interactively monitoring and controlling well operating parameters. A method embodying the present invention optimizes well production and operating efficiency.