Downhole Pump Production Determination via Leakage Compensation

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Solution Overview

Problem

Downhole pumps face challenges in accurately determining production due to leakage between the piston and bore, which reduces fluid volume and complicates measurement.

Innovation Solution

A method and apparatus that use the number of strokes, geometry of the downhole pump, and a leakage proportionality constant to infer production, where the leakage constant is determined based on observed production, sum of pump card areas, and pressure difference across the pump.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If clearance is provided between the piston and bore to prevent debris interference, then reliability is improved, but leakage increases and measurement precision deteriorates

Engineering Contradiction:

Improvepump performanceVSAvoidproduction measurement

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The patent introduces an intermediary mathematical model (leakage calculation model) that mediates between the physical leakage phenomenon and the production measurement requirement. The model uses measurable parameters (pump card area, pressure difference, stroke count) to calculate and compensate for leakage effects, enabling accurate production measurement despite the presence of clearance-induced leakage.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If clearance is provided between the piston and bore, then ease of operation is improved, but loss of substance increases

Engineering Contradiction:

Improvedebris resistanceVSAvoidfluid leakage

Core Design Contradiction:

Ease of operationVSLoss of substance

Solution Approach 1:

The patent implements a feedback mechanism where leakage is continuously calculated based on real-time operational parameters (pump card area, pressure difference, stroke count) and used to compensate the production measurement. The system measures actual production, calculates leakage based on operational conditions, and uses this feedback to determine net production, thereby accounting for substance loss due to clearance.

Inventive Principle:

Principle #23Feedback

3Device complexity

If traditional production measurement methods are used, then device complexity is reduced, but measurement precision deteriorates due to unaccounted leakage

Engineering Contradiction:

Improvemeasurement systemVSAvoidproduction determination

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent replaces direct physical measurement of production with a computational approach. Instead of using complex physical measurement devices to directly measure net production, the system substitutes a mathematical calculation model that processes readily available operational data (pump card area, pressure difference, stroke count) to compute production while automatically compensating for leakage effects.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP3129655B1Method and apparatus to determine production of downhole pumps

Publication Date: 2021.11.10 BRISTOL INC

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AI summary

Methods and apparatus to determine production of downhole pumps are disclosed. An example method includes measuring an amount of liquid produced from a well by a pumping unit during a predetermined time period and determining first areas of first pump cards during the predetermined time period. The example method also includes summing the first areas and, based on the amount of liquid produced and the summed first areas, determining a leakage proportionality constant of a downhole pump of the pumping unit.