Downhole Pump Production Estimation Using Leakage Correction
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Solution Overview
Problem
Downhole pumps face inefficiencies due to leakage and incomplete fillage, which affect fluid production estimates, and existing methods lack accurate measurement of leakage and intake pressure, hindering optimal operation and reservoir management.
Innovation Solution
The proposed solution involves determining a pump fillage factor and leakage proportionality constant using dynamometer cards and processor-based calculations to accurately estimate production and control pump operations, accounting for factors like tubing anchoring and pressure differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If clearance is provided between the piston and the bore to prevent debris damage, then reliability is improved, but fluid leakage increases reducing production efficiency
Solution Approach 1:
A seal element is introduced as an intermediary component between the piston and bore to prevent fluid leakage while maintaining the necessary clearance for debris protection. The seal acts as a mediator that allows the clearance to exist for reliability purposes while blocking the harmful fluid loss.
2Ease of operation
If the pump is operated without considering fillage factors, then operational simplicity is maintained, but production estimation accuracy deteriorates
Solution Approach 1:
The patent replaces complex mechanical measurement systems with computational methods. By using processor-based calculations that consider fillage factors, the system achieves high measurement precision while maintaining ease of operation through automated computations rather than manual measurements.
3Device complexity
If traditional production estimation methods are used without leakage correction, then calculation simplicity is maintained, but production measurement precision deteriorates
Solution Approach 1:
The patent introduces leakage correction as an additional parameter in the production estimation calculation. By modifying the calculation to include leakage factors derived from dynamometer card analysis, the system improves measurement precision while adding only moderate computational complexity through parameter expansion.
4Ease of operation
If pump operations are controlled without intake pressure data, then control simplicity is maintained, but energy consumption increases
Solution Approach 1:
The patent implements feedback control by using intake pressure data derived from dynamometer card analysis to optimize pump operations. The system continuously monitors and adjusts pump parameters based on measured pressure conditions, improving energy efficiency while maintaining control simplicity through automated feedback loops.
Data Source
AI summary
Methods and apparatus to determine production of a downhole pump are described herein. An example method includes measuring a first amount of liquid produced from a well by a pump during a first stroke of the pump, computing a first pump card based on the first stroke, determining a first area of the first pump card and determining a leakage proportionality constant of the pump based on the first amount of liquid produced and the first area. The example method also includes computing a second pump card based on a second stroke of the pump, determining a second area of the second pump card and determining a second amount of liquid produced by the pump during the second stroke based on the leakage proportionality constant and the second area.