Downhole Pump Rod Control via Machine Learning
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Solution Overview
Problem
Downhole pump systems in subterranean environments face challenges such as gas interference and fluid pound, which reduce efficiency and can damage equipment, and there is a need for improved monitoring and control to manage rod wear and buckling.
Innovation Solution
The implementation of a system that includes a controller and sensors to monitor and control the pump system, using models and machine learning to estimate downhole conditions, predict rod failure, and adjust operations to prevent damage and optimize performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If downhole pump systems operate in subterranean environments, then fluid production is achieved, but gas interference and fluid pound occur which reduce efficiency and can damage equipment
Solution Approach 1:
The system performs preliminary monitoring of rod position, speed, and acceleration to detect conditions that may lead to gas interference or fluid pound before they occur. The controller adjusts operating parameters in advance to prevent these harmful conditions, rather than responding after damage has occurred.
Solution Approach 2:
The system continuously monitors rod position, speed, and acceleration using sensors and provides feedback to the controller. The controller uses this feedback to adjust pump operations in real-time, modifying stroke rate, stroke length, or other parameters to eliminate gas interference and fluid pound conditions as they develop.
2Reliability
If monitoring and control systems are implemented to manage rod wear and buckling, then equipment life is extended, but system complexity increases
Solution Approach 1:
The system uses the pump's own operational parameters (rod position, speed, acceleration) to monitor its own condition. The sensors and controller are integrated into the existing pump structure, allowing the system to self-diagnose rod wear and buckling conditions without requiring external monitoring equipment or complex additional infrastructure.
Solution Approach 2:
The monitoring system serves multiple functions: it detects rod position for control purposes, monitors rod speed and acceleration for performance optimization, and simultaneously detects conditions indicating rod wear or buckling. This multi-functionality reduces the need for separate specialized sensors and simplifies the overall system architecture.
Data Source
AI summary
A method can include operating a pump system; determining a condition associated with the pump system; and controlling the pump system based at least in part on the condition.