Hybrid Well Pumping Control System for Remote Sites
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Remote well sites, particularly in the hydrocarbon and livestock industries, face challenges with low production rates, high maintenance costs, and water wastage due to limitations in existing solar-powered and windmill-based pumping systems, as well as the inefficiencies and hazards associated with generator-powered systems.
Innovation Solution
A well pumping and control system that utilizes a combustion engine-driven generator and field sensors to provide on-demand electrical power, continuously monitors fluid levels and operating conditions, and automatically controls the pumping process to optimize fluid production, reduce waste, and enhance operational safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If solar powered pumping systems are used at remote wells, then operational independence is improved, but fluid production rate deteriorates
Solution Approach 1:
The system combines a solar powered generator with a combustion engine driven generator to create a hybrid power system. The solar generator operates during daylight hours providing clean energy, while the combustion engine generator activates when solar power is insufficient or unavailable, ensuring continuous operation at full production capacity without compromising operational independence
Solution Approach 2:
The control system is designed to universally accept multiple power sources (solar and combustion engine) and automatically manage transitions between them. This multi-functional approach allows the system to maintain operational independence while achieving full fluid production rates by selecting the appropriate power source based on environmental conditions and production requirements
2Ease of operation
If windmills are used at remote well sites, then operational independence is improved, but water waste increases
Solution Approach 1:
The system incorporates level sensors that continuously monitor the water storage tank and provide feedback to the control system. When the tank reaches sufficient levels, the control system automatically shuts off the pump and generator, preventing water waste. This feedback mechanism eliminates the need for manual monitoring while ensuring water is not wasted, resolving the contradiction between operational independence and water conservation
3Productivity
If generator powered systems are used at remote wells, then fluid production rate is improved, but operational complexity increases
Solution Approach 1:
The control system is designed to be self-managing, automatically monitoring system status, managing fuel levels, controlling pump operation, and coordinating between solar and combustion engine generators. This self-service capability eliminates the need for constant manual intervention, reducing operational complexity while maintaining high fluid production rates through automated decision-making and system coordination
4Device complexity
If solar powered systems are used without level control, then device complexity is reduced, but water waste increases
Solution Approach 1:
The system incorporates level sensors that continuously monitor the water storage tank and provide feedback to the control system. When the tank reaches sufficient levels, the control system automatically shuts off the pump and generator, preventing water waste. This feedback mechanism adds minimal complexity while effectively eliminating water waste, demonstrating that simple automation can resolve the contradiction between system simplicity and water conservation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system increases fluid production rates, reduces fuel consumption and emissions, conserves water, and decreases maintenance and operational costs while minimizing health and safety hazards for technicians, providing a reliable and efficient pumping solution for remote locations.
Implementation Method 1
a combustion engine-driven generator
Implementation Method 2
generator to produce electrical power
Data Source
AI summary
A well pumping and control system that is capable of operating in a wide range of ambient conditions. The system automatically maintains fluid level in a fluid storage vessel, while protecting the pump and generator from operating in conditions outside preset operating parameters to prevent premature failure and reduce repair. By operating to pump fluid only when preset operating conditions exist, e.g. low fluid level, ambient temperature, etc., the system reduces labor, fuel, and maintenance operating costs to the owner, improves well pumping reliability and production, reduces generator fuel consumption, reduces emissions, and conserves ground water or liquid hydrocarbons, whichever is being pumped into the fluid storage vessel by the system.