Jet Pump Controller for Downhole Cavitation Prediction
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Solution Overview
Problem
Current jet pump systems for hydrocarbon wells require frequent recalibration and maintenance due to inefficiencies caused by changing well conditions and installation errors, leading to decreased production and significant downtime, as they often rely on desktop software for configuration and are prone to cavitation damage.
Innovation Solution
An artificial lift system with a surface unit, jet pump, pressure transducer, flowmeter, and controller that adjusts operations in real-time based on measured pressure and flowrate, trending changes, and initiating actions to prevent cavitation and optimize performance, allowing for on-site optimization without the need for transferring data to a separate software location.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If desktop software is used to configure and predict jet pump operation, then initial system setup can be performed, but the system requires frequent recalibration and maintenance due to changing well conditions
Solution Approach 1:
The patent implements a controller that continuously monitors well conditions and dynamically adjusts jet pump operational parameters in real-time. This dynamic adaptation allows the system to maintain optimal performance as well conditions change, eliminating the need for frequent manual recalibration and maintenance that characterized static desktop software approaches.
Solution Approach 2:
The system incorporates continuous feedback loops where sensors monitor well conditions and performance metrics, which are then fed back to the controller. The controller uses this feedback to automatically adjust operational parameters, creating a self-optimizing system that maintains reliability over time without requiring external intervention for recalibration.
2Ease of operation
If the jet pump system operates without real-time monitoring, then initial configuration can be completed, but efficiency decreases over time due to changing well conditions and installation errors
Solution Approach 1:
The patent implements continuous monitoring and adjustment of jet pump operations throughout its service life. Sensors continuously measure well conditions and performance parameters, and the controller continuously optimizes operational settings. This continuous action maintains peak efficiency despite changing well conditions, contrasting with one-time configuration approaches where efficiency deteriorates over time.
Solution Approach 2:
The system performs self-optimization through automated monitoring and control. The controller automatically adjusts operational parameters based on real-time sensor data without requiring external intervention. This self-service capability maintains productivity by adapting to changing conditions, eliminating the need for manual reconfiguration that characterizes non-self-adjusting systems.
3Ease of manufacture
If the jet pump system is not optimized regularly, then initial setup can be completed, but the system may become damaged or fail due to cavitation and other issues
Solution Approach 1:
The system takes preliminary anti-action by continuously monitoring conditions that lead to cavitation and other damaging phenomena. The controller detects early signs of problematic conditions and adjusts operational parameters before damage occurs. This preventive approach protects the jet pump from cavitation damage and extends system life, contrasting with reactive approaches where damage has already occurred.
Solution Approach 2:
The patent implements a protective monitoring system that cushions against potential damage by detecting conditions that could lead to cavitation or failure. The controller prepares compensatory adjustments in advance, modifying operational parameters before damaging conditions fully develop. This beforehand cushioning protects the system from damage that would otherwise occur during normal operation changes.
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 enables continuous optimization and prevention of cavitation, reducing downtime and maintaining efficient production by adjusting operations dynamically, thus extending the life of the jet pump and improving overall well production efficiency.
Implementation Method 1
The first pressure transducer is disposed to measure discharge pressure in the discharge line of the surface unit
Implementation Method 2
the flowmeter is disposed to measure discharge flowrate in the discharge line of the surface unit
Implementation Method 3
The jet pump mixes the power fluid and the production fluid and outputs a product of the mixed fluid
Implementation Method 4
The surface unit is operable to pressurize the power fluid from the suction line to the discharge line
Data Source
AI summary
An artificial lift system has a surface pump operated by a prime mover powered by a variable speed drive. A jet pump disposed downhole in tubing receives pressurized power fluid from the surface pump, mixes the power and production fluid and delivers the product uphole. A controller disposed at surface adjusts the artificial lift system relative to a set value based on a measured discharged pressure or a measured flowrate and trends a change in the other of the measured flowrate or the measured discharged pressure over time. The controller can also trend an operating condition (intake pressure vs. production rate) to determine changes relative to cavitation conditions. Based on the trended changes, the controller initiates an operation in the artificial lift system, such as adjusting the discharge pressure, initiating an alarm condition, etc.