Polished Rod Sensor for Beam Pump Diagnostics
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Solution Overview
Problem
Traditional SCADA systems for analyzing beam pump unit performance have a large footprint, are costly, and often incompatible with wellsite computing systems, limiting comprehensive analysis of beam pump unit efficiency and health conditions.
Innovation Solution
A system and method using integrated sensors with strain gauges, gyroscopes, and accelerometers to measure strain, orientation, and acceleration of the polished rod, coupled with a transceiver for wireless data transmission to an external computing system, enabling detailed dynamometer surveys and diagnostics without the need for extensive local infrastructure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If traditional SCADA systems are used for analyzing beam pump unit performance, then comprehensive analysis capability is improved, but system footprint and cost increase
Solution Approach 1:
The patent combines multiple sensing functions (strain measurement, acceleration measurement, orientation measurement) into a single integrated sensor assembly that attaches to the polished rod. This merging of functions eliminates the need for separate SCADA systems and multiple individual sensors, thereby reducing system footprint while maintaining comprehensive analysis capability.
Solution Approach 2:
The integrated sensor assembly serves multiple purposes simultaneously: it measures strain on the polished rod, measures acceleration during pump strokes, and determines orientation angles. This multi-functionality replaces what would traditionally require separate specialized systems, reducing overall system complexity while providing comprehensive performance analysis.
2Loss of information
If traditional SCADA systems are deployed at the wellsite, then data acquisition capability is improved, but compatibility with wellsite computing systems deteriorates
Solution Approach 1:
The patent extracts the data acquisition and processing functions from the wellsite infrastructure and embeds them directly within the integrated sensor assembly. The sensor includes an onboard processor that handles data acquisition and preliminary processing, eliminating the need for complex SCADA systems and improving compatibility with simpler wellsite computing environments.
Solution Approach 2:
The integrated sensor assembly acts as an intermediary between the beam pump unit and the wellsite computing systems. It includes wireless communication capabilities that interface with standard wellsite equipment, serving as a bridge that translates and adapts data formats to ensure compatibility with existing wellsite computing infrastructure.
3Measurement precision
If integrated sensors with multiple measurement capabilities are used, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent merges strain gauges, accelerometers, and orientation sensors into a single integrated assembly that attaches to the polished rod. By combining these measurement functions in one unit, the patent achieves precise multi-parameter measurement while reducing the overall complexity compared to installing and coordinating multiple separate sensor systems.
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
Provides comprehensive data for analyzing volumetric efficiency, mechanical integrity, and operating efficiency of the beam pump unit, reducing the need for costly infrastructure and enhancing compatibility with wellsite systems, allowing for improved diagnostics and adjustments.
Implementation Method 1
a strain gauge coupled to the base and configured to measure a strain on the tubular member as the tubular member moves
Implementation Method 2
a gyroscope configured to measure an orientation, an angular velocity, or both of the beam pump unit as the beam pump unit operates
Implementation Method 3
an accelerometer configured to measure an acceleration of the beam pump unit as the beam pump unit operates
Data Source
AI summary
An apparatus includes a body. The body includes first and second clamping mechanisms that are configured to grip a tubular member of a beam pump unit at first and second axially-offset locations along the tubular member, respectively. The body also includes a base positioned at least partially between the first and second clamping mechanisms. The apparatus also includes a strain gauge coupled to the base and configured to measure a strain on the tubular member as the tubular member moves. The apparatus also includes a gyroscope configured to measure an orientation, an angular velocity, or both of the beam pump unit as the beam pump unit operates. The apparatus also includes an accelerometer configured to measure an acceleration of the beam pump unit as the beam pump unit operates.