Downhole Pump Fillage Calculation via Sensor Data
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Solution Overview
Problem
Existing methods for determining pump fillage in sucker-rod pumps rely heavily on graphical representations, which are subjective and often lead to inaccurate fluid production calculations due to the diversity of downhole card shapes, causing inefficiencies and potential damage to the pumping system.
Innovation Solution
The method involves determining the transfer point of a pump stroke using data arrays of pump position and load with respect to time, calculating pump fillage as the volume between the bottom of stroke and the transfer point, and using numerical methods such as ratio-of-load-and-position-derivatives, derivatives-of-position, and ratio-of-areas to accurately assess pump fillage and control the pumping system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If graphical representation methods are used to determine pump fillage, then the diagnostic process is simplified, but measurement precision deteriorates leading to inaccurate pump fillage calculations
Solution Approach 1:
The patent replaces the manual graphical analysis method with an automated computational system that uses numerical algorithms (such as the indicator diagonalization method) to calculate pump fillage from sensor data. This substitution eliminates human interpretation errors and provides precise, objective measurements while maintaining ease of operation through automated processing.
Solution Approach 2:
The patent introduces intermediate computational algorithms and processing steps that transform raw sensor data into accurate pump fillage calculations. These intermediary computational methods serve as a bridge between the simple data collection process and the precise diagnostic results, enabling both ease of operation and high measurement precision.
2Productivity
If pump speed is increased to maintain production, then productivity improves, but harmful factors increase due to pounding conditions when pump is not completely filled
Solution Approach 1:
The patent implements a feedback control system that continuously monitors pump fillage calculations and uses this information to adjust pump operation parameters. When pump fillage falls below optimal levels, the system provides feedback to reduce pump speed or adjust operating conditions, preventing pounding damage while maintaining maximum safe productivity. This closed-loop control ensures the pump operates efficiently without exceeding fluid supply capacity.
Data Source
AI summary
Methods and apparatus are provided for determining pump fillage, using data arrays of pump plunger position with respect to time and/or pump plunger load with respect to time. In this manner, well operators may be able to accurately monitor the pump fillage and control the pump accordingly.