Progressive Cavity Pump Torque Sensing for Rotating Rod Load Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing well fluid extraction systems, particularly those using rotating rod pumping units, face challenges in predicting peak and average loads due to system elasticity, leading to inefficient operation and premature wear or failure, especially when dealing with gaseous media or abrasive particles, and lack precise pressure control without direct measurement.
Innovation Solution
A well fluid extraction system with a contactless strain-based torque sensor that measures torque on the rotating rod without physical contact, integrated with a monitoring and control system to provide real-time, high-resolution data for improved management and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a contactless torque sensor is used to measure torque on the rotating rod, then measurement precision is improved and equipment reliability is enhanced, but device complexity increases due to the need for additional sensing components and integration infrastructure
Solution Approach 1:
The patent replaces traditional mechanical contact-based torque measurement methods with a contactless electromagnetic sensing system. The torque sensor uses electromagnetic fields to detect torque on the rotating rod without physical contact, eliminating mechanical wear and improving measurement precision while reducing the complexity of mechanical coupling components.
Solution Approach 2:
The patent introduces an electromagnetic field as an intermediary between the torque sensor and the rotating rod. This intermediary enables torque measurement without direct physical contact, allowing the sensor to detect torque through the electromagnetic interaction while maintaining spatial separation and avoiding mechanical complexity.
2Reliability
If real-time torque monitoring is implemented, then equipment reliability is improved and maintenance timing is optimized, but loss of time during system setup and data processing increases
Solution Approach 1:
The patent implements preliminary action by pre-configuring the torque sensor system to continuously monitor rotating rod conditions before failure occurs. The system establishes baseline torque values and sets threshold alerts in advance, enabling proactive maintenance scheduling that reduces unexpected downtime and optimizes maintenance timing without requiring extensive real-time analysis.
Solution Approach 2:
The patent employs feedback mechanisms where torque measurement data is continuously fed back to the control system, which automatically adjusts operational parameters or triggers maintenance alerts. This closed-loop feedback reduces the need for manual data processing and minimizes time loss by providing real-time actionable insights.
3Productivity
If the progressive cavity pump operates at higher speeds to increase productivity, then productivity is improved, but the risk of damage from gaseous media and abrasive particles increases
Solution Approach 1:
The patent applies dynamics by enabling variable speed operation of the progressive cavity pump based on real-time torque measurements. The system dynamically adjusts the pump speed to optimize productivity while avoiding conditions that would increase the risk of damage from gaseous media or abrasive particles, thereby maintaining reliability during high-speed operation.
Solution Approach 2:
The patent uses feedback from torque sensors to monitor pump operating conditions and automatically adjust speed to prevent damage. When torque values indicate the presence of gas or abrasives, the system reduces speed or alerts operators, preventing premature wear while maintaining optimal productivity during normal operation.
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
Enables precise torque measurement and real-time data analysis, enhancing operational efficiency, reducing equipment failure, and optimizing production by allowing for proactive maintenance strategies.
Implementation Method 1
a contactless strain based torque sensor; the torque sensor measures the torque of the rotating rod
Data Source
AI summary
The invention relates to a well fluid extraction system using a progressive cavity pump; comprising a stator, a rotor; a rotating drive rod, and a drive motor; the rotor is installed in the stator and has an external threaded curve surface; and the rotating rod is connected to the rotor; the drive motor, a fluid outlet of the progressive cavity pump is connected to an input end of a tank or a fluid pipeline; a fluid inlet immersed in a reservoir in the production zone of a well including a well head and a well casing; at least one torque sensor; which measures the torque of the rotating rod in a non-contact way, and includes a sensor housing supported by a mounting assembly adapted to be connected to the well head or well casing and comprising at least one elongate axially orientated support for the sensor housing.