Pumping Unit Counterbalance Phase Angle Determination
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Solution Overview
Problem
Pumping units used for hydrocarbon extraction face challenges in maintaining optimal operating conditions, particularly in managing forces and torques on components, which can lead to reduced operational life if not properly monitored and managed.
Innovation Solution
A method and apparatus that determine the load on a polished rod and estimate the torque of a motor in a pumping unit, using sensors to calculate a torque factor and subsequently determine the phase angle of the counterbalance, allowing for real-time monitoring and adjustment to keep peak loads below predetermined values, thereby extending the operating life of the unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If the pumping unit operates without real-time monitoring and adjustment, then the device complexity is reduced, but the operating life of components decreases due to excessive forces and torques
Solution Approach 1:
The system continuously monitors the load on the polished rod and the position of the polished rod, then feeds this information back to calculate torque factors and determine counterbalance parameters. This closed-loop feedback mechanism enables real-time adjustment of counterbalance moment to maintain optimal operating conditions and extend component life.
Solution Approach 2:
The pumping unit system performs self-diagnosis and self-adjustment by automatically calculating torque factors from sensor data and determining the appropriate counterbalance phase angle and moment without external intervention. The system serves itself by autonomously optimizing its own operational parameters.
2Reliability
If sensors and real-time monitoring are implemented, then the reliability of operation is improved, but the device complexity increases
Solution Approach 1:
The monitoring system serves multiple functions: it measures polished rod load, tracks polished rod position, calculates torque factors, determines counterbalance parameters, and enables real-time control adjustments. By consolidating these diverse functions into a single integrated system, the patent reduces overall complexity while maintaining high reliability.
Solution Approach 2:
The processor acts as an intermediary that receives raw sensor data from multiple sensors, processes this information through torque factor calculations, and translates it into control decisions for the counterbalance system. This intermediary processing layer simplifies the connection between sensing and control components.
3Duration of action of stationary object
If the counterbalance moment is increased to reduce peak loads, then the operating life is extended, but the torque requirements of the motor increase
Solution Approach 1:
The system dynamically adjusts the counterbalance moment parameter based on real-time measurements of polished rod load and position. By changing the counterbalance moment parameter in response to varying operational conditions, the system optimizes component life extension while adapting motor torque requirements to actual needs rather than using fixed conservative settings.
Data Source
AI summary
Methods and apparatus to determine parameters of a pumping unit for use with wells are disclosed. An example apparatus includes a housing and a processor positioned in the housing. The processor is to determine a first load on a polished rod of a pumping unit, to estimate a first torque of a motor of the pumping unit, and determine a first torque factor for the pumping unit. The processor is to, based on the first load, the first torque, and the first torque factor, determine a phase angle of a counterbalance of the pumping unit or a moment of the counterbalance.