Variable Speed Progressing Cavity Pump Control
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Solution Overview
Problem
Progressing cavity pumps used in down-hole operations face challenges in efficiently controlling speed and torque to prevent pumped-off conditions, leading to inefficient fluid extraction and potential damage from excessive gas handling.
Innovation Solution
A variable speed progressing cavity pump system equipped with a sensor system for monitoring fluid production and a control system that automatically adjusts the pump speed using dual-mode flow meters and a control algorithm to maintain optimal operation, ensuring efficient fluid extraction and preventing gas pumping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual control of pump speed and torque is used, then the pump can be operated to avoid pumped-off conditions, but the control complexity and human intervention requirements increase
Solution Approach 1:
The pump system performs self-diagnosis and self-adjustment by automatically monitoring fluid production and adjusting pump speed based on detected conditions, eliminating the need for continuous manual control while maintaining reliable operation and avoiding pumped-off conditions
Solution Approach 2:
The system continuously monitors fluid production and uses this feedback to automatically adjust pump speed and torque, creating a closed-loop control system that maintains reliable operation without manual intervention by comparing actual performance with desired performance and making real-time adjustments
2Productivity
If pump speed is increased to maximize fluid extraction, then productivity improves, but the risk of pumped-off conditions and gas handling increases
Solution Approach 1:
The pump system dynamically adjusts its operating speed based on real-time fluid production conditions, transitioning between different speed levels to maximize productivity when fluid is available while reducing speed to prevent pumped-off conditions and gas handling, optimizing both productivity and reliability
Solution Approach 2:
The system detects early signs of pumped-off conditions or gas accumulation and takes preventive action by reducing pump speed before the harmful condition fully develops, thereby maintaining productivity while preventing reliability issues from occurring
3Measurement precision
If dual-mode flow meters and automated control systems are implemented, then measurement precision and control accuracy improve, but device complexity increases
Solution Approach 1:
The dual-mode flow meter system provides multiple measurement capabilities (positive displacement and ultrasonic modes) within a single integrated device, enabling accurate measurement of different fluid types and conditions while consolidating what could be separate systems into one multi-functional unit, improving measurement precision without proportionally increasing complexity
Data Source
AI summary
A pump system including a pump and a sensor system for monitoring a fluid production of the pump and providing an output indicative of the fluid production. The sensor system is configured to use at least two discreet methodologies for measuring the fluid production. The pump system further includes a control system operatively coupled to the sensor system and the pump and configured to automatically vary the speed of the pump at least partially based upon the output of the sensor system.