CA2772462A1 - Method, system, and device for displaying operating parameters of reciprocating oil well pumping apparatus - Google Patents

Method, system, and device for displaying operating parameters of reciprocating oil well pumping apparatus Download PDF

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Publication number
CA2772462A1
CA2772462A1 CA2772462A CA2772462A CA2772462A1 CA 2772462 A1 CA2772462 A1 CA 2772462A1 CA 2772462 A CA2772462 A CA 2772462A CA 2772462 A CA2772462 A CA 2772462A CA 2772462 A1 CA2772462 A1 CA 2772462A1
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Prior art keywords
pumping apparatus
difference
spm
pump
latest
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Abandoned
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CA2772462A
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French (fr)
Inventor
Shane M. Seitz
Justin M. Seitz
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EEES OILFIELD SERVICES Ltd
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Eees Oilfield Services Ltd.
Shane M. Seitz
Justin M. Seitz
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Priority to CA2772462A priority Critical patent/CA2772462A1/en
Publication of CA2772462A1 publication Critical patent/CA2772462A1/en
Abandoned legal-status Critical Current

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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B49/00Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
    • F04B49/06Control using electricity
    • F04B49/065Control using electricity and making use of computers
    • EFIXED CONSTRUCTIONS
    • E21EARTH DRILLING; MINING
    • E21BEARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/12Methods or apparatus for controlling the flow of the obtained fluid to or in wells
    • E21B43/121Lifting well fluids
    • E21B43/126Adaptations of down-hole pump systems powered by drives outside the borehole, e.g. by a rotary or oscillating drive
    • E21B43/127Adaptations of walking-beam pump systems
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B47/00Pumps or pumping installations specially adapted for raising fluids from great depths, e.g. well pumps
    • F04B47/02Pumps or pumping installations specially adapted for raising fluids from great depths, e.g. well pumps the driving mechanisms being situated at ground level
    • F04B47/04Pumps or pumping installations specially adapted for raising fluids from great depths, e.g. well pumps the driving mechanisms being situated at ground level the driving means incorporating fluid means
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B51/00Testing machines, pumps, or pumping installations

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  • Engineering & Computer Science (AREA)
  • Geology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Mining & Mineral Resources (AREA)
  • Environmental & Geological Engineering (AREA)
  • Fluid Mechanics (AREA)
  • Physics & Mathematics (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Computer Hardware Design (AREA)
  • Control Of Positive-Displacement Pumps (AREA)

Abstract

A device for monitoring and displaying operating parameters of a reciprocating oil well pumping apparatus which moves a pump rod between a top-of-stroke position (TOSP) and a bottom-of-stroke position (BOSP).
The device comprises a display means, a processor, and a connecting means for operatively connecting the device to at least one of a first and second pump control signal sensor. The processor is connected to the connecting means and programmed to a) detect at least one of the first and second pump control signals from at least one of the first and second pump sensors; b) measure time intervals between the detected first and second signals; c) calculate at least one operating parameter of the pumping apparatus based on the measured time intervals; and d) provide an output of the at least one of the operating parameter. The display means receives and displays the output. The device is for use in conjunction with hydraulic oil well pumping apparatus and horsehead pumping apparatus. A method associated with the device and a system incorporating the device are also disclosed.

Description

. = CA 02772462 2012-03-20 Title: METHOD, SYSTEM, AND DEVICE FOR DISPLAYING OPERATING
PARAMETERS OF RECIPROCATING OIL WELL PUMPING
APPARATUS
FIELD OF THE INVENTION
The present invention relates generally to reciprocating oil well pumping apparatus which has a rod that is moveable between a top-of-stroke position (TOSP) and a bottom-of-stroke position (BOSP). More particularly, the present invention relates to methods, systems and devices for displaying operating parameters of reciprocating oil well pumping apparatus.
BACKGROUND OF THE INVENTION
There are many different methods for producing oil from an oil well. Some wells, known as "free flowing" oil wells require no pumping as the oil flows freely from the ground to the surface. Most oil wells, however, are not free-flowing and require a method to lift the oil from the well to bring it to the surface. These methods are broadly included in a wide spectrum of methods called "artificial lift". Artificial lift is needed in cases when oil wells are not free-flowing, or are free-flowing at an insufficient rate. Many different types of artificial lift pumping systems are known and employed throughout the world. Typical artificial lift pumping systems are reciprocating rod-lift pumping apparatus, the most common examples of which are horse head or walking beam pumps and hydraulic pumps.
One example of a typical known horse head pump arrangement is described in U.S. Pat. No. 4,651,578 to Thomson. Such horse head pumps include a walking beam pivotally mounted on a Samson post which serves as a fulcrum about which the walking beam oscillates. One end of the walking beam carries the horse head, and the other end is connected to the , oscillation drive means which includes a pitman and counter-weight crank arm drive unit. The horse head is pivotally attached to the one end of the walking beam and is fitted with a cableguide on which cable is mounted for connecting the horse head to a sucker rod string extending downwardly to the subsurface pump located in the well.
One example of a known hydraulic oil well pump is described in U.S. Pat.
No. 7,762,321 to Fesi et al. This hydraulic oil well pump employs a compensating type hydraulic pump, a directional valving arrangement and a proportioning valving arrangement. When the directional valve is energized, oil is directed to the rod end of the hydraulic cylinder. The rod or piston part of the hydraulic cylinder will then elevate until a first limit switch is actuated which then will de-energize the directional valve and send a current signal to the proportional valve. The current signal to the proportional valve forces it to open to a point at which the cylinder rod would extend at the desired velocity until it reaches a second limit switch. The second limit switch is near the bottom of travel of the rod or piston. The current signal to the proportional valve is then decreased, creating a choking arrangement that forces the cylinder rod to decelerate. The cylinder rod then reaches another limit switch. Upon reaching the third limit switch, the signal is removed from the proportional valve so that it closes. This halts a draining of fluid from the hydraulic cylinder. At the same time, a voltage signal is sent to the directional valve opening it so that pump flow again travels from the pump to the hydraulic cylinder and once again elevates the rod and the connected pumping string or sucker rod.
The up and down movements of the sucker rod (i.e. upstroke and downstroke) in a typical oil well pump is governed by either a simple mechanical translation of a rotational motion of an electric motor as in the case of horse head pumps, or a rudimentary controller which simply energizes and de-energizes the directional valve in direct response to activity of limit sensors as in the case of hydraulic pumps.
When an oil well pump is installed in the field it is set up and calibrated to operate with a specific strokes per minute. Over time, the SPM value may change due to changes in the oil well, changes in the oil well pump, or any of a number of other factors. A decrease in SPM can equate to significant yearly production losses. An increase in SPM can also be problematic as it can result in inefficient pumping and increased wear and tear on the equipment.
Accordingly, changes in SPM of oil well pumps are typically monitored by operators using their eyes to count upstrokes and downstrokes and relating that information to a time obtained with a stop watch. The problem with this method of monitoring pumping apparatus parameters is that it results in readings which are inconsistent and imprecise. More problematic is that slight deviations in the stroke speeds or strokes per minute, intermittent deviations, or deviations occurring between scheduled readings go unnoticed.
One attempt at monitoring the SPM of a hydraulic oil well pump is disclosed in U.S. Pat. No. 4,076,458 (Jones). Jones discloses an automatic pump speed controller for controlling and maintaining the strokes per minute of a down-hole oil well pump and providing signals on the surface indicating the actual strokes per minute of the pump. The Jones controller calculates the SPM of the pump with use of a transducer which changes the shock waves from changes in the pressure accompanying each stroke of the pistons of the hydraulic pump into electrical signals. As such the Jones controller is integral to the oil well pump itself and is not intended as a stand alone device for use in conjunction with for example a conventional pump controller governed reciprocating hydraulic oil well pump, or a conventional horse head oil well pump driven with a motor as opposed to hydraulics.
U.S. Pat. No. 5,184,507 issued to Drake discloses measuring and using surface hydraulic fluid pressure and sucker rod displacement to analyze the performance of a pumped oil well having a surface hydraulic actuator connected to a downhole pump by the sucker rod. The pressurized hydraulic fluid actuates a cyclic motion of the rod and a pumping of the oil.
The measured rod motion and hydraulic fluid pressure are used together with an added flexible rod simulator to calculate a performance characteristic, namely hydraulic pressure vs. displacement, which is said to account for rod interactions with the hydraulic actuator and hydraulic pump.
Drake requires tapping into the oil well pump's hydraulics and adding a rod displacement transducer. However, the performance characteristic measured by Drake is not easily understandable and requires careful interpretation and analysis by the operator.
U.S. Pat. No. 5,406,482 issued to McCoy discloses mounting an accelerometer on a horse head oil well pump to move in conjunction with the sucker rod. An output signal from the accelerometer is digitized and provided to a portable computer. The computer processes the digitized accelerometer signal to integrate it to first produce a velocity data set and second produce a position data set. The computer then processes the accelerometer data sets and calculates strokes per minute and velocity parameters of the rod, and displays the information in the form of plots. As in the above Drake reference the information displayed by computer is not easily understandable and requires interpretation and analysis by the operator.
Other prior art patent documents of general interest in the field include U.S.
Pat. Nos. 3,343,409 (Gibbs), 4,213,740 (Chien), 4,503,752 (Olson), 4,680,930 (Dollison), 5,044,888 (Hester), 5,159,832 (White), 5,184,507 (Drake), 5,406,482 (McCoy), 5,800,063 (Stanley), U.S. Pat. App. Pub. No.
2011/0103974 (Lamascus), and CA Pat. Nos. 2,414,646 (Watson), and 2,526,345 (Palka).
SUMMARY OF THE INVENTION
In view of the foregoing, there is a need for a simple device for monitoring, and displaying operating parameters of an oil well pump to an operator in a straightforward and easily understandable manner and to alert the operator to changes in the operating parameters which may warrant further investigation. Preferably, the device is inexpensive to manufacture and install, and overcomes at least some of the problems associated with prior art.
The present invention is directed to a monitor device to display operating parameters of a reciprocating oil well pumping apparatus to an operator in a straightforward and easily understandable manner. Preferably the monitor device has display means which displays at least the following operating parameters to the operator: a strokes per minute (SPM) value, an upstroke time interval, a down stroke time interval, and a percentage increase or decrease in SPM as compared to a predetermined calibrated SPM (CSPM) value. Preferably the monitor device also has means to transmit the operating parameters wiredly or wirelessly to a remote display device such as for example a cell phone or smart phone.
One embodiment of the present invention has the monitor device tapping into pump control proximity or limit sensors already preexisting on a hydraulic oil well pumping apparatus. These pump control proximity sensors are integral to the hydraulic oil well pumping apparatus, with one proximity switch being positioned to detect when the pump rod reaches a top-of-stroke position (TOSP) and a second proximity switch being positioned to detect when the pump rod reaches a bottom-of-stroke position (BOSP). The proximity sensors create signals which are used by the pumping apparatus controller to cause the pumping apparatus to raise and lower a pump rod into the oil well. Thus, the monitor device is simply tapping into signals from pre-existing pump control proximity sensors which are normally used for a different purpose, namely, signalling to the pump controller when to, for example, energize or de-energize the directional valve which causes the movement of the pump rod to change directions.
However, the monitor device may also be used with reciprocating oil well pumping apparatus which do not have pre-existing proximity sensors to detect when the pump rod reaches the TOSP or BOSP, such as for example horse head type pump apparatus. In this case, the proximity sensors need to be mounted on the pumping apparatus and connected to the monitor device to permit the monitor device to calculate and display the operating parameters.
While preferred embodiments will include proximity sensors to detect both TOSP and BOSP, permitting the monitor device to calculate upstroke time intervals and downstroke time intervals separately, it is contemplated that less preferred embodiments may include only one, or more than two proximity sensors. Furthermore, it is contemplated that sensors for detecting TOSP and BOSP other than proximity sensors may be employed, and will be selectable from a pool of sensors based on availability and characteristics which make them suitable for the intended function in accordance with the present invention.
Therefore, according to one aspect of the present invention, there is provided a device for monitoring and displaying operating parameters of a reciprocating oil well pumping apparatus to an operator, said pumping apparatus moving a pump rod between a top-of-stroke position (TOSP) and a bottom-of-stroke position (BOSP), in conjunction with at least one of:
i) a first sensor for creating a first signal when said pump rod is at said TOSP, and ii) a second sensor for creating a second signal when said pump rod is at said BOSP' said device comprising:
a connecting means for operatively connecting said device to said at least one of said first and second sensors;
a processor connected to said connecting means and programmed to:
a) detect said at least one of said first and second signals from said at least one of said first and second sensors;
b) measure time intervals between said detected signals;
c) calculate at least one operating parameter of said pumping apparatus based on said measured time intervals; and d) provide an output of said at least one operating parameter; and a display means for receiving said output and displaying same.
According to another aspect of the present invention, there is provided a method of monitoring and displaying operating parameters of a reciprocating oil well pumping apparatus to an operator, the pumping apparatus moving a pump rod between a top-of-stroke position (TOSP) and a bottom-of-stroke-position (BOSP), said method comprising:
detecting instances when said pump rod is at at least one of said TOSP and said BOSP;
measuring time intervals between said instances;
calculating at least one operating parameter of said pumping apparatus based on said measured time intervals; and displaying said at least one operating parameter on a display means.
According to yet another aspect of the present invention there is provided a system for monitoring and displaying operating parameters of a reciprocating oil well pumping apparatus to an operator, said pumping apparatus moving a pump rod between a top-of-stroke position (TOSP) and a bottom-of-stroke position (BOSP), said system comprising:
at least one of:
i) a first sensor for creating a first signal when said pump rod is at said TOSP, said first sensor being adapted for mounting on said pumping apparatus; and ii) a second sensor for creating a second signal when said pump rod is at said BOSP, said second sensor being adapted for mounting on said pumping apparatus;
a monitor device operatively connected to said at least one of said first and second sensors, said monitor device comprising:
a processor programmed to:
a) detect said at least one of said first and second signals from said at least one of said first and second sensors;
b) measure time intervals between said at least one first and second signals;
c) calculate at least one operating parameter of said pumping apparatus based on said measured time intervals; and d) provide an output of said at least one operating parameter; and a display means for receiving said output and displaying same.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference will now be made to the preferred embodiments of the present invention with reference, by way of example only, to the following drawings in which:
Fig. 1 is a perspective view of the monitor device according to an embodiment of the present invention;
Fig. 2 is a schematic diagram of the back of the monitor device of Fig.
1;
Fig. 3 is a schematic diagram of the back of a monitor device according to another embodiment of the present invention;
Fig. 4 is a schematic diagram of a prior art hydraulic pumping apparatus;
Fig. 5 is a schematic diagram of the monitor device of Fig. 2 connected to the pump controller of the hydraulic pumping apparatus of Fig.
4;
Fig. 6 is a schematic diagram of the monitor device of Fig. 1; and Fig. 7 is a side view of a horse head pumping apparatus according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is described in more detail with reference to exemplary embodiments thereof as shown in the appended drawings. While the present invention is described below including preferred embodiments, it should be understood that the present invention is not limited thereto.
Those of ordinary skill in the art having access to the teachings herein will recognize additional implementations, modifications, and embodiments which are within the scope of the present invention as disclosed and claimed herein. In the figures, like elements are given like reference numbers. For the purposes of clarity, not every component is labelled in every figure, nor is every component of each embodiment of the invention shown where illustration is not necessary to allow those of ordinary skill in the art to understand the invention. Orientative words such as "front", "back", "top", "bottom", and "side" as used herein are used for clarity with reference to the orientation of elements in the figures and are not intended to be limiting.
A monitor device 10 according to the present invention is disclosed in Fig.
1. The monitor device 10 shown in Fig. 1 has on its front side 12 an on/off toggle switch 14, a calibrate push button 16, and a display consisting of an alpha numeric LCD screen 18 and a series of five LEDs 20.
As shown in Fig. 2, the back side 22 of the monitor device 10 is provided with a power connector to permit connection of the monitor device 10 to a source of electric power for powering the monitor device 10. Examples of preferred sources of electric power include 12 or 24 volt DC electric power sources such as batteries 24, generators, and alternators, as well as standard 120 or 240 volt AC electric power supplied by, for example, an electricity generating plant. If the monitor device 10 is to be powered by 12 or 24 volt DC electric power, the preferred power connector will include a pair of power terminals 26 to facilitate the connection to the 12 or 24 volt DC
electric power source with suitable wires 28. If the monitor device 10 is to Figs. 2 and 3 also show a connecting means for operatively connecting the monitor device 10 to one or more sensors 40 for detecting one or more positions of a pump rod 42 of a reciprocating oil well pumping apparatus.
With reference to Fig. 4, there is shown a typical hydraulic pumping apparatus 44 as described in U.S. Pat. No. 7,762,321 to Fesi et al. As shown, the hydraulic pumping apparatus 44 has two sensors 40 and 40' mounted to a frame 56. Sensor 40 is used to create a first signal when the pump rod 42 is at the top-of-stroke position (TOSP), by detecting when the lower end portion 58 of the coupling 60 on pump rod 42 is abeam the sensor 40. Sensor 40' is used to create second signal when the pump rod 42 is at the bottom-of-stroke position (BOSP), by detecting when the lower end portion 58 of the coupling 60 on pump rod 42 is abeam the sensor 40'. The coupling 60 is connected to a sucker rod 62. In the hydraulic pumping apparatus of Fesi et al., the sensors 40 and 40' are connected to controller 54 by wires 50, and the controller 54 uses the first and second signals to cause the hydraulic pumping apparatus 44 to move the pump rod 42 between the TOSP and the BOSP. In other words, the sensors 40 and 40' of the hydraulic pumping apparatus 44 are pump control sensors which create pump control signals used by the controller 54 to operate the hydraulic pumping apparatus 44. Fesi. et al. describes the sensors as proximity or limit switches, examples of which are those manufactured by Turck Company, model number N129CP40AP6X2/510, which are a type of inductive proximity sensor. The inductive proximity sensor creates electric signals by switching from a normally open state (i.e. electrical discontinuity) to closed state (i.e. electrical continuity) when triggered by, for example, the proximity of the lower end portion 58 of coupling 60. Other hydraulic pumping apparatus 44 may be provided with other types of sensors, for example, mechanical contact sensors and optical sensors, all of which sensors are comprehended by the present invention. What is important is that the sensor be configured to create signals when the pump rod 42 is at the TOSP or the BOSP, which signals are detected by the monitor device 10.
Referring now to Fig. 5, there is shown a representation of the electronic bus 52 inside of the hydraulic pumping apparatus controller 54. Typically, the electronic bus 52 consists of a series of terminals 64 for electrically connecting devices to the controller 54. As shown, wires 50 leading from the pump control sensors 40 and 40' are connected to respective terminals 64 on the electronic bus 52. The back side 22 of the monitor device 10 is shown on top of the controller 54. Wires 50 connect the two pairs of sensor connecting terminals 48 on the monitor device 10 to the same electronic bus terminals 64 connecting the pump control sensors 40 and 40'. Wires 28 connect the pair of power terminals 26 on the monitor device 10 to battery 24 for electric power. Accordingly, it can now be appreciated that according to this embodiment of the present invention, the monitor device 10 taps into the wires 50 leading from the pump control sensor 40, 40' at the electronic bus 52 in the hydraulic pump controller 54.
As shown in Fig.6, the inside of the monitor device 10 houses a processor 66 which is connected to the sensor connecting terminals 48 and programmed to detect the first and second signals created by the pump control sensors 40 and 40'. The processor 66 can be a general purpose processor, a high speed processor, an application specific integrated circuit (ASIC), a digital signal processor, a programmable array, or the like. The processor 66 may include, or be associated with a memory and a bus in order to retrieve and store information in the memory. It will be appreciated that in some configurations, the processor 66 can constitute other interconnection being integrated together and packaged into the monitor device 10. When the monitor device 10 is switched on with on/off switch 14, the processor 66 measures time intervals between the detected signals, and uses the measured time intervals to calculate at least one operating parameter of the pumping apparatus. Once the operating parameters are calculated, the processor 66 outputs one or more of the operating parameters to the display means, which in the preferred embodiment includes an LCD screen 18 and a series of five LEDs 20, as mentioned above.
Preferably, the operating parameters calculated by the processor 66 will include one or more of:
a) a ratio of a number of strokes per unit time based on the measured time intervals, such as strokes per minute (SPM), b) an upstroke time interval (i.e. the length of time taken by the pump rod 42 to move from BOSP to TOSP), and c) a downstroke time interval (i.e. the length of time taken by the pump rod 42 to move from TOSP to BOSP).
The upstroke time interval is preferably calculated by measuring the time interval between sensor 40' creating the second pump control signal indicating the pump rod 42 is at the BOSP and sensor 40 creating the first pump control signal indicating that the pump rod 42 is at the TOSP.
Similarly, the downstroke time interval is preferably calculated by measuring the time interval between sensor 40 creating the first pump control signal indicating the pump rod 42 is at the TOSP and sensor 40' creating the second pump control signal indicating that the pump rod 42 is at the BOSP.
Most preferably, the operating parameters calculated by the processor 66 will include a percent difference between the latest SPM value calculated by the processor 66 and a predetermined SPM value. For example, as shown in Fig. 1, the preferred monitor device 10 is provided with a user interface consisting of a button 16 for selecting a calibrate function which directs the processor 66 to calculate the average of a predetermined number of stroke per minute values, and to store the average as a calibrated SPM (CSPM) value. While the predetermined number of SPM values which are used by the processor 66 in calculating the CSPM value can be set to any number, good results have been obtained with between 2 and 200 SPM values calculated by the processor 66 following selection of the calibrate function.
According to the present invention, the calibrate function establishes a baseline value for the strokes per minute the reciprocal oil well pumping apparatus is experiencing at that particular point in time. Accordingly, the calibrate function is preferably selected when the monitor device 10 is first installed on the reciprocal oil well pumping apparatus, and subsequently when any adjustments are made to the oil well pumping apparatus. The CSPM value, as then set, is used by the monitor device 10 to detect a difference between the CSPM value and the latest SPM value calculated by the processor 66.
Although connecting the monitor device 10 to two sensors is preferred in order to permit sensing both TOSP and BOSP, other embodiments in which the monitor device 10 connects to only one sensor are also comprehended by the present invention. It will be appreciated, however, that relying on signals from only one sensor will limit the operating parameters of the hydraulic pumping apparatus 44 that can be measured, since at least two sensors (i.e. one for signalling TOSP and one for signalling BOSP), are required, for example, to measure separately the upstroke time and downstroke time intervals. However, with one sensor the monitor device 10 can still display the ratio of stroke per unit time, and difference or percent difference as compared to the CSPM value.
Very small changes in SPM values are difficult to detect by operators using the prevailing method of counting pump rod strokes visually and timing them with a stop watch. It has been found however that decreases in SPM values as small as 0.2 relative to the CSPM value can result in substantial losses in oil production at the well, which potentially equates to thousands of dollars in lost revenues. For example, assuming a $460.00/m3 oil production on a 5m3/day oil well, a 5% decrease in SPM value relative to a CSPM value of 4 represents a difference of only 0.2 strokes per minute but results in 12 lost strokes per hour (i.e. 288 lost strokes per day) which translates to losses of about $115 per day (i.e. $3,450/month, or $43,070/year). A 10% decrease in SPM value relative to a CSPM value of 4 represents a difference of only 0.4 strokes per minute but results in 24 lost strokes per hour (i.e. 576 lost strokes per day) which translates to losses of about $230/day (i.e.
$6,900/month, or $83,950/year). Increases in SPM values are also problematic as they can result in inefficient pumping and increased wear and tear on the equipment.
Accordingly, as mentioned above, the processor 66 calculates a percent difference between the CSPM and the latest SPM value and displays the difference on the display for the operator to see. Preferably, the display includes beside the alphanumeric LCD screen 18, a series of five LEDs 20 in proximity to each other to display the percent difference, as shown in Fig.
1. Thus illumination of the first LED 68 indicates to the operator viewing the monitor device 10 that the latest SPM value calculated by the processor 66 is increased relative to the CSPM value by 10% or more. Illumination of the second LED 70 indicates to the operator that the latest SPM value is increased relative to the CSPM value by anywhere from 5% to less than 10%. Illumination of the third LED 72 indicates to the operator that the latest SPM value is increased or decreased relative to the CSPM value by less than 5%. Illumination of the fourth LED 74 indicates to the operator that the latest SPM value is decreased relative to the CSPM value by anywhere from 5% to less than 10%. Illumination of the fifth LED 76 indicates to the operator that the latest SPM value is decreased relative to the CSPM value by 10% or more. Although the preferred embodiment is described as including an arrangement of five LEDs to indicate increases and decreases in the latest SPM value relative to the CSPM value of about 0%, 5%, and 10%, other arrangements of more or less LEDs (or for that matter other indicating or signalling devices, whether incandescent bulbs, florescent bulbs, etc), indicating other percent increases or decreases in the latest SPM value, are possible, all of which other arrangements are comprehended by the present invention.
In addition to the visual indications provided by the series of five LEDs 20, the preferred monitor device 10 includes a sound emitting device, and the processor is further programmed to activate the sound emitting device to alert the operator to an alarm condition, which may be for example either an increase or decrease in the latest SPM value of 10% or more relative to the CSPM value. Although the sound emitting device according to the preferred embodiment is a speaker or a horn, other sound emitting devices for generating sounds or tones indicating other percent increases or decreases in the latest SPM value, are possible, all of which other arrangements are comprehended by the present invention.
Preferably, the monitor device 10 also has means for establishing a wired or wireless connection to a remote display device 78, such as for example, a remote computer, cellphone, or smartphone. Most preferably, the wired or wireless connection means connects to a Supervisory Control and Data Acquisition (SCADA) system. Shown in Fig. 6, for example, is a cellular modem 80, which is operatively connected to the processor 66 for wirelessly transmitting one or more of the operating parameters of the pumping apparatus (i.e. SPM, the upstroke time interval, the downstroke time interval, the percent difference between the CSPM value and the latest SPM value, etc.) to the remote display device 78 for displaying the one or more operating parameters thereon.
Although the wireless connection is preferred, the present invention also comprehends using a network (ethernet) card, telephone modem, or the like, in place of the cellular modem 80 to establish a wired connection to the remote display device 78. What is important is that the preferred monitor device 10 includes a means for establishing a wired or wireless connection to the remote display device 78, and the processor 66 is further programmed to transmit one or more of the operating parameters of the oil well pumping apparatus via the wired or wireless connection to be displayed on the remote display device 78. This will enable an operator away from the oil well pumping apparatus to view on the remote display device 78 the same operating parameters being displayed by the monitor device 10 at the oil well pumping apparatus in the field.
As mentioned above, the monitor device 10 of the present invention can also be set up to be used with a horse head pumping apparatus 46. However, unlike the hydraulic pumping apparatus 44 described above, the horse head pumping apparatus 46 does not normally include pump control sensors for signalling when the pump rod 42 is at the TOSP or the BOSP. Accordingly, at least one of a first sensor 40 and a second sensor 40' must be mounted on the horse head pumping apparatus 46 and connected to the monitor device 10, for the monitor device 10 to function. As shown in Fig. 7, the first sensor 40 is mounted at the top of the Samson post 82, to the rear side of bearing housing 84 (i.e. the side furthest away from horse head 86). The second sensor 40' is also mounted at the top of the Samson post 82, but to the front side of bearing housing 84 (i.e. the side closest to the horse head 86). In this configuration, when the walking beam 88 rotates about shaft 90 in a counter clockwise direction to its limit, pump rod 42 will be at the TOSP, and first sensor 40 will be triggered. When the walking beam 88 rotates about shaft 90 in a clockwise direction to its limit, pump rod 42 will be at the BOSP, and the second sensor 40' will be triggered. Therefore, the first sensor 40 creates a first signal when the pump rod 42 is at the TOSP, and the second sensor 40' creates a second signal when the pump rod 42 is at the BOSP.
Although the preferred first or second sensors are inductive proximity sensors, other types of sensors may also be found to be suitable by persons skilled in the art, for example, mechanical contact sensors and optical sensors, all of which sensors are comprehended by the present invention.
What is important is that the sensors be configured to create signals when the pump rod 42 is at the TOSP or the BOSP, which signals are detected by the monitor device 10.
Accordingly, operatively connecting the monitor device 10 to the first sensor 40 and the second sensor 40' will permit its processor 66 to calculate and display the operating parameters of the horse head pumping apparatus 46 in the same way as described above in connection with the hydraulic pumping apparatus 44. The only difference between how the monitor device 10 is set up for use with a hydraulic pumping apparatus 44 as compared to a horse head pumping apparatus 46 is that the hydraulic pumping apparatus 44 has pre-existing pump control sensors 40 and 40', whereas the horse head pumping apparatus 46 does not.
Although mounting two sensors to the horse head pumping apparatus 46 is preferred to permit sensing of both TOSP and BOSP, less preferred embodiments in which only one sensor is mounted are also comprehended by the present invention. It will be appreciated, however, that relying on signals from only one sensor will limit the operating parameters of the horse head pumping apparatus 46 that can be measured, since at least two sensors (i.e. one for signalling TOSP and one for signalling BOSP), are required to measure, for example, upstroke time and downstroke time intervals. However, with one sensor the monitor device 10 can still display the ratio of stroke per unit time, and difference or percent difference as compared to the CSPM value.
Having described preferred embodiments of the monitor device 10 and how they are connected to pre-existing sensors on, for example, a hydraulic pumping apparatus 44, or retrofit sensors on, for example, a horse head pumping apparatus 46, it will be appreciated that at the heart of the present invention is a method of monitoring and displaying operating parameters of a reciprocating oil well pumping apparatus to an operator involving at least the following steps:
a) detecting instances when the pump rod 42 is at at least one of the TOSP and the BOSP;
b) measuring time intervals between the instances detected in step a);

, c) calculating at least one operating parameter of the pumping apparatus based on the measured time intervals; and d) displaying the at least one operating parameter on a display.
While reference has been made to various preferred embodiments of the invention other variations, implementations, modifications, alterations and embodiments are comprehended by the broad scope of the appended claims. Some of these have been discussed in detail in this specification and others will be apparent to those skilled in the art. Those of ordinary skill in the art having access to the teachings herein will recognize these additional variations, implementations, modifications, alterations and embodiments, all of which are within the scope of the present invention, which invention is limited only by the appended claims.

Claims (60)

1. A device for monitoring and displaying operating parameters of a reciprocating oil well pumping apparatus to an operator, said pumping apparatus moving a pump rod between a top-of-stroke position (TOSP) and a bottom-of-stroke position (BOSP), in conjunction with at least one of:
i) a first sensor for creating a first signal when said pump rod is at said TOSP, and ii) a second sensor for creating a second signal when said pump rod is at said BOSP' said device comprising:
a connecting means for operatively connecting said device to said at least one of said first and second sensors;
a processor connected to said connecting means and programmed to:
a) detect said at least one of said first and second signals from said at least one of said first and second sensors;
b) measure time intervals between said detected signals;
c) calculate at least one operating parameter of said pumping apparatus based on said measured time intervals; and d) provide an output of said at least one operating parameter; and a display means for receiving said output and displaying same.
2. The device as claimed in claim 1, wherein said first sensor is a first pump control sensor, said first signal is a first pump control signal, said second sensor is a second pump control sensor, said second signal is a second pump control signal, and said pumping apparatus further comprises a controller operatively connected to said first and second pump control sensors, said controller using said first and second pump control signals to cause said pumping apparatus to move said pump rod between said TOSP and said BOSP.
3. The device as claimed in claim 2, wherein said pumping apparatus is a hydraulic oil well pumping apparatus.
4. The device as claimed in claim 3, wherein said at least one operating parameter comprises a ratio of a number of strokes per unit time based on said measured time intervals.
5. The device as claimed in claim 4, wherein said unit time is minutes and said ratio is strokes per minute (SPM).
6. The device as claimed in claim 5, wherein said connecting means is adapted for operatively connecting said device to both of said first and second sensors; said processor is programmed to detect both of said first and second pump control signals; and said at least one operating parameter further comprises one or both of an upstroke time interval defined as a length of time taken by said pump rod to move from said BOSP to said TOSP, and a downstroke time interval defined as a length of time taken by said pump rod to move from said TOSP to said BOSP.
7. The device as claimed in claim 6, further comprising a user interface, said user interface comprising means for selecting a calibrate function which directs the processor to calculate an average of a predetermined number of strokes per minute and record said average as a calibrated SPM (CSPM) value.
8. The device as claimed in claim 7, wherein said predetermined number of strokes per minute is between 2 and 200.
9. The device as claimed in claim 7, wherein said processor is further programmed to:
a) calculate a percent difference between a latest SPM value and said CSPM value; and b) display said difference on said display means.
10. The device as claimed in claim 9, further comprising means for establishing a wired or wireless connection to a remote display device.
11. The device as claimed in claim 10, wherein said processor is further programmed to transmit said ratio, said upstroke time interval, said downstroke time interval, or said difference via said wired or wireless connection to be displayed on said remote display device.
12. The device as claimed in claim 11, wherein said wireless connection means comprises a cellular modem.
13. The device as claimed in claim 12, wherein said wired or wireless connection means connects to a Supervisory Control and Data Acquisition (SCADA) system.
14. The device as claimed in claim 9, wherein said display means further comprises a series of LEDs adapted to display said difference.
15. The device as claimed in claim 14, wherein said series of LEDs comprises five LEDs in proximity to each other, and wherein:
a first LED represents said difference being an increase in said latest SPM value of 10% or more, a second LED represents said difference being an increase in said latest SPM value of 5% to less than 10%, a third LED represents said difference being either an increase or a decrease in said latest SPM value of less than 5%, a fourth LED represents said difference being a decrease in said latest SPM value of 5% to less than 10%, a fifth LED represents said difference being a decrease in said latest SPM value of 10% or more.
16. The device as claimed in claim 9, further comprising a sound emitting device, and said processor being further programmed to activate said sound emitting device to alert said operator to an alarm condition.
17. The device as claimed in claim 16, wherein said alarm condition is defined as said difference being either an increase or decrease in said latest SPM value of 10% or more.
18. The device as claimed in claim 1, wherein said first and second signals are electric signals.
19. The device as claimed in claim 1, wherein said display means comprises an alphanumeric screen.
20. A method of monitoring and displaying operating parameters of a reciprocating oil well pumping apparatus to an operator, the pumping apparatus moving a pump rod between a top-of-stroke position (TOSP) and a bottom-of-stroke-position (BOSP), said method comprising:
detecting instances when said pump rod is at at least one of said TOSP and said BOSP;
measuring time intervals between said instances;
calculating at least one operating parameter of said pumping apparatus based on said measured time intervals; and displaying said at least one operating parameter on a display means.
21. The method as claimed in claim 20, wherein said pumping apparatus comprises a first pump control sensor which creates a first pump control signal when said pump rod is at said TOSP, and a second pump control sensor which creates a second pump control signal when said pump rod is at said BOSP, and a controller operatively connected to said first and second pump control sensors, said controller using said first and second pump control signals to cause said pumping apparatus to move said pump rod between said TOSP and said BOSP, and said detecting step detects said instances when said pump rod is at said TOSP and said instances when said pump rod is at said BOSP by detecting said first and second pump control signals from said first and second pump control sensors.
22. The method as claimed in claim 21, wherein said first and second pump control signals are electric signals.
23. The method as claimed in claim 20, wherein said at least one operating parameter comprises a ratio of a number of strokes per unit time based on said measured time intervals.
24. The method as claimed in claim 23, wherein said unit time is minutes and said ratio is strokes per minute (SPM).
25. The method as claimed in claim 24, further comprising calculating and displaying on said display means an upstroke time interval defined as a length of time taken by said pump rod to move from said BOSP to said TOSP, and a downstroke time interval defined as a length of time taken by said pump rod to move from said TOSP to said BOSP.
26. The method as claimed in claim 25, further comprising the step of calculating an average of a predetermined number of strokes per minute and recording said average as a calibrated SPM (CSPM) value.
27. The method as claimed in claim 26, wherein said predetermined number of strokes per minute is between 2 and 200.
28. The method as claimed in claim 26, further comprising the steps of:
a) calculating a percent difference between a latest SPM value and said CSPM value; and b) displaying said difference on said display means.
29. The method as claimed in claim 28, further comprising the steps of establishing a wired or wireless connection to a remote display device.
30. The method as claimed in claim 29, further comprising the step of transmitting said ratio, said upstroke time interval, said downstroke time interval, or said difference to be displayed on said remote display device.
31. The method as claimed in claim 30, wherein said wireless connection is established using a cellular modem.
32. The method as claimed in claim 31, wherein said wired or wireless connection connects to a Supervisory Control and Data Acquisition (SCADA) system.
33. The method as claimed in claim 28, wherein said display further comprises a series of LEDs adapted to display said difference.
34. The method as claimed in claim 33, wherein said series of LEDs comprises five LEDs in proximity to each other, and wherein:
a first LED represents said difference being an increase in said latest SPM value of 10% or more, a second LED represents said difference being an increase in said latest SPM value of 5% to less than 10%, a third LED represents said difference being either an increase or a decrease in said latest SPM value of less than 5%, a fourth LED represents said difference being a decrease in said latest SPM value of 5% to less than 10%, a fifth LED represents said difference being a decrease in said latest SPM value of 10% or more.
35. The method as claimed in claim 33, further comprising the step of providing an auditory alarm to alert to said operator to an alarm condition.
36. The method as claimed in claim 35, wherein said alarm condition is defined as said difference being either an increase or decrease in said latest SPM value of 10%.
37. The method as claimed in claim 20, wherein said display means comprises an alphanumeric screen.
38. A system for monitoring and displaying operating parameters of a reciprocating oil well pumping apparatus to an operator, said pumping apparatus moving a pump rod between a top-of-stroke position (TOSP) and a bottom-of-stroke position (BOSP), said system comprising:
at least one of:
i) a first sensor for creating a first signal when said pump rod is at said TOSP, said first sensor being adapted for mounting on said pumping apparatus; and ii) a second sensor for creating a second signal when said pump rod is at said BOSP, said second sensor being adapted for mounting on said pumping apparatus;
a monitor device operatively connected to said at least one of said first and second sensors, said monitor device comprising:
a processor programmed to;
a) detect said at least one of said first and second signals from said at least one of said first and second sensors;
b) measure time intervals between said at least one first and second signals;
c) calculate at least one operating parameter of said pumping apparatus based on said measured time intervals; and d) provide an output of said at least one operating parameter; and a display means for receiving said output and displaying same.
39. The system as claimed in claim 38, wherein said first sensor is a first pump control sensor, said first signal is a first pump control signal, said second sensor is a second pump control sensor, said second signal is a second pump control signal, and said pumping apparatus further comprises a controller operatively connected to said first and second pump control sensors, said controller using said first and second pump control signals to cause said pumping apparatus to move said pump rod between said TOSP and said BOSP.
40. The system as claimed in claim 39, wherein said controller has an electronic bus, said at least one of said first and second sensors are connected to said controller at said electronic bus, and said monitor device is connected to said first and second sensors at said electronic bus.
41. The system as claimed in claim 39, wherein said at least one operating parameter comprises a ratio of a number of strokes per unit time based on said measured time intervals.
42. The system as claimed in claim 41, wherein said unit time is minutes and said ratio is strokes per minute (SPM).
43. The system as claimed in claim 42, wherein said monitor device is operatively connected to both of said first and second pump control sensors; said processor is programmed to detect both of said first and second pump control signals; and said at least one operating parameter further comprises one or both of an upstroke time interval defined as a length of time taken by said pump rod to move from said BOSP to said TOSP, and a downstroke time interval defined as a length of time taken by said pump rod to move from said TOSP to said BOSP.
44. The system as claimed in claim 43, wherein said pumping apparatus is a hydraulic oil well pumping apparatus.
45. The system as claimed in claim 44, wherein said monitor device further comprises a user interface, said user interface comprising means for selecting a calibrate function which directs the processor to calculate an average of a predetermined number of strokes per minute and record said average as a calibrated SPM (CSPM) value.
46. The system as claimed in claim 45, wherein said predetermined number of strokes per minute is between 2 and 200.
47. The system as claimed in claim 45, wherein said processor is further programmed to:
a) calculate a percent difference between a latest SPM value and said CSPM value; and b) display said difference on said display means.
48. The system as claimed in claim 47, further comprising means for establishing a wired or wireless connection to a remote display device.
49. The system as claimed in claim 48, wherein said processor is further programmed to transmit said ratio, said upstroke time interval, said downstroke time interval, or said difference via said wired or wireless connection to be displayed on said remote display device.
50. The system as claimed in claim 49, wherein said wireless connection means comprises a cellular modem.
51. The system as claimed in claim 50, wherein said wired or wireless connection means connects to a Supervisory Control and Data Acquisition (SCADA) system.
52. The system as claimed in claim 51, wherein said display means further comprises a series of LEDs adapted to display said difference.
53. The system as claimed in claim 47, wherein said series of LEDs comprises five LEDs in proximity to each other, and wherein:
a first LED represents said difference being an increase in said latest SPM value of 10% or more, a second LED represents said difference being an increase in said latest SPM value of 5% to less than 10%, a third LED represents said difference being either an increase or a decrease in said latest SPM value of less than 5%, a fourth LED represents said difference being a decrease in said latest SPM value of 5% to less than 10%, a fifth LED represents said difference being a decrease in said latest SPM value of 10% or more.
54. The system as claimed in claim 47, further comprising a sound emitting device, and said processor being further programmed to activate said sound emitting device to alert said operator to an alarm condition.
55. The system as claimed in claim 54, wherein said alarm condition is defined as said difference being either an increase or decrease in said latest SPM value of 10% or more.
56. The system as claimed in claim 38, wherein said first and second signals are electric signals.
57. The system as claimed in claim 38, wherein said first and second sensors are inductive proximity sensors.
58. The system as claimed in claim 38, wherein said pumping apparatus is controlled by a controller that does not use said first and second pump control sensors to cause said pumping apparatus to move said pump rod between said TOSP and said BOSP.
59. The system as claimed in claim 58, wherein said pumping apparatus is a horse head oil well pumping apparatus.
60. The system as claimed in claim 38, wherein said display means comprises an alphanumeric screen.
CA2772462A 2012-03-20 2012-03-20 Method, system, and device for displaying operating parameters of reciprocating oil well pumping apparatus Abandoned CA2772462A1 (en)

Priority Applications (1)

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Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CA2772462A CA2772462A1 (en) 2012-03-20 2012-03-20 Method, system, and device for displaying operating parameters of reciprocating oil well pumping apparatus

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