Method for monitoring and optimizing the performance of a well pumping system

Patent metadata

Field	Value
Publication number	US-9938805-B2
Application number	US-201514611814-A
Country	US
Kind code	B2
Filing date	Feb 2, 2015
Priority date	Jan 31, 2014
Publication date	Apr 10, 2018
Grant date	Apr 10, 2018

Abstract

A system for controlling a speed of a pump jack system having a variable speed prime mover includes a sensor attached to the pump jack system. The sensor is capable of detecting an absolute position of a first component of the pump jack system relative to a second component of the pump jack system and configured to send a signal proportional to the sensed absolute position and/or velocity and/or acceleration. The system includes process circuitry configured to accept the signal and perform a calculation related to absolute position and/or velocity and/or acceleration of the first component relative to the second component. The system includes a controller that is configured to receive the signal from the process circuitry and configured to send a signal to the prime mover to adjust a rotational speed of the prime mover and the position of the first component relative to the second component.

First claim

What is claimed is:

1. A pump jack system comprising:
a base having a frame extending upwardly;
a walking beam pivotally secured to the frame to pivot about a pivot axis on the frame;
a variable speed prime mover operably coupled to the walking beam to pivot the walking beam;
a magnetostrictive sensor having a magnet secured to the walking beam to move therewith and a waveguide secured to the frame such that the waveguide detects a position of the magnet corresponding to a pivotal position of the walking beam relative to the base or frame wherein the magnetostrictive sensor is configured to send a signal proportional to a sensed absolute position of the walking beam relative to the base or frame or velocity and/or acceleration of the pivotal motion of the walking beam relative to the base or frame;
process circuitry configured to accept the signal from the magnetostrictve sensor and configured to calculate an absolute position of the walking beam relative to the base or frame a velocity and/or an acceleration of the walking beam relative to the base or frame, the process circuitry configured to send a signal proportional to the calculated absolute position of the walking beam relative to the base or frame or velocity and/or acceleration of the walking beam relative to the base or frame;
and
a controller configured to receive the signal from the process circuitry and configured to send a signal to the prime mover to adjust the speed of the prime mover to adjust a rotational speed of the prime mover based on the sensing by the magnetostrictive sensor.

2. The pump jack system of claim 1 wherein the magnet is secured to a pendulum arm that is secured to the walking beam wherein the pendulum arm has a second pivot axis that aligns with the pivot axis of the walking beam and wherein the magnet is secured on the pendulum arm a distance from the second pivot axis.

3. The pump jack system of claim 2 wherein the waveguide is configured into an arcuate configuration having a radius approximately a length of the pendulum arm defined by the distance from the second pivot axis and the position of the magnet on the pendulum arm.

4. The pump jack system of claim 3 wherein the waveguide has a length sufficient to detect a position of the magnet through a complete pumping cycle of the pump jack system.

5. The pump jack system of claim 4 and further comprising a mounting plate secured to the frame and wherein the waveguide is secured to the mounting plate.

6. The pump jack system of claim 1 and further comprising:
a gearbox coupled to the variable speed prime mover;
a crank arm couple to the gearbox;
a Pittman arm coupled to the crank arm;
wherein the walking beam has a first end and a second end, an end of the Pittman arm pivotally attached to the first end of the walking beam;
a horsehead attached to a second end of the walking beam;
at least one cable having a first end and a second end, the first end of the cable attached to the horsehead;
a bridle bar attached to the second end of the at least one cable;
a polished rod having a first end and a second end, the first end of the polished rod engaging the bridle bar;
a sucker rod having a first end and a second end, the first end of the sucker rod attached to the second end of the polished rod;
and
a down-hole pump section attached to the second end of the sucker rod.

7. The pump jack system of claim 1 wherein the magnet is secured to the walking beam wherein pivotal motion of the walking beam causes pivotal motion of the magnet.

8. The pump jack system of claim 7 wherein the waveguide is secured to a mounting plate that is secured to the frame.

9. A method for controlling a pump jack system, the method comprising:
providing the pump jack system having a base with a frame extending upwardly and a walking beam pivotally connected to the frame, the walking beam pivoting about a pivot axis on the frame and a variable speed prime mover operably coupled to the walking beam to pivot the beam;
providing a magnetostrictive sensor having a magnet secured to the walking beam to move therewith and a waveguide secured to the frame such that the waveguide detects a position of the magnet corresponding to an absolute position of the walking beam relative to the base or frame;
sensing the absolute position of the walking beam relative to the base or frame or a velocity and/or an acceleration of pivotal motion of the walking beam relative to the base or frame with the magnetostrictive sensor;
sending a signal from the magnetostrictive sensor indicative of the absolute position of the walking beam relative to the base or frame or the velocity and/or the acceleration of pivotal motion of the walking beam relative to the base or frame to process circuitry;
sending a signal from the process circuitry to a controller related to the absolute position of the walking beam relative to the base or frame or the velocity and/or the acceleration of pivotal motion the walking beam relative to the base or frame;
and
sending a signal from the controller to the prime mover to adjust a rotational speed of the prime mover to adjust the absolute position of the walking beam relative to the base or frame or the velocity and/or the acceleration of pivotal motion of the walking beam relative to the base or frame based on the sensing by the magnetostrictive sensor.

10. The method of claim 9 wherein providing the magnetostrictive sensor comprises:
securing the magnet to a pendulum arm and a pivot axis of the pendulum arm aligns with the pivot axis of the walking beam frame;
and
securing the waveguide to the frame wherein the waveguide has an arcuate configuration with a radius substantialy the same as a distance from the magnet to the pivot axis of the pendulum arm such that the waveguide can detect the position of the magnet through an entire pump cycle.

11. The method of claim 9 wherein providing the magnetostrictive sensor on the pump jack system comprises: securing the magnet to the walking beam wherein pivotal motion of the walking beam causes pivotal motion of the magnet.

12. The method of claim 11 wherein providing the magnetostrictive sensor on the pump jack system comprises: securing the waveguide to a mounting plate that is secured to the frame.

Assignees

• Mts System Corp

Inventors

• Suprick Joseph Bernard
• Hankinson John Matthew
• Balding John William
• Wardle Michael Stephen

Classifications

• F04B47/022

  driving of the walking beam · CPC title

• E21B47/009

  Monitoring of walking-beam pump systems · CPC title

• G05B15/02

  electric · CPC title

• E21B2043/125

  Fixed Constructions · mapped topic

• E21B43/127 Primary

  Adaptations of walking-beam pump systems · CPC title