Mitigating fluid pound effects under incomplete pump fillage conditions

The current subject matter provides a tool and user interface for estimating a velocity at which a plunger of a rod lift pump system will impact a fluid within a well when the rod lift pump system is altered to operate under various conditions of pump fillage. In some embodiments, the estimated impact velocity can be determined using a velocity pattern characterizing a velocity and position of a plunger of a rod lift pump system operating under a condition of complete pump fillage. The estimated impact velocity can provide a user with useful insight into potential operation of the rod lift pump system when operating under various conditions of pump fillage.

BACKGROUND

Rod lift pump systems such as, e.g., beam pump systems, or sucker-rod pump systems, can be used to generate artificial lift to extract liquid from wells. Rod lift pump systems can include a surface pumping unit, which drives a plunger up and down within a barrel positioned within a well to generate artificial lift to extract liquid from the well. One parameter that can affect performance of the rod lift pump systems is pump fillage. Pump fillage can describe an amount of fluid that is within the barrel prior to a downstroke of the plunger. Pump fillage can be expressed as the amount of fluid within the well prior to the downstroke of the plunger, relative to a total amount of fluid that can be extracted based on a stroke length of the plunger. A fillage set point can describe a minimum acceptable pump fillage prior to a downstroke of the plunger. In some cases, if the pump fillage is less than the fillage set point prior to a downstroke of the plunger, the rod lift system can stop or slow pumping to allow the barrel to fill (thereby increasing the pump fillage). Typically, rod lift systems are set to operate with a pump fillage set point that is between 70% and 80%. By adjusting the pump fillage set point, the performance of the rod lift system can be altered. For example, decreasing the pump fillage set point can increase a volume of production from the well, but it can also lead to an increased risk of damaging components of the pump as a result of fluid pound. Fluid pound can occur when the rod lift system operates at less than 100% fillage causing the plunger to strike fluid within the barrel during down stroke.

SUMMARY

Systems, devices, articles, and methods for mitigating fluid pound are provided. In an aspect, a method is provided that includes receiving position data characterizing a position of a plunger over time. The plunger can form part of a rod lift pump system and the position can be measured by a first sensor. The plunger can be configured to travel between a first position and a second position within a barrel within a well, where a distance between the first position and the second position can define a stroke length. The method can also include receiving load data characterizing a load on a rod over time. The load can be measured by a second sensor and the rod can be coupled to the plunger. The method can further include receiving velocity data characterizing a velocity of the plunger while the rod lift pump system is operating under a condition of complete pump fillage. When operating under a condition of complete pump fillage, a portion of the barrel between the first position and the second position is completely filled with liquid prior to a downstroke of the plunger. The method can also include correlating, using at least the received load data and position data, the load on the rod and the position of the plunger. The method can include and displaying, on a graphical interface display space, a visualization of the velocity data simultaneously with a visualization of the correlated load and position.

One or more of the following features can be included in any feasible combination. In some embodiments, correlating the load on the rod and the position of the plunger can include determining a position of the plunger at a first time, determining a load on the rod at the first time, and matching the position of the plunger at the first time and load of the rod at the first time.

In some embodiments, the method can include determining the velocity data using at least the received position data.

In some embodiments, the load data can characterize the load on the rod coupled to the plunger over time while the rod lift pump system is operating under a condition of incomplete pump fillage. When operating under a condition of incomplete pump fillage, a portion of the barrel between a first position and the second position can be filled with gas prior to a downstroke of the plunger.

In some embodiments, the rod can be configured to drive the plunger between the first position and the second position.

In some embodiments, the method can include correlating, using at least the position data and the velocity data, the position and the velocity of the plunger. The method can also include displaying, on the graphical interface display space, an interactive graphical element that can be configured to interact with the visualization of the correlated load and position. A position of the interactive graphical element can be adjustable by a user. The position of the interactive graphical element can identify a position of the plunger and a correlated load on the rod. The method can include displaying, on a graphical interface display space, a visualization of a velocity of the plunger corresponding to the identified position of the plunger based on the correlated velocity and position of the plunger.

In some embodiments, the visualization of the velocity of the plunger corresponding to the identified position of the plunger can include a textbox graphical element.

In some embodiments, at least one of the receiving, the correlating, and the displaying can be performed by at least one data processor forming part of at least one computing system.

In another aspect, a non-transitory computer program product is provided having computer readable instructions, which, when executed by at least one data processor forming part of at least one computing system, implement operations which can include receiving position data characterizing a position of a plunger over time. The plunger can form part of a rod lift pump system and the position can be measured by a first sensor. The plunger can be configured to travel between a first position and a second position within a barrel within a well, where a distance between the first position and the second position can define a stroke length. The operations can also include receiving load data characterizing a load on a rod over time. The load can be measured by a second sensor and the rod can be coupled to the plunger. The operations can further include receiving velocity data characterizing a velocity of the plunger while the rod lift pump system is operating under a condition of complete pump fillage. When operating under a condition of complete pump fillage, a portion of the barrel between the first position and the second position is completely filled with liquid prior to a downstroke of the plunger. The operations can also include correlating, using at least the received load data and position data, the load on the rod and the position of the plunger. The operations can include and displaying, on a graphical interface display space, a visualization of the velocity data simultaneously with a visualization of the correlated load and position.

One or more of the following features can be included in any feasible combination. In some embodiments, correlating the load on the rod and the position of the plunger can include determining a position of the plunger at a first time, determining a load on the rod at the first time, and matching the position of the plunger at the first time and load of the rod at the first time.

In some embodiments, the operations can include determining the velocity data using at least the received position data.

In some embodiments, the load data can characterize the load on the rod coupled to the plunger over time while the rod lift pump system is operating under a condition of incomplete pump fillage. When operating under a condition of incomplete pump fillage, a portion of the barrel between a first position and the second position can be filled with gas prior to a downstroke of the plunger.

In some embodiments, the rod can be configured to drive the plunger between the first position and the second position.

In some embodiments, the operations can include correlating, using at least the position data and the velocity data, the position and the velocity of the plunger. The operations can also include displaying, on the graphical interface display space, an interactive graphical element that can be configured to interact with the visualization of the correlated load and position. A position of the interactive graphical element can be adjustable by a user. The position of the interactive graphical element can identify a position of the plunger and a correlated load on the rod. The operations can include displaying, on a graphical interface display space, a visualization of a velocity of the plunger corresponding to the identified position of the plunger based on the correlated velocity and position of the plunger.

In some embodiments, the visualization of the velocity of the plunger corresponding to the identified position of the plunger can include a textbox graphical element.

In another aspect, a system is provided having at least one data processor and memory coupled to the processor, the memory storing executable instructions, which, when executed by the at least one data processor, implement operations which can include receiving position data characterizing a position of a plunger over time. The plunger can form part of a rod lift pump system and the position can be measured by a first sensor. The plunger can be configured to travel between a first position and a second position within a barrel within a well, where a distance between the first position and the second position can define a stroke length. The operations can also include receiving load data characterizing a load on a rod over time. The load can be measured by a second sensor and the rod can be coupled to the plunger. The operations can further include receiving velocity data characterizing a velocity of the plunger while the rod lift pump system is operating under a condition of complete pump fillage. When operating under a condition of complete pump fillage, a portion of the barrel between the first position and the second position is completely filled with liquid prior to a downstroke of the plunger. The operations can also include correlating, using at least the received load data and position data, the load on the rod and the position of the plunger. The operations can include and displaying, on a graphical interface display space, a visualization of the velocity data simultaneously with a visualization of the correlated load and position.

One or more of the following features can be included in any feasible combination. In some embodiments, correlating the load on the rod and the position of the plunger can include determining a position of the plunger at a first time, determining a load on the rod at the first time, and matching the position of the plunger at the first time and load of the rod at the first time.

In some embodiments, the operations can include determining the velocity data using at least the received position data.

In some embodiments, the load data can characterize the load on the rod coupled to the plunger over time while the rod lift pump system is operating under a condition of incomplete pump fillage. When operating under a condition of incomplete pump fillage, a portion of the barrel between a first position and the second position can be filled with gas prior to a downstroke of the plunger.

In some embodiments, the rod can be configured to drive the plunger between the first position and the second position.

In some embodiments, the operations can include correlating, using at least the position data and the velocity data, the position and the velocity of the plunger. The operations can also include displaying, on the graphical interface display space, an interactive graphical element that can be configured to interact with the visualization of the correlated load and position. A position of the interactive graphical element can be adjustable by a user. The position of the interactive graphical element can identify a position of the plunger and a correlated load on the rod. The operations can include displaying, on a graphical interface display space, a visualization of a velocity of the plunger corresponding to the identified position of the plunger based on the correlated velocity and position of the plunger.

In some embodiments, the visualization of the velocity of the plunger corresponding to the identified position of the plunger can include a textbox graphical element.

DETAILED DESCRIPTION

Certain exemplary embodiments will now be described to provide an overall understanding of the principles of the structure, function, manufacture, and use of the systems, devices, and methods disclosed herein. One or more examples of these embodiments are illustrated in the accompanying drawings.

Rod lift pump systems, or sucker-rod pump systems, can be used to generate artificial lift to extract liquid from wells. As described above, one parameter that can affect performance of the rod lift pump systems is pump fillage. In some cases, incomplete pump fillage can lead to fluid pound, which can damage the rod lift pump system due to high forces exerted on components that drive the plunger. In some cases, a pump fillage set point can be implemented as an operational parameter. The pump fillage set point can describe a minimum acceptable pump fillage prior to a downstroke of the plunger. In some cases, if the pump fillage is less than the pump fillage set point prior to a downstroke of the plunger, the rod lift pump system can stop, or slow, pumping to allow the pump fillage to increase. By adjusting the pump fillage set point, the performance of the rod lift pump system can be altered. For example, decreasing the pump fillage set point can increase runtime, well inflow, and ultimately a volume of production from the well, but it can also lead to an increased risk of damaging components of the pump as a result of fluid pound.

But there may be limited information available for a production engineer or rod lift system operators to determine whether it is safe to decrease, or increase, a pump fillage set point of a rod lift system. The current subject matter provides a tool and user interface for estimating a velocity at which a plunger of a rod lift system will impact a fluid, gas, or a combination of both fluid and gas, within a well. The estimated impact velocity can provide a user with useful insight into potential operating conditions of the rod lift system while operating under various conditions of pump fillage. For example, if the estimated impact velocity is high under a certain condition of pump fillage, a user can choose to set the pump fillage set point at a different value, where an estimated impact velocity is lower. Therefore, the user can limit the estimated plunger impact velocity. The tool and user interface can provide a quick estimate of impact velocity of the plunger without requiring time consuming modeling efforts.

As described herein, rod lift systems can include a surface pumping unit, which can be attached to a rod string that drives a plunger up and down within a barrel positioned within a well to generate artificial lift to extract liquid from the well.FIGS. 1-2are cross section views showing a downhole portion of a well100that includes a downhole pump102configured to facilitate extracting liquid from the well100.FIG. 1shows a plunger114of the downhole pump102in a first position101, andFIG. 2shows the plunger114in a second position103.

In the illustrated embodiment, the well100has a primary well bore104, and includes a casing106that extends along the length of the well bore104. The casing106can include perforations108that can align with fractures110in the well bore104such that fluid can flow from the fractures110, through the perforations108, and into the casing106of the well100.

The well100can include tubing112that can extend into the well bore104from a surface opening of the well100. The tubing112can be configured to receive liquid from the well100and to facilitate extraction of liquid from the well100. The downhole pump102can be retained within and/or coupled to the tubing112, and can include the plunger114, a stationary valve assembly116, and a barrel118. The barrel118can retain the plunger114, and can be positioned within the tubing112. The stationary valve assembly116can be coupled to the barrel118, and can be positioned downhole relative to the plunger114. The plunger114and the stationary valve assembly116can include a traveling valve120and a standing valve122, respectively. The traveling valve120and the standing valve122can be configured to permit fluid to flow upward relative to the plunger114and the stationary valve assembly116, respectively.

As shown inFIGS. 1-2, a rod119can be coupled to the plunger114. The rod119can also be coupled to a surface pumping unit (not shown) such that the surface pumping unit can drive the plunger114back and forth between the first position101and the second position103to extract liquid from the well100. The motion of the plunger between the first position101and the second position103can define a pump cycle. A distance between the first position101and the second position103can define a stroke length L of the plunger114. A stroke rate, typically defined in strokes per minute, can characterize a number of complete strokes, including an upstroke and a downstroke, which the plunger114can undergo in a given amount of time.

In operation, as the plunger114driven from the first position101to the second position103, e.g., during an upstroke, the traveling valve120is forced against a seat124of the plunger114, the standing valve122is drawn away from a seat126of the stationary valve assembly116, and liquid is drawn into the barrel118. During the upstroke, liquid that is positioned above the traveling valve120is forced toward the surface opening of the well100, thereby allowing it to be extracted.

As the plunger114is driven from the second position103to the first position101, e.g., during a downstroke, the standing valve122is forced against the seat126of the stationary valve assembly116, the traveling valve120is forced away from the seat124of the plunger114, and liquid between the plunger114and the stationary valve assembly116flows into, and/or through, the plunger114.

While the downhole pump102is operating under a condition of complete pump fillage, as shown inFIGS. 1-2, liquid from the well100is drawn into the barrel118at the same rate as the plunger114is driven toward the second position103during the upstroke, and a portion of the barrel118between the first position101and the second position103is completely filled with liquid prior to the downstroke, as shown inFIG. 2. During operation, a position sensor127and a load sensor129can measure a position of the plunger114over time, and a load on the rod119, over time, respectively. In some embodiments, the position sensor127can be an accelerometer, and the load sensor129can be a load cell. In some embodiments, position and load sensors can be located at a surface location of the well100, and can measure a position of the rod119, and a load on the rod119, at the surface. The position sensors can be a combination or rotations-per-minute (RPM) and crank transducers, inclinometers, and/or accelerometers. The load sensors can be, e.g., one or more load cells.

In some cases, well production can be increased by operating the downhole pump under conditions of incomplete pump fillage. As an example, incomplete pump fillage can occur in systems in which gas is not separated, or in systems in which pump displacement exceeds well inflow. For example, if a rate of extraction of liquid from a well exceeds a rate at which the well can refill, gas can be drawn into the well during the upstroke, thereby creating a condition of incomplete pump fillage. In some cases, a void section can be created in an upper part of the pump during the upstroke, thereby creating a condition of incomplete pump fillage.FIGS. 3-4show the well100when the downhole pump102is operating under a condition of incomplete fillage.

While operating under a condition of incomplete fillage, liquid and gas can be drawn into the barrel118during an upstroke of the plunger114, and a portion of the barrel118between the first position101and the second position103can contain a combination of gas128and liquid130, as shown inFIG. 4. Pump fillage can be described as a height of the liquid130between the first position101and a liquid-gas interface132relative to the stroke length L. Pump Fillage can be expressed as a percentage.

The presence of the gas128, or a void or empty portion of an upper section of the barrel118can result in “fluid pound” during a downstroke of the plunger114. For example, as the plunger114is driven from the second position103to the first position101during the downstroke, the plunger can compress the vapor128and can strike the liquid-gas interface132. An abrupt change in density and viscosity between the gas128and the liquid130during the downstroke can jar components of the rod lift system. For example, fluid pound can buckle the rod119as a result of an abrupt change in load on the rod119.

In some cases, a pump fillage set point can be used to control operating conditions of a rod lift system. As described herein, a pump fillage set point can describe a minimum acceptable pump fillage prior to a downstroke of a plunger. In certain cases, decreasing the pump fillage set point can result in increased production from wells. However, decreasing the pump fillage set point can also result in more fluid pound, which, as described herein, can be detrimental to the rod lift system.

There may be limited information available for a rod lift system operator, such as a production engineer, to determine whether it is safe to decrease or increase, a pump fillage set point of a rod lift system.FIG. 5illustrates a process flow diagram of an exemplary method200for estimating a velocity at which a plunger of a rod lift system (e.g., a sucker rod system or a beam pump system) will impact a fluid within a well when the rod lift system is altered to operate under various pump fillage conditions. The estimated impact velocity can provide a user with useful insight into potential operation of the rod lift system while operating under various conditions of pump fillage. For example, if the estimated impact velocity is high under a certain condition of pump fillage, which might cause a rod of the rod lift system to buckle, a user can choose to set the pump fillage set point at a different value in which an estimated impact velocity is lower.

As shown at step202inFIG. 5, the method200can include receiving position data characterizing a position of a plunger (e.g., the plunger114shown inFIGS. 1-4) over time. The plunger can form part of a rod lift system, and the position can be measured by a first sensor (e.g., the position sensor127shown inFIGS. 1-4). The plunger can be configured to travel between a first position and a second position within a barrel within a well, and a distance between the first position and the second position can define a stroke length. In some embodiments, the position sensor can provide the position data to a data processor that can process the position data.FIG. 6shows a plot300that includes exemplary position data302that characterizes a position of a plunger over time. As shown in the illustrated example, the plunger can travel between a first position301and a second position303in which a distance between the first position and the second position defines a stroke length L3.

The method200can also include receiving load data characterizing a load on a rod (e.g., the rod119shown inFIGS. 1-4) over time, the being load measured by a second sensor (e.g., the load sensor129), the rod coupled to the plunger, as shown at step204. In some embodiments, the load sensor can provide the load data to a data processor that can process the data. As an example, the data processor can be the same data processor that receives the position data.FIG. 7shows a plot400that includes exemplary load data402that characterizes a load on a rod over time. In some cases, a “surface dynagraph” can be generated based on sensor measurements from sensors positioned at a surface of the well. A “downhole dynagraph” can be determined using the surface dynagraph. The downhole dynagraph can include the load data and position data.

As shown as step206, the method200can include receiving velocity data characterizing a velocity of the plunger while the rod lift system is operating under a condition of complete pump fillage, wherein a portion of the barrel between the first position and the second position is completely filled with liquid prior to a downstroke of the plunger, as described above with regard toFIGS. 1-2. In some embodiments, the velocity of the plunger can be determined using position data. For example, the data processor can process the position data, and determine a change in position over a corresponding change in time to determine a velocity of the plunger at a given time.

At step208, the method200can include correlating, using at least the received load data and position data, the load on the rod and the position of the plunger. As shown inFIGS. 6-7the position data302and the load data402can characterize a position of the plunger and a load on the rod over a period of time. Accordingly, the position of the plunger at a given time can be correlated to the load on the rod at the given time. In some cases, the position data302and the load data402can have different temporal resolutions, and can have data points that do not align in time, as shown inFIGS. 6-7. In such cases, the load data402can be interpolated such that the load data402has the same temporal resolution as the position data302, and the position of the plunger and the load on the rod can be correlated.FIG. 8shows a plot500that includes load data502, based on the load data402shown inFIG. 7, that has been interpolated such that the load data502has the same temporal resolution as the position data302, and such that data points of load data502and data points of the position data302align in time. Therefore, a load on the rod at a given time can be matched to a position of the plunger at the given time. Accordingly, load on the rod can be determined based on a position of the plunger, and vice versa. There are a number of other ways that can facilitate correlating the load on the rod and the position of the plunger. For example, portions of the load data402and position data302can be curve fit, providing a set of equations that can be solved for load as a function of position, or vice versa. Other implementations are possible.

During normal operation, the load on the rod and the velocity of the plunger at a given position in the pump cycle can vary between pump cycles. Accordingly, load data used can be averaged over two or more pump cycles. For example, load on the rod at a given position in the pump cycle can be averaged over multiple pump cycles to generate an averaged value of load on the rod at the given position. Similarly, velocity data can be averaged over two or more pump cycles. For example, velocity of the plunger at a given position in the pump cycle can be averaged over multiple pump cycles to generate an averaged velocity of the plunger at the given position.

In some embodiments, the velocity of the plunger can be correlated to the position of the plunger in a manner similar to that described herein with regard to the correlated load on the rod and position of the plunger. Accordingly, the velocity data can characterize the velocity and correlated position of the plunger.

As shown at step210, the method can further include displaying, on a graphical interface display space, a visualization of the velocity data simultaneously with a visualization of the correlated load and position. For example, the data processor can provide the velocity data and correlated load and position data to a user device such that the user device can display the data on graphical interface display space. The velocity data can provide an estimate of a velocity at which the plunger will impact liquid under various conditions of pump fillage, as described in more detail below.

FIG. 9shows a view600of an exemplary graphical user interface (GUI) that can be rendered on a display of a user device. The GUI includes a load plot602that shows a load pattern604, and a velocity plot606that shows first and second velocity patterns608,610.

The load pattern604characterizes correlated load on a rod and position of a plunger of a rod lift system operating under a first set of operating parameters. For example, the first set of operating parameters can include a current set of operating parameters, and can include a first stroke rate, a first stroke length, and a first pump fillage. In some embodiments, the load pattern can characterize correlated load on the rod and position of the plunger of the rod lift system while operating under a condition of complete pump fillage. In other embodiments, the load pattern can characterize correlated load on the rod and position of the plunger of the rod lift system while operating under a condition of incomplete pump fillage. During operation, the plunger can travel between a first position601and a second position603. The plunger can travel from the first position601to the second position603during an upstroke, and from the second position603to the first position301during a downstroke. An upper portion611of the load pattern604corresponds to an upstroke of the plunger, and a lower portion613of the plunger corresponds to a downstroke of the plunger.

As shown inFIG. 9, the load plot602can include a slider612that can be moved along an X axis of the plot602to identify a hypothetical pump fillage set point. The slider612can also identify current values of load on the rod corresponding to a position of the slider612. The current values of load on the rod can be load values corresponding to positions in which the slider612intersects the upper and lower portions611,613of the load pattern604. The load plot602can also include a graphical element614that identifies a fill base and characterizes a buoyancy force on the rod of the lift rod system. In the illustrated example, the stroke length of the plunger is 100 inches (in.), and the slider is positioned at 58 in. Accordingly, the slider612identifies a hypothetical, or current, pump fillage set point of 58%.

The load plot602can also include a first graphical indicator616that can be moved along the downstroke portion613of the load pattern604to identify the hypothetical pump fillage set point. The first graphical indicator616can also identify a magnitude of load on the rod during a downstroke of the plunger. The first graphical indicator616can have a default location corresponding to a position where the slider612intersects the downstroke portion613of the load pattern604. In the illustrated example, the first graphical indicator616identifies a hypothetical, or current, pump fillage set point of 58%. In some embodiments, the first graphical indicator616can move in conjunction with movement of the slider612. For example, if the slider is moved to 50 in. on the X axis, the first graphical indicator can move along the downstroke portion613of the load pattern604with the slider612to the position of 50 in. In other embodiments, the slider612and the first graphical indicator616can be moved independently.

The first velocity pattern608characterizes correlated velocity and position of the plunger of the rod lift system while operating under the first set of operating parameters. Accordingly, the load pattern and the first velocity pattern characterize operation of the rod lift system under the first set of operating parameters.

The second velocity pattern610characterizes correlated velocity and position of the plunger of the rod lift system when operating under a second set of operating parameters which can be different than the first set of operating parameters. The second set of operating parameters can include a second stroke rate, a second stroke length, and second pump fillage that can be different from the first stroke rate, the first stroke length, and the first pump fillage. However, in certain cases, the second stroke rate and the second stroke length can be approximately equal to the first stroke rate and the first stroke length, respectively. As used herein, approximately equal includes values of the second stroke rate and the second stroke length that are within about 10% of the values of the first stroke rate and the first stroke length, respectively. In the illustrated example, the second velocity pattern610characterizes correlated velocity and position of the plunger while operating under a condition of complete pump fillage. The second stroke rate and stroke length are approximately equal to the first stroke rate and stroke length. In the illustrated example, positive values of velocity correspond to the upstroke of the plunger, and negative values of velocity correspond to the downstroke of the plunger.

During normal operation, the load on the rod and the velocity of the plunger at a given position in the pump cycle can vary between pump cycles. Accordingly, load data used to generate the load pattern604can be averaged over two or more pump cycles. For example, load on the rod at a given position in the pump cycle can be averaged over multiple pump cycles to generate an averaged value of load on the rod at the given position. Similarly, velocity data used to generate the velocity patterns608,610can be averaged over two or more pump cycles for each of the velocity patterns608,610. For example, velocity of the plunger at a given position in the pump cycle can be averaged over multiple pump cycles to generate an averaged velocity of the plunger at the given position.

Alternatively, the load pattern604can correspond to load data from a single pump cycle (e.g., the previous complete pump cycle). Similarly, the first velocity pattern608can correspond velocity data from a single pump cycle (e.g., the previous complete pump cycle). The second velocity pattern610can correspond velocity data that has been averaged over two or more pump cycles.

The velocity plot606can include a second graphical indicator618that can identify an estimated velocity at which a plunger will impact liquid within a well given a pump fillage that is equal to the hypothetical pump fillage set point identified by the first graphical indicator616. The second graphical indicator618can be located on the downstroke portion of the second velocity pattern610, at a position that corresponds to the position of the first graphical indicator616on the load pattern604. For example, as shown inFIG. 9, the second graphical indicator618is located on the downstroke portion of the velocity pattern at a position of 58 in., which corresponds to the hypothetical pump fillage of 58%, as identified by first graphical indicator616. Accordingly, the second graphical indicator618identifies an estimated impact velocity of approximately 40 in./second (sec.) based on the condition of 58% pump fillage. In the illustrated embodiment, the position of the second graphical indicator618can change as a result of a change of the position of the first graphical indicator616changes. In some embodiments, the position of the first graphical indicator616can change as a result of a change of the position of the second graphical indicator618. Therefore, the position of the slider612can change as a result of a change of the position of the second graphical indicator618, and vice versa.

Under ideal conditions, a plunger can be expected to reach a maximum velocity magnitude at a point midway through the downstroke of the pump cycle, with the velocity smoothly increasing until the midway point, and decreasing thereafter, until the downstroke is complete. Accordingly, for a stroke length of 100 in., a maximum magnitude of velocity can be expected to occur at a position of 50 in. during the downstroke. However, as shown in the second velocity pattern610, the velocity of the plunger can deviate from the ideal condition during the downstroke. Accordingly, in some cases, the plunger can reach a maximum velocity at a position other than the point midway through the downstroke. For example, during the downstroke, between the second position603and the position identified by the second graphical indicator618, the velocity of the plunger reaches a maximum magnitude of approximately 45 in./sec., while the estimated velocity corresponding to the condition of 58% pump fillage is approximately 40 in./sec. Accordingly, a maximum estimated impact velocity can be determined based on the position of the second graphical indicator618. The maximum estimated impact velocity can be a maximum magnitude of velocity observed between the second position603and the position of the second graphical indicator618. A third graphical indicator622can identify a maximum estimated impact velocity based on based on the hypothetical, or current, pump fillage condition.

The velocity plot606can include a fourth graphical indicator623that can identify a current set maximum velocity of the plunger. The fourth graphical indicator623that can be located on the downstroke portion of the second velocity pattern610. If the hypothetical condition of pump fillage, identified by the second graphical indicator618, is set or entered, the position of the fourth graphical indicator623can be adjusted to represent the estimated impact velocity identified by the second graphical indicator618.

In some embodiments, the current set maximum velocity of the plunger, identified by the fourth graphical indicator623, can have a corresponding deadband value, and/or range of values, to prevent the plunger from reaching a velocity that is above the current set maximum velocity. For example, the deadband can limit the velocity of the plunger based on the set maximum velocity of the plunger. In the illustrated embodiment, the current set maximum velocity of the plunger is approximately 20 in./sec. In some embodiments, the deadband can limit the maximum velocity of the plunger such that it is within a certain margin of error. For example, the deadband can limit the velocity of the plunger to a value of the current set maximum velocity of 20 in./sec. plus, or minus, about 5 in./sec.

As described herein, the second graphical indicator identifies an estimated impact velocity of approximately 40 in./sec. If the hypothetical pump fillage set point corresponding to the second graphical indicator618is entered, the set maximum velocity of the plunger, identified by the fourth graphical indicator623, will be adjusted to 40 in./sec. Although the maximum velocity is observed to be approximately 45 in./sec., the deadband can prevent the velocity of the plunger from exceeding the set maximum velocity of 40 in./sec. In some embodiments, the deadband can limit the maximum velocity of the plunger such that it is within a certain margin of error. For example, the deadband can limit the velocity of the plunger to a value of the set maximum velocity plus, or minus, 5 in./sec.

The view600can also include information panel605that can provide options and information related to the velocity plot606. The information panel can include a checkbox620option to display the second velocity pattern610, as well as first and second textboxes607,609that can provide information related to the second velocity pattern610. In the illustrated example, the first textbox607provides a stroke rate match percentage, and indicates that the second stroke rate, corresponding to the second velocity pattern610, is a 99% match to the first stroke rate, corresponding to the first velocity pattern608. The second textbox609provides a stroke length match percentage, and indicates that the second stroke length, corresponding to the second velocity pattern610, is a 99% match to the first stroke length, corresponding to the first velocity pattern608.

In some embodiments, plunger position and velocity can be normalized as a percentage of gross stroke length. Therefore, the velocity patterns608,610can characterize normalized velocity as a function of normalized position.

In some embodiments, the view600can include a set point panel624. The set point panel624can provide values corresponding to a current pump fillage set point, a current fill base, and a maximum fluid load. The set point panel624can include textboxes626,628,630corresponding to pump fillage set point, fill base, and maximum fluid load, respectively. The textboxes626,628,630can be configured to received input from a user to set the pump fillage set point, fill base, and maximum fluid load, respectively. The set point panel624can include a button632that a user can select to apply values entered into the textboxes626,628,630. As an example, a user can input a value for a pump fillage set point, and press the button632. A data processor can receive an input pump fillage set point, process the data, and provide the data for a controller that controls the rod lift system. The controller can receive the data characterizing the input pump fillage set point, and apply the input pump fillage set point as a parameter within a set of operating parameters of the rod lift system. Similarly, values characterizing a fill base and/or maximum fluid load can be delivered to the controller.

In some embodiments, magnitudes of the estimated impact velocities identified by the second and third graphical indicators618,622can be displayed in textboxes634,636, as shown inFIG. 10. Similarly the hypothetical, or current, pump fillage set point and corresponding estimated maximum velocity can be displayed in a textbox638. The current set maximum velocity identified by the fourth graphical indicator623can displayed in a textbox640. In some embodiments, the textboxes634,636,638,640can be positioned adjacent to the graphical indicators618,622,616,623, for example, as shown inFIG. 10. In other embodiments, the values of pump fillage set point and velocity identified by the graphical indicators616,618,622,623can be displayed elsewhere in the view600.

Accordingly, the velocity pattern610can provide a user with useful information regarding potential operation of a rod lift system under various pump fillage conditions, without requiring complex modeling efforts. An estimated impact velocity corresponding to a hypothetical pump fillage set point, identified by the first and second graphical indicators616,618, can provide a user with useful insight into potential operation of the rod lift system such that the user can make informed decisions. For example, a user can use the estimated velocity to determine if it is safe to adjust (e.g., increase, or decrease) the pump fillage set point. If the estimated impact velocity, or the maximum estimated impact velocity, identified by the second and third graphical indicators618,622, respectively, is high under a hypothetical condition of pump fillage, a user may choose to set the pump fillage set point at a different value, limiting an estimated impact velocity, and/or the maximum estimated impact velocity.

In some embodiments, a view of the GUI can show information related to a number of wells on a well pad, as illustrated in the view700shown inFIG. 11. In the illustrated example, the view700includes a pump fillage plot702, a legend704, and a parameter panel706.

InFIG. 11, the pump fillage plot702includes data points characterizing pump fillage set points and maximum plunger velocity for multiple wells. In some embodiments, the data points corresponds to wells of a single well pad. In other embodiments, the data points can corresponds to well of more than one well pad. In some embodiments, data points on the pump fillage plot702can characterize pump fillage set points, as well as other parameters such as, e.g., average plunger velocities, maximum and/or acceleration, etc.

The legend704can identify and characterize data sets that can be illustrated in the pump fillage plot702. The data sets can be determined based on sorting criterion entered into the parameter panel706, as discussed in more detail below. In the illustrated example, the data point in the pump fillage plot702are sorted into six data sets705a,705b,705c,705d,705e,705fthat characterize operation of a rod lift system. The data sets705a,705bcorrespond to rod lift systems that have plungers that can achieve velocities greater than a maximum set velocity. The data set705aidentifies rod lift systems with plungers that operate below perforations in a casing in of the wells. The data set705bidentifies rod lift systems with plungers that operate at, or above, perforations in a casing of the wells.

The data sets705c,705dcorrespond to rod lift systems that have plungers that have maximum velocities that are below the maximum set velocity. The data set705cidentifies rod lift systems with plungers that operate below perforations in a casing in of the wells. The data set705didentifies rod lift systems with plungers that operate at, or above, perforations in a casing of the wells.

The data sets705e,705fcorrespond to rod lift systems that have plungers that have maximum velocities that at the maximum set velocity. The data set705eidentifies rod lift systems with plungers that operate below perforations in a casing in of the wells. The data set705fidentifies rod lift systems with plungers that operate at, or above, perforations in a casing of the wells.

The parameter panel706can include options for displaying information on the pump fillage plot702. For example, the parameter panel can include textboxes708,710that can be configured to receive input data characterizing a current pump fillage set point to diagnose or assess current operating conditions, and a maximum plunger velocity to create hypothetical cases, respectively. A user can choose to sort data points on the pump fillage plot702based on operating parameters such as, e.g., a maximum plunger velocity, or a pump fillage set point, using a menu712. In the illustrated example, the data points in the pump fillage plot702are sorted by maximum plunger velocity.

The parameter panel706can also include buttons714,716that can allow a user to plot data points characterizing current well operating conditions, or hypothetical well operating conditions. For example, if the button714is selected, the pump fillage plot702can show data points characterizing wells based on current pump fillage set points and maximum plunger velocities. The plot can also sort the wells based on the option selected in the menu712, and the corresponding value entered into the textboxes708,710. As another example, if the button716is selected, the plot702can identify data points corresponding to wells that can operate under one or more of the conditions entered into the textboxes708,710, depending on a sorting method selected in the menu712. The parameter panel can also include preview and reset buttons718,720that can execute hypothetical models based on hypothetical well operating conditions, and reset the plot702to show data points based on current operating conditions, respectively. The ability to assess hypothetical operating conditions of a well can provide a user with the ability to quickly evaluate aggressive models, or hypothetical well operating conditions, in which a pump fillage set point is set to be low, as well as providing the ability for a user to assess more conservative models in which the pump fillage set point is set high to protect the rod lift systems.

In the illustrated embodiment, a user can select a data point on the pump fillage plot702, and a textbox703showing information about the well and a corresponding rod lift system can be displayed, as shown inFIG. 12. The textbox703can display a well name, a pump fillage set point, a stroke rate, a stroke length, or gross stroke, and a maximum plunger velocity. In some cases, for example if the button716corresponding to hypothetical inputs is selected, the textbox703can show information related to the hypothetical inputs.

In some embodiments, parameter panel706can also include a textbox707that can receive data that can identify one or more wells. For example, a user can enter a well identification number, a well name, or other identifying parameter, into the textbox707, and can press a button709to display a data point corresponding to the well on the pump fillage plot702. In some embodiments, a data point can be identified based on values entered into the textboxes708,710, and a sorting criterion selected in the dropdown menu712.FIG. 13shows a view800that includes a pump fillage plot802with a data point803corresponding to a well identified by data entered into the textbox707. A legend804can provide identifying characteristics of the data point803, and can describe selection criterion entered into the textboxes707,708,710.

FIG. 14shows another view900of a GUI that can be rendered on a display of a user device. The view can include a well plot902and a well table904. The well plot902includes data points characterizing well numbers and pump fillage set points for multiple wells. The well table904can include data characterizing stroke rates and pump fillage set points of the wells identified in the well plot902.

FIG. 15illustrates an exemplary system block diagram of an embodiment of a monitoring and control system1000configured to facilitate estimating plunger impact velocities at various hypothetical pump fillage set points. The monitoring and control system1000can include an advisory system1001that can be configured to provide a rod lift operator with useful insight into potential operation of the rod lift system such that the plant operator can make informed decisions. In the illustrated embodiment, the advisory system1001is operably coupled to a well pad1002that includes a number of rod lift systems1004in which each rod lift system1004corresponds to a well. Each rod lift system1004can have one or more sensors1006operable coupled thereto for measuring operating values of the rod lift systems1004. For example, the sensors1006can be similar to the sensor127,129, described herein with regard toFIGS. 1-4, and can measure positions of plungers of the rod lift systems1004, as well as loads on rods of the beam bump systems1004, over time. Alternatively, the sensors1006can be positioned at a surface of the well. The sensors1006can communicate with the advisory system1001via a gateway1008(e.g., a router). The advisory system1001can also be operably coupled to other type of facilities as well. Each rod lift system1004can also have one or more controllers1007operably couple thereto for controlling operation of the rod lift systems1004. The controllers1007can communicate with the advisory system1001via the gateway1008. For example, the advisory system1001deliver data characterizing instructions for setting a stroke rate and/or a pump fillage set point to the controllers1007via the gateway1008.

The advisory system1001can include an analysis module1010and a dashboard1012, both of which can be, or can include a data processor. The analysis module1010can be configured to process data from the sensor and generate operational data characterizing an operational status of the rod lift systems1004of the well pad1002. For example, the analysis module1010can receive sensor data such as position data characterizing a position of a plunger, and/or a position of a rod at the surface, over time, load data characterizing a load on a rod over time, and velocity data characterizing a velocity of the plunger, from the sensor1006. In some embodiments, the analysis module1010can determine the velocity data using the position data. The analysis module1010can also correlate the load on the rod and the position of the plunger using the load data and the position data, as well as the position and velocity of the plunger, using the position data and the velocity data. Data characterizing the correlated load on the rod and the position of the plunger can be referred to as load pattern data, and data characterizing the correlated position and velocity of the plunger can be referred to as velocity pattern data. The analysis module1010can provide the operational data, including the load pattern data and the velocity pattern data, to the dashboard1012.

The dashboard1012can be configured to facilitate communication between the analysis module1010and a user device1014. The dashboard1012can receive the operational data, format the operational data, and create instructions that the user device1014can use to render a GUI (e.g. the GUIs illustrated inFIGS. 9-14) that can provide the user with some, or all, of the operational data, as desired. For example, the dashboard1012can receive the load pattern data, and the velocity pattern data, format the load pattern data and the velocity pattern data, and generate instructions for rendering the load pattern data and the velocity pattern data on a display of the user device1014. In some embodiments, the dashboard can render a GUI, including a load pattern and velocity pattern based on the load pattern data and the velocity pattern data, respectively. The dashboard can provide the rendered GUI to the user device1014. The user device1014can display the GUI on a graphical interface display space of the user device1014.

The dashboard1012can also receive input data from the user device1014. For example, a plant operator can provide instructions for altering a maximum fluid load, stroke rate and/or a pump fillage set point for one or more of the rod lift systems1004via the user device1014. The dashboard1012can receive the instructions, format the instructions, and provide the instructions to the analysis module1010. The analysis module1010can receive the instructions, format the instructions, and deliver data characterizing the formatted instructions to the controllers1007coupled to the rod lift systems1004. The controllers1007can receive the data characterizing the instructions, process the data, and apply the instructions to alter operation of the rod lift systems1004.

Exemplary technical effects of the subject matter described herein include the ability to estimate a velocity at which a plunger of a rod lift system will impact a fluid within a well if the rod lift system is altered to operate under various conditions of pump fillage. Estimated impact velocities corresponding to various hypothetical conditions of pump fillage can be determined by operating the rod lift system under a condition of complete pump fillage, using sensors to determine a position of the plunger of the rod lift system, and generating a velocity pattern characterizing a pump cycle of the operation, based on data from the sensor. For example, the sensor data can be delivered to an analysis module, which can be, or can include, a data processor. The analysis module can receive the sensor data, process the data, and generate the velocity pattern. In some embodiments, the velocity pattern can characterize an average pump cycle for a given set of operating parameters. Data characterizing the velocity pattern can be delivered to a dashboard, which can be, or can include, a data processor. The dashboard can receive the data, format the data, and deliver it to a user device to be displayed on a graphical interface display space of the user device.

In some embodiments, the dashboard can render a GUI, including a graphical representation of the velocity pattern, and deliver data characterizing the GUI to the user device to be displayed. In other embodiments, the dashboard can deliver data characterizing the GUI to the user device, and a data processor of the user device can render the GUI to be displayed. The user can identify a hypothetical condition of pump fillage by interacting with a graphical element displayed on the graphical interface display space of the user device. The estimated impact velocity corresponding to the identified hypothetical condition of pump fillage can be displayed on the graphical interface display space of a user device. The user can adjust the hypothetical condition of pump fillage by interacting with the graphical element display on the graphical interface displace space of the user device, and the estimated impact velocity can be updated accordingly. The estimated impact velocity can provide a user with useful insight into potential operation of the rod lift system while operating under various conditions of pump fillage, without requiring time consuming modelling efforts. For example, if the estimated impact velocity is high under a certain hypothetical condition of pump fillage, the user can choose to set the pump fillage set point at a different value to operate in a section of the plunger velocity pattern that limits the impact velocity during conditions of incomplete pump fillage.

As described herein, in some embodiments, the user can enter a pump fillage set point using a GUI displayed on the graphical interface display space of the user device. Data characterizing the pump fillage set point can be delivered to a dashboard. The dashboard can receive the data instructions, and provide the instructions to an analysis module. The analysis module can receive the instructions, format the instructions, and deliver data characterizing the formatted instructions to controllers coupled to the rod lift systems. The controllers can receive the data characterizing the instructions, process the data, and apply the instructions to alter operation of the rod lift systems.

As described herein, utilizing a velocity pattern to provide an estimated impact velocity can provide a user with useful insight into potential operation of the rod lift system while operating under various conditions of pump fillage, without requiring time consuming modelling efforts. Computer generated models that can be used to simulate operation of rod lift systems can be complex and involve a relatively high number of variables. As a result of the complexity of the models, the modeling can be very time intensive. Estimating the impact velocity of the plunger when operating under a hypothetical condition of pump fillage provides a quick and easy way to gain insight into potential operation of the rod lift system, as compared to other modeling techniques.

One skilled in the art will appreciate further features and advantages of the subject matter described herein based on the above-described embodiments. Accordingly, the present application is not to be limited specifically by what has been particularly shown and described. All publications and references cited herein are expressly incorporated herein by reference in their entirety.

Other embodiments are within the scope and spirit of the disclosed subject matter. Those skilled in the art will understand that the systems, devices, and methods specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary embodiments and that the scope of the present invention is defined solely by the claims. The features illustrated or described in connection with one exemplary embodiment may be combined with the features of other embodiments. Such modifications and variations are intended to be included within the scope of the present invention. Further, in the present disclosure, like-named components of the embodiments generally have similar features, and thus within a particular embodiment each feature of each like-named component is not necessarily fully elaborated upon.

Further, in the present disclosure, like-named components of the embodiments generally have similar features, and thus within a particular embodiment each feature of each like-named component is not necessarily fully elaborated upon. Additionally, to the extent that linear or circular dimensions are used in the description of the disclosed systems, devices, and methods, such dimensions are not intended to limit the types of shapes that can be used in conjunction with such systems, devices, and methods. A person skilled in the art will recognize that an equivalent to such linear and circular dimensions can easily be determined for any geometric shape.