11 th Annual Sucker Rod Pumping Workshop Renaissance Hotel Oklahoma City, Oklahoma September 15-18, 2015

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1 11 th Annual Sucker Rod Pumping Workshop Renaissance Hotel Oklahoma City, Oklahoma September 15-18, 2015 Sucker Rod Pump Fluid Pound Avoidance & Stress Limiting Control Omar Al Assad, Justin Barton, Rogier Blom, Gary Hughes, Peter Westerkamp General Electric

2 Motivation Unplanned outages due to equipment failures impacts throughput - typical failures cost $20K-35K without considering the lost production Many unplanned outages can be avoided/managed by real time equipment health monitoring and appropriate control action Overloading due to internal factors such as the operational speed of the pump or external factors such as fluid pound are the root causes of failure New computational power capabilities on LWM 2.0 unlocks advanced controls algorithm implementation Design a controller to reduce failure rate of parts of the pumping system representing the majority of failure modes : Rod, Gearbox, Motor* LWM 2.0 *Patent filed with related inventions Sept , Sucker Rod Pumping Workshop 2

3 Controller Design Sept , Sucker Rod Pumping Workshop 3

4 Controls Implementation Approach Sept , Sucker Rod Pumping Workshop 4

5 Intra-stroke Speed Modulation Approach User defined parameters : FPA: % pump speed reduction Stress Control : % DN stroke speed modulation % UP stroke speed modulation Sept , Sucker Rod Pumping Workshop 5

6 stress (PSI) Simulation Platform Integrated dynamic surface pump and downhole equipment modeling Joints, Motor, GB Stresses (Matlab/SimMechanics) Rod stress (Wave Equation) Wave Equation 2 u t = 2 u u 2 a2 c x2 t x sample x 10 4 Sept , Sucker Rod Pumping Workshop 6

7 Case Study Simulation conditions Pump Fillage : 60% Fillage recovery speed 6.5 SPM Simulation scenarios Baseline FPA FPA + rod stress monitoring Sept ,

8 Case Study Results FPA: Reduced shock loading from collision reduces gear box torque 2 3 Stress control reduces stress level on taper 1 FPA: Reduces amplitude of cyclic stress due to collision of plunger with fluid surface by 50 % Stress control reduces gear box torque Production rate not impacted ~120 Bpd Sept ,

9 Dynamics Model of Surface Pumping Unit Motion Mechanical equation of motion of crank: Net Torque = Inertia effect + Pitman moment - CBE Sept , Sucker Rod Pumping Workshop 9

10 Validation of Dynamic Gear Box Torque Calculation Validation simulation run with pumping speed of 8 SPM Sept , Sucker Rod Pumping Workshop 10

11 Rod String Dynamics Displacement along rod string governed by wave equation: Force along rod string governed by Hooke s Law: Stress along rod string governed by: Wave equation solved using finite difference numerical method (Everitt-Jennings method) Sept , Sucker Rod Pumping Workshop 11

12 Validation of Finite Difference Diagnostic Pump Card Algorithm Parameters: 3 taper rod string and well depth of 7425 ft. Sept , Sucker Rod Pumping Workshop 12

13 Stress Level Monitoring on Pump Components Signal Stress level in gear box, motor and rod continually monitored against user / manufacturer specified limits User / manufacturer limit Control limit Control dead band Stress limiting control action applied Physical signal Time Sept , Sucker Rod Pumping Workshop 13

14 Conclusion and Perspectives New computational power capabilities on LWM 2.0 unlocks advanced controls algorithm implementation Simulation of a novel Fluid Pound Avoidance Controls algorithm shows a 50% reduction in the amplitude of the rod stress due to the collision of the plunger with the fluid Stress monitoring module aims to operate the pump within user / manufacturer stress limits and with that reducing the risk of failure Next Generation Advanced Rod Pump Controls will investigate the impact of proactive stroke planning Sept , Sucker Rod Pumping Workshop 14

15 Copyright Rights to this presentation are owned by the company(ies) and/or author(s) listed on the title page. By submitting this presentation to the Sucker Rod Pumping Workshop, they grant to the Workshop, the Artificial Lift Research and Development Council (ALRDC), and the Southwestern Petroleum Short Course (SWPSC), rights to: Display the presentation at the Workshop. Place it on the web site, with access to the site to be as directed by the Workshop Steering Committee. Place it on a CD for distribution and/or sale as directed by the Workshop Steering Committee. Other use of this presentation is prohibited without the expressed written permission of the author(s). The owner company(ies) and/or author(s) may publish this material in other journals or magazines if they refer to the Sucker Rod Pumping Workshop where it was first presented. Sept , Sucker Rod Pumping Workshop 15

16 Disclaimer The Artificial Lift Research and Development Council and its officers and trustees, and the Sucker Rod Pumping Workshop Steering Committee members, and their supporting organizations and companies (here-in-after referred to as the Sponsoring Organizations), and the author(s) of this Technical Presentation or Continuing Education Training Course and their company(ies), provide this presentation and/or training material at the Sucker Rod Pumping Workshop "as is" without any warranty of any kind, express or implied, as to the accuracy of the information or the products or services referred to by any presenter (in so far as such warranties may be excluded under any relevant law) and these members and their companies will not be liable for unlawful actions and any losses or damage that may result from use of any presentation as a consequence of any inaccuracies in, or any omission from, the information which therein may be contained. The views, opinions, and conclusions expressed in these presentations and/or training materials are those of the author and not necessarily those of the Sponsoring Organizations. The author is solely responsible for the content of the materials. The Sponsoring Organizations cannot and do not warrant the accuracy of these documents beyond the source documents, although we do make every attempt to work from authoritative sources. The Sponsoring Organizations provide these presentations and/or training materials as a service. The Sponsoring Organizations make no representations or warranties, express or implied, with respect to the presentations and/or training materials, or any part thereof, including any warrantees of title, non-infringement of copyright or patent rights of others, merchantability, or fitness or suitability for any purpose. Sept , Sucker Rod Pumping Workshop 16