The present disclosure relates to fluid pumps for use with wells, and more particularly to a cycle counter system for use with a fluid pump used in dewatering a wellbore of a well, as well gas extraction applications, and which is able to even more accurately count the On/Off cycles of the fluid pump.
This section provides background information related to the present disclosure which is not necessarily prior art.
With fluid pumps such as groundwater sampling pumps, a cycle counter has often been included as a subsystem of the pump for counting the number of cycles that the pump cycles on and off. Typically these pulse counter subsystems have involved the use of a non-mechanical counter, or in some instances the use of a reed switch, which works together with a linearly movable component, often referred to as a “shuttle”. The shuttle typically includes a magnet, and the magnet is typically positioned in a center of the shuttle. The shuttle typically uses a spring which applies a spring force to the shuttle which biases the shuttle towards a home location. The shuttle includes an air passage that is able to receive an air flow signal, and when the air flow signal is acting on the shuttle, an air pressure differential is created. The air flow differential creates pressure that pushes the shuttle to an equilibrium position.
One drawback of the above described construction is that the shuttle is allowed to travel a relatively long distance as it moves from its home position to its equilibrium position (i.e., its “stop” or end of stroke position). In some instances, this results in the reed switch changing state or “count” multiple times when only a single state change (i.e., detection of a single pump On/Off cycle) should have occurred. The multiple state changes are caused by multiple magnetic flux fields which are presented to the reed switch as the shuttle is moved from the home position to its end-of-stroke position. Another disadvantage with present day devices is the need to adjust/calibrate the counter for each well and/or well condition.
Accordingly, it would be highly useful to provide a cycle counter system and method which is not susceptible to varying magnetic flux fields caused by movement of the shuttle.
This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
The present disclosure relates to a cycle counter apparatus for use with an air-driven fluid pump. In one embodiment the apparatus may comprise a main housing having a bore in communication with a pressurized fluid signal being applied to remove a liquid from a location filling with the liquid. A magnet housing may be included which is moveable linearly within the bore of the main housing in response to the pressurized fluid signal entering the bore. A magnet may be secured to the magnet housing. A switch housing may be included which is operably associated with the main housing and which includes first and second longitudinally spaced apart sensing components. The sensing components are used to detect movement of the magnet in response to the pressurized fluid signal.
In another aspect the present disclosure is directed to a cycle counter apparatus for use with an air-driven fluid pump. The apparatus may include a main housing having an inlet, an outlet and a bore extending between the inlet and the outlet. The inlet and the bore are both in communication with a pressurized fluid signal being applied to remove a liquid from a wellbore filling with the liquid. The apparatus may further include a magnet housing moveable linearly within the bore of the main housing from a first position to a second position in response to the pressurized fluid signal entering the bore. A magnet may be secured to the magnet housing, and a switch housing is releasably secured to the main housing generally parallel to the main housing. The first and second longitudinally spaced apart sensing components may be disposed within the switch housing for detecting movement of the magnet in response to the pressurized fluid signal. Detection of the movement of the magnet provides an indication of cycling of the air driven fluid pump. A biasing element may also be included which is disposed within the bore of the main housing. The biasing element provides a biasing force to bias the magnet housing toward into the first position when no pressurized fluid signal is being received in the bore.
In still another aspect the present disclosure is directed to a cycle counter apparatus for use with an air-driven fluid pump. The apparatus may comprise a main housing having an inlet, an outlet and a bore extending between the inlet and the outlet. The inlet and the bore are both in communication with a pressurized fluid signal being applied to remove a liquid from location filling with the liquid. A magnet housing may be included which is moveable linearly within the bore of the main housing from a first position to a second position in response to the pressurized fluid signal entering the bore. A magnet may be positioned within the magnet housing. A stroke limiter may be secured to the outlet of the main housing for limiting linearly movement of the magnet housing while allowing the pressurized fluid to exit the outlet of the main housing. A switch housing may be releasably secured to the main housing generally parallel to the main housing. The switch housing may include a plurality of circumferential arms to enable attachment and removal of the switch housing. First and second longitudinally spaced apart sensing components may be disposed within the switch housing for detecting movement of the magnet in response to the pressurized fluid signal. Detection of the movement of the magnet provides an indication of cycling of the air driven fluid pump. A biasing element may also be disposed within the bore of the main housing to provide a biasing force to bias the magnet housing toward into the first position when no pressurized fluid signal is being received in the bore.
Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
Example embodiments will now be described more fully with reference to the accompanying drawings.
Referring to
The external electronic equipment 30 may be located at the wellhead 12 or may be located remotely from the wellhead. Both implementations are contemplated by the present disclosure. The external electronic equipment 30 may include, but is not limited to, a processor 30a, a memory (e.g., non-volatile memory such as RAM and/or ROM) 30b, and an input/output communications subsystem 30c. The memory 30b may include a look-up table 30d which the processor 30a may use in determining a cycle count of the pump 12 from electrical signals received over conductors 28. The look-up table 30d will be discussed further in connection with the operation of the system 10 and
Referring to
A pair of normally open (“NO”) reed switches 52a and 52b are fixedly mounted, such as via adhesives, on a reed switch mounting plate 54. Alternatively, the NO reed switches 52a and 52b could be “Normally Closed” (NC) reed switches, and both implementations are envisioned. A threaded nut 56 allows the bushing 50 to be locked into place to prevent unthreading of the bushing 50 during operation of the system 10. In this regard the bushing 56 can be seen in
As can be seen in
With further reference to
Referring specifically to
Referring further to
When the compressed air signal is removed from the system 10, the spring 46 biases the magnet housing 40 and the internally mounted magnet 42 back into the position shown in
With brief reference to
The time between state changes of the reed switches 52a and 52b will also be detectable by the processor 30a. This time may be used by the processor 30a to extrapolate other potentially important information, such as for example how quickly the pump 12 is emptying fluid once a new pump cycle is initiated. For example, it may be known in advance that one pump cycle should take a predetermined amount of time to complete (e.g., 5 seconds), and if the state changes of the reed switches are separated by a 10-30 second (or greater) time span, then this may indicate the early stage of a pump malfunction. Conversely, if the state changes occur with a shorter time interval than what is expected, then this condition may also indicate a problem with the pump 12, such as, for example, a leak path on the outside of the pump 12 through which fluid escapes, a hole in the discharge tube fitting of the pump, etc. Alternatively, a pneumatic valve failure could easily be detected by the system 10 and would be indicated by a short cycle.
The system 10 thus overcomes the condition where short, momentary axial oscillations in the position of the magnet 42 could potentially cause a single reed switch to sense multiple changes in the magnetic flux field, even though only one pump cycle has occurred. Using the two reed switches 52a and 52b virtually ensures that small oscillations in the magnetic flux field caused by movement of the magnet 42 will not be detected as multiple On/Off cycles of the pump 12.
One or both of the reed switches 52a and 52b can also be converted to ratiometric sensors Hall effect sensors. The use of ratiometric Hall effect sensors will provide even more detail and signal resolution, but will likely require more power to operate. However, the use of ratiometric Hall sensors in place of the reed switches 52a and 52b will enable pump performance activity to be stored and pump characteristics to be monitored and analyzed, in a manner similar to the data produced by the reed switches 52a and 52b. The Hall effect sensors can act as a switch and provide digital state changes just like the reed switches 52a and 52b. The Hall effect sensors can also produce an analog output which can be analyzed for different pumping characteristics. Accordingly, it will be appreciated that only reed switches 52a and 52b may be used, or only one or a pair of Hall effect sensors may be used, or a combination of a reed switch and a Hall effect sensor may be used. All of the foregoing embodiments are contemplated by the present disclosure.
It will also be appreciated that while two reed switches 52a and 52b have been shown, the system 10 is not limited to use with only two reed switches or two Hall Effect sensors. Using three or more reed switches or Hall Effect sensors would provide even greater resolution and a greater amount of data concerning the performance of the pump 12. The use of three or more reed switches may also help to recognize a scenario where pump freezing is beginning to occur. Still another benefit of the system 10 is that it is readily retrofittable for use with existing pumps and wellheads. The only requirement is the connection of an airline that can provide a compressed air signal to the system 10 when the pump is receiving a compressed air signal.
It will also be appreciated that the various embodiments of the system and method described herein may be used with any type of device to track cycle “counts”, and is therefore not limited to any particular counter device or system. As such, the various embodiments described herein may be used with electronic microcontrollers, mechanical tumblers, and any other suitable electronic or mechanical counting devices or systems.
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
This application is a PCT International Application of U.S. Provisional Patent Application No. 62/579,574 filed on Oct. 31, 2017. The entire disclosure of the above application is incorporated herein by reference.
Filing Document | Filing Date | Country | Kind |
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PCT/US2018/058389 | 10/31/2018 | WO | 00 |
Number | Date | Country | |
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62579574 | Oct 2017 | US |