U.S. patent application number 17/431967 was filed with the patent office on 2022-05-05 for fluid pump system for groundwater wells with intelligent cycle count and air supply valve monitoring.
This patent application is currently assigned to Q.E.D. ENVIRONMENTAL SYSTEMS, INC.. The applicant listed for this patent is Q.E.D. ENVIRONMENTAL SYSTEMS, INC.. Invention is credited to John F. SCHAUPP.
Application Number | 20220136381 17/431967 |
Document ID | / |
Family ID | |
Filed Date | 2022-05-05 |
United States Patent
Application |
20220136381 |
Kind Code |
A1 |
SCHAUPP; John F. |
May 5, 2022 |
FLUID PUMP SYSTEM FOR GROUNDWATER WELLS WITH INTELLIGENT CYCLE
COUNT AND AIR SUPPLY VALVE MONITORING
Abstract
The present disclosure relates to a pump system having a
pneumatically actuated fluid pump, which makes use of standard
cycle counter to assist in determining when an air supply control
valve is stuck in an open state after a fluid discharge cycle has
completed. The system includes an electronic controller which
receives signals from the cycle counter. The signals indicate a
position of a sensing element inside the cycle counter. The
electronic controller uses the signals to determine if the sensing
element is still experiencing a pressurized airflow after a fluid
discharge cycle has completed and the air supply control valve has
been commanded to close.
Inventors: |
SCHAUPP; John F.; (Sylvania,
OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Q.E.D. ENVIRONMENTAL SYSTEMS, INC. |
Dexter |
MI |
US |
|
|
Assignee: |
Q.E.D. ENVIRONMENTAL SYSTEMS,
INC.
Dexter
MI
|
Appl. No.: |
17/431967 |
Filed: |
February 14, 2020 |
PCT Filed: |
February 14, 2020 |
PCT NO: |
PCT/US2020/018214 |
371 Date: |
August 18, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62866977 |
Jun 26, 2019 |
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International
Class: |
E21B 47/008 20060101
E21B047/008; E21B 43/12 20060101 E21B043/12 |
Claims
1. A pump system for use in a well bore of a well, the system
comprising: a pneumatically actuated fluid pump; an electronic
controller for controlling operation of the fluid pump; an air
supply control valve responsive to commands from the electronic
controller, and in communication with the fluid pump, for admitting
a pressurized airflow from a compressed air source into the fluid
pump in response to a first command received from the electronic
controller which causes the air supply control valve to assume an
open state, and interrupting the pressurized airflow to the fluid
pump when a second command is received from the electronic
controller which causes the air supply control valve to assume a
closed state; a sensing component in communication with the air
supply control valve for counting a number of fluid discharge
cycles carried out by the fluid pump, the cycle counter including a
movable element and a sensing element for sensing movement of the
movable element in response to the presence of the pressurized
airflow being supplied to the pump, the sensing component
generating: a first signal when the movable element is in a first
position, indicating the pressurized airflow is not flowing through
the sensing component to the fluid pump; and a second signal when
the movable element is in a second position indicative of a
condition where the pressurized airflow is flowing through the
sensing component to the fluid pump; and the electronic controller
configured to use the first and second signals to detect when the
air supply control valve has become stuck in the open state after
being commanded by the electronic controller to assume a closed
state.
2. The system of claim 1, wherein the sensing component comprises a
cycle counter, the movable element comprises a magnet, and the
sensing element comprises a reed switch.
3. The system of claim 2, wherein electronic controller is
configured to implement a predetermined time interval counter to
enable the fluid discharge cycle to be carried out, and during
which the air supply control valve is commanded to be in the open
state.
4. The system of claim 3, wherein the electronic controller is
configured to implement an additional time interval counter, upon
expiration of the predetermined time interval counter, which
enables the magnetic element of the cycle counter to return to the
first position, before making a determination of the air supply
control valve has become stuck in the open state.
5. The system of claim 3, wherein the predetermined time interval
comprises a time interval of between 1 second and 59 seconds.
6. The system of claim 4, wherein the additional time interval
comprises a time interval between 1 second and 59 seconds.
7. The system of claim 1, further comprising at least one of: a
quick exhaust valve in communication with an interior area of the
fluid pump, for providing accelerated venting of the interior area
of the pump; or at least one of a wireless, short range radio or
communications subsystem for enabling at least one of one-way or
bi-directional communications with the electronic controller.
8. The system of claim 1, further comprising a water separator in
communication with the air supply control valve for removing at
least one of water or moisture from the pressurized airflow being
injected into the fluid pump.
9. The system of claim 1, further comprising a compressed air
source for providing the pressurized airflow to the fluid pump.
10. The system of claim 1, further comprising a look-up table
accessible by the electronic controller for assisting the
electronic controller in making a determination when the air supply
control valve is stuck in the open position; and wherein the
look-up table assists the controller in identifying at least one of
the following error conditions: the air supply control valve is
stuck in an open condition; the air supply control valve is stuck
in a closed condition; the air supply control valve opens when
commanded to open to start a fluid discharge cycle, but an
air-water separator or an air supply line is blocked, preventing
pressurized airflow to the fluid pump; the air supply control valve
is commanded to open, the air supply control valve opens, but a
fluid discharge from the fluid pump line is blocked; the electronic
controller sends a signal to open the air supply control valve to
start a fluid discharge cycle, and the air supply control valve
opens, but a force main is blocked, preventing fluid ejection from
the fluid pump from occurring; or when the air supply line is
partially obstructed.
11. The system of claim 1, wherein the air supply control valve
includes: a primary valve, which is controlled by the electronic
controller to control the admission of pressurized airflow to the
fluid pump; and a secondary valve which is controlled by the
electronic controller to interrupt the pressurized airflow to the
pump only in the event that the primary valve is detected as being
stuck in the open state.
12. A pump system for use in a well bore of a well, the system
comprising: a pneumatically actuated fluid pump; an electronic
controller for controlling operation of the fluid pump; an air
supply control valve responsive to commands from the electronic
controller, and in communication with the fluid pump and a
compressed air source, for admitting a pressurized airflow from the
compressed air source into the fluid pump in response to a first
command received from the electronic controller which causes the
air supply control valve to assume an open state, and interrupting
the flow of the pressurized airflow to the fluid pump when a second
command is received from the electronic controller which causes the
air supply control valve to assume a closed state; a cycle counter
in communication with the air supply control valve and the fluid
pump for receiving the pressurized airflow prior to the pressurized
airflow reaching the fluid pump, and assisting the electronic
controller in counting a number of fluid discharge cycles carried
out by the fluid pump; the cycle counter including an axially
movable magnet and a reed switch component for sensing movement of
the magnet in response to the presence of the pressurized airflow
being supplied through the cycle counter to the fluid pump, the
cycle counter generating: a first signal when the magnet is in a
first position, indicating the pressurized airflow is not flowing
through the cycle counter to the fluid pump; and a second signal
when the magnet is in a second position indicative of a condition
where the pressurized airflow is flowing through the cycle counter
to the fluid pump; and the electronic controller configured to use
the first and second signals to detect when the air supply control
valve has become stuck in the open state after a fluid discharge
cycle has completed.
13. The system of claim 12, wherein the electronic controller
includes a predetermined time interval counter to enable the fluid
discharge cycle to be carried out, and during which the air supply
control valve is commanded to be in the open state.
14. The system of claim 13, wherein the electronic controller
includes an additional time interval counter, upon expiration of
the predetermined time interval counter, which enables the magnetic
element of the cycle counter to return to the first position,
before making a determination of the air supply control valve has
become stuck in the open state.
15. The system of claim 12, wherein the electronic controller
includes a look-up table containing information on the first and
second positions for the magnet, to assist the electronic
controller in making a determination if the air supply control
valve is stuck in the open state.
16. The system of claim 12, further comprising at least one quick
exhaust valve in communication with an interior area of the fluid
pump, which provides accelerated venting of the interior area of
the pump after a fluid discharge cycle is completed.
17. The system of claim 12, The system of claim 1, wherein the air
supply control valve includes: a primary valve, which is controlled
by the electronic controller to control the admission of
pressurized airflow to the fluid pump; and a secondary valve which
is controlled by the electronic controller to interrupt the
pressurized airflow to the pump only in the event that the primary
valve is detected as being stuck in the open state.
18. A method for forming a pumping system for use in a well bore of
a well, the method comprising: providing a pneumatically actuated
fluid pump disposed in the well bore; using an electronic
controller to control operation of the fluid pump; using air supply
control valve responsive to commands from the electronic
controller, and in communication with the fluid pump, for admitting
a pressurized airflow from a compressed air source into the fluid
pump in response to a first command received from the electronic
controller which causes the air supply control valve to assume an
open state, and interrupting the flow of the pressurized airflow to
the fluid pump when a second command is received from the
electronic controller which causes the air supply control valve to
assume a closed state; using a sensing component in communication
with the air supply control valve for counting a number of fluid
discharge cycles carried out by the fluid pump, the cycle counter
including a movable element and a sensing element for sensing
movement of the movable element in response to the presence of the
pressurized airflow being supplied to the fluid pump, wherein the
sensing component generates: a first signal when the movable
element is in a first position, indicating the pressurized airflow
is not flowing through the sensing component to the fluid pump; and
a second signal indicative of the movable element being in a second
position when the pressurized airflow is flowing through the
sensing component to the fluid pump; and using the electronic
controller to monitor the first and second signals to detect when
the air supply control valve has become stuck in the open state
after being commanded by the electronic controller to assume a
closed state.
19. The method of claim 18, wherein using a sensing component
comprises using a cycle counter.
20. The method of claim 19, wherein using a cycle counter comprises
using a cycle counter having an axially movable magnet and a reed
switch for sensing movement of the magnet in response to the
pressurized airflow.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a PCT International Application and
claims priority of U.S. Patent Application No. 62/866,977, filed on
Jun. 26, 2019. The entire disclosure of the above application is
incorporated herein by reference.
FIELD
[0002] The present disclosure relates to fluid pumps for use with
wells, and more particularly to electronically controlled pump
systems for use in dewatering a wellbore of a well or in well gas
extraction applications, and enabling control over fluid discharge
and admission cycles of a pump component while interpreting
information from a well-head based component to ensure that pump
cycling is being carried out in accordance with controller
generated fluid discharge and fluid admission cycle commands.
BACKGROUND
[0003] This section provides background information related to the
present disclosure which is not necessarily prior art.
[0004] 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 magnetic
sensing component, such as a Hall effect switch (HES) or a
Ratiometric Hall effect Sensor, 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. The reed switch
(e.g., HES) generates a first signal when the shuttle is in its
home position, and a different second signal when the shuttle has
been moved out of the home position in response to a pressurized
airflow signal.
[0005] One drawback is that once a controller initiates a fluid
discharge cycle by commanding an air supply solenoid valve to open
and admit compressed air into the pump, there is no way for the
controller to determine if an error condition has arisen, where the
error condition is preventing termination of the fluid discharge
cycle. For example, if the air supply solenoid valve becomes stuck
in the open position, compressed air will be supplied continuously
through the air supply solenoid valve into the interior of the
pump, even though the controller may have removed the "open" signal
being applied to the air supply solenoid valve. Since the
controller will typically allow the compressed air to be applied to
the pump for a predetermined time to carry out a fluid discharge
cycle (e.g., five seconds), once the signal from the controller is
removed from the air supply solenoid valve, the controller would
not be apprised that compressed air is still being injected into
the pump. Put differently, the controller will "assume" that the
air supply solenoid valve has closed, and that the next fill cycle
is commencing. This condition of the air solenoid valve being stuck
in the "open" position, admitting pressurized air into the pump
interior, will delay the next "fill" cycle for the pump, which in
turn may allow the fluid level in the wellbore to rise to an
unacceptably high level before it is recognized that a problem
exits with the air supply solenoid valve.
[0006] Another error mode which can arise is when the pump
controller sends a signal to open the air valve to start a pumping
(i.e., fluid discharge) cycle. If the air valve fails to open, the
fluid ejection which is supposed to occur during the pumping cycle
will not happen.
[0007] Still another error mode which can arise is when the pump
controller sends a signal to open the air valve to start a pumping
(fluid discharge) cycle. The air valve opens but the air water
separator or air supply line to the pump is plugged or blocked; in
this instance the fluid ejection that is supposed to occur during
the pumping cycle will not happen.
[0008] Still another error mode which can arise is when the pump
controller sends a signal to open the air valve to start a pumping
cycle. The air valve opens but the fluid discharge line is blocked;
so the fluid ejection that is supposed to occur during the pumping
cycle will not happen.
[0009] Still another error mode which can arise is when the pump
controller sends a signal to open the air valve to start a pumping
cycle. The air valve opens, but Force Main is blocked; in this
instance the fluid ejection which is supposed to occur during the
pumping cycle will not happen. The Force Main plugging is a common
occurrence which can be seasonally created when leachate in a
wellbore freezes in the force main, and particles obstruct the
line. In any of these later conditions, the cycle counter will not
be able to index to keep an accurate cycle count.
SUMMARY
[0010] This section provides a general summary of the disclosure,
and is not a comprehensive disclosure of its full scope or all of
its features.
[0011] In one aspect the present disclosure relates to a pump
system for use in a well bore of a well. The system comprises a
pneumatically actuated fluid pump, an electronic controller for
controlling operation of the fluid pump; an air supply control
valve; and a sensing component. The air supply control valve is
responsive to commands from the electronic controller and in
communication with the fluid pump for admitting a pressurized
airflow from a compressed air source into the fluid pump in
response to a first command received from the electronic
controller, and interrupting the pressurized airflow to the fluid
pump when a second command is received from the electronic
controller. The sensing component is in communication with the air
supply control valve for counting a number of fluid discharge
cycles carried out by the fluid pump. The sensing component
generates a first signal when the movable element is in a first
position, indicating the pressurized airflow is not flowing through
the sensing component to the fluid pump; and a second signal when
the movable element is in a second position indicative of a
condition where the pressurized airflow is flowing through the
sensing component to the fluid pump. The electronic controller may
be configured to use the first and second signals to detect when
the air supply control valve has become stuck in the open state
after being commanded by the electronic controller to assume a
closed state.
[0012] In another aspect the present disclosure relates to a pump
system for use in a well bore of a well. The system may comprise a
pneumatically actuated fluid pump; an electronic controller for
controlling operation of the fluid pump; an air supply control
valve responsive to commands from the electronic controller; and a
cycle counter. The cycle counter may be in communication with the
air supply control valve and the fluid pump for receiving the
pressurized airflow prior to the pressurized airflow reaching the
fluid pump, and assisting the electronic controller in counting a
number of fluid discharge cycles carried out by the fluid pump. The
cycle counter may include an axially movable magnet and a reed
switch component for sensing movement of the magnet in response to
the presence of the pressurized airflow being supplied through the
cycle counter to the fluid pump. The cycle counter generates a
first signal when the magnet is in a first position, indicating the
pressurized airflow is not flowing through the cycle counter to the
fluid pump; and a second signal when the magnet is in a second
position indicative of a condition where the pressurized airflow is
flowing through the cycle counter to the fluid pump. The electronic
controller may be configured to use the first and second signals to
detect when the air supply control valve has become stuck in the
open state after a fluid discharge cycle has completed.
[0013] In another aspect the present disclosure relates to a method
for forming a pumping system for use in a well bore of a well. The
method may comprise providing a pneumatically actuated fluid pump
disposed in the well bore, using an electronic controller to
control operation of the fluid pump; using an air supply control
valve for admitting a pressurized airflow from a compressed air
source into the fluid pump in response to a first command received
from the electronic controller, and interrupting the flow of the
pressurized airflow to the fluid pump when a second command is
received from the electronic controller. The method may further
include using a sensing component in communication with the air
supply control valve for counting a number of fluid discharge
cycles carried out by the fluid pump. The cycle counter may include
a movable element and a sensing element for sensing movement of the
movable element in response to the presence of the pressurized
airflow being supplied to the fluid pump. The sensing component may
be used to generate a first signal when the movable element is in a
first position, indicating the pressurized airflow is not flowing
through the sensing component to the fluid pump; and further used
to generate a second signal indicative of the movable element being
in a second position when the pressurized airflow is flowing
through the sensing component to the fluid pump. The method may
further comprise using the electronic controller to monitor the
first and second signals to detect when the air supply control
valve has become stuck in the open state after being commanded by
the electronic controller to assume a closed state.
[0014] 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.
DRAWINGS
[0015] 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.
[0016] Corresponding reference numerals indicate corresponding
parts throughout the several views of the drawings.
[0017] FIG. 1 is a high level illustration illustrating an
intelligent pump system which is able to detect when an air supply
solenoid valve has become stuck in the open position;
[0018] FIG. 2 is one example of a look-up table which may be used
by the electronic controller of the pumping system of FIG. 1 to
help determine when an error condition involving the solenoid valve
exists, based on information supplied by the cycle counter shown in
FIG. 1; and
[0019] FIG. 3 is a high level flowchart illustrating operations in
accordance with one example of a method carried out by the
electronic controller of FIG. 1 to detect when an error condition
has arisen with operation of the air supply solenoid valve.
DETAILED DESCRIPTION
[0020] Example embodiments will now be described more fully with
reference to the accompanying drawings.
[0021] 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.
[0022] Referring to FIG. 1 there is shown a pump system 10 in
accordance with one embodiment of the present disclosure. The pump
system 10 in this example may include a pump 12 disposed in a well
bore 14 for pumping fluids collecting within the well bore 14. The
pump 12 is in communication with a wellhead 16.
[0023] The system 10 also includes a compressed air source 18, an
air supply solenoid control valve 20 (hereinafter simply "air
supply control valve 20") having a primary valve 20a and a
redundant valve 20b, an air valve 22, an optional quick exhaust
valve 24, a cycle counter subsystem 26, a quick exhaust valve 28,
and a water separator 30. An electronic controller 32 is included
which may include a processor 32a, a non-volatile memory 32b (RAM,
ROM, etc.), an input/output communication system 32c, a look-up
table 32d, a first counter 32e and a second ("overdrive") counter
32f. The input/output subsystem may include one or more of a
BLUETOOTH.RTM. protocol radio, a LORA radio, a plug-in controller
component, or any other form of wired or wireless communication
subsystem/circuit/device, etc., which enables either
one-directional or bi-bi-directional communications with the
electronic controller.
[0024] The electronic controller 32 may generate a signal to turn
on the compressed air source to begin a fluid discharge cycle for
the pump 12, and to cause the compressed air source to be turned
off as well by removing the turn-on signal. The electronic
controller 32 also communicates with the air supply control valve
20 and applies commands to open and close the air supply control
valve 20, in this example, specifically, the primary air supply
control valve 20a. It is an important feature of the pump system 10
that the electronic controller 32 also receives signals from the
cycle counter 26, from which it uses the received signals to
monitor for and detect an error condition arising with the air
supply control valve 20, that being that the primary air supply
control valve 20a does not close, in which case the electronic
controller 32 can command the secondary air supply control valve
20b to close to block the flow of pressurized air to the pump
12.
[0025] This important feature will be discussed in greater detail
in the following paragraphs. The cycle counter 26 is a standard
cycle counter for counting pump cycles which employs a magnet 26a
and at least one reed switch, for example a well-known HES, a
well-known Ratiometric sensor, etc., which will be referred to
throughout the following discussion simply as "reed switch" 26b,
and where the magnet is movable axially in response to the
compressed air flowing through the cycle counter during a fluid
discharge cycle. Optionally, a second reed switch 26c may be used,
although the pump system 10 may operate with just one reed switch
in the cycle counter 26.
[0026] The reed switch 26b senses a position of the magnet 26a and
generates signals in accordance therewith. The magnet 26a moves
from a first or "home" position, when no compressed air is flowing
through the cycle counter 26, to a second or "End of Travel"
("EOT") position when compressed air is flowing through the cycle
counter. The reed switch 26b senses this movement of the magnet 26a
and generates electrical signals in accordance with the sensed
position of the magnet. If the second reed switch 26c is used, then
the electronic controller 32 will receive signals from both reed
switches 26b and 26c indicating the position of the magnet (e.g.,
one by reed switch 26b outputting a "0" signal, indicating the
magnet is not present at a first location, while the second reed
switch 26c outputs a "1" signal, indicating that the magnet is
present at the second location, and vice versa). These electrical
signals are transmitted to the electronic controller 32. The
magnet/reed switch based cycle counter 26 is well known in the
industry, and as such further details will not be provided. The
precise location of the cycle counter 26 may vary from that shown
in FIG. 1, but in any event it needs to be located at some point
between the air supply control valve 20 and the pump 12, in other
words in the path of the pressurized air flowing between air supply
control valve 20 and the pump 12.
[0027] The quick exhaust valves 24 and 28 enhance operation of the
system 10 but are not absolutely required for satisfactory
operation of the system. The quick exhaust valve 28 operates
automatically to vent either to atmosphere or to a vacuum line
connected to its "Vent" port, when a predetermined lower limit of
air pressure is reached within the quick exhaust valve 28. Optional
quick exhaust valve 24 operates in the same manner, and
collectively, the two quick exhaust valves 24 and 28 enable rapid
venting of the interior of the pump 12 after a fluid discharge
cycle is completed, which helps to facilitate the immediate start
of another fill cycle. Similarly, the water separator 30 is not
essential for operation of the system 10, but nevertheless is
desirable for removing water and moisture from the compressed air
stream injected into the pump 12, and thus helping to prolong the
life of valving components exposed to the compressed air
stream.
[0028] A significant problem that can arise is if the primary valve
20a of the air supply control valve 20 becomes stuck in the open
position after a fluid discharge cycle is initiated by the
electronic controller 32. In that instance, compressed air will
flow through the air supply control valve 20, to open and allow the
air supply valve 22 to communicate air from the cycle counter 26,
thru the air valve, through the quick exhaust valve 28, and through
the water separator 30 before entering an airflow line 34 which
leads into a pump casing 12a of the pump 12. The compressed air
stream is used to eject fluid which has collected within the pump
casing 12a out through a fluid discharge line 36. While flowing
through the cycle counter 26, the magnet 26a will be held in its
"EOT" position, and this position will be detected by the reed
switch 26b. After a predetermined fluid eject cycle time (e.g.,
3-10 seconds), the electronic controller 32 will remove the signal
to the air supply control valve 20, but because the primary valve
20a of the air supply control valve 20 will have become stuck in
the "open" condition, compressed air will continue to be admitted
to the interior of the pump casing 12a, and the electronic
controller 32 would ordinarily have no way of knowing that this
condition has arisen.
[0029] The pump system 10 addresses the above condition where the
primary valve 20a of the air supply control valve 20 has become
stuck in the "open" position by monitoring the signals received
from the cycle counter 26. Ordinarily, these signals would just be
used by the electronic controller 32 to maintain an on-going count
of pump cycles, and possibly to save the count in the memory 32b
for use in a future evaluation of pump performance and/or to
determine when periodic pump maintenance is needed, or for other
diagnostic or maintenance purposes. However, the pump system 10
also uses the electronic controller 32 to analyze the cycle counter
26 signals in relation to when expected transitions of the magnet
26a position within the cycle counter 26 should be occurring.
[0030] In one aspect the electronic controller 32 intelligently
determines that at the end of a fluid discharge cycle, which for
example may last for a predetermined time period, a change in
position of the magnet 26a should trigger a corresponding signal
from the reed switch 26b of the cycle counter 26. In other words,
the reed switch 26b should be generating an electrical signal in
accordance with the "home" position of the magnet 26a, in this
example a Level "1" signal. If the "home" signal from the reed
switch 26b is not detected, that is, if the signal being received
is still a Level "0" signal, then the electronic controller 32
knows that compressed air is still flowing through the cycle
counter 26 and into the pump 12. In this event, the electronic
controller 32 may then use its input/output communications
subsystem 32c to generate an alarm signal 38. In one example, the
alarm signal 38 may be a wireless signal which is received by a
monitoring station in a vicinity of the well bore 14, but it need
not necessarily be in the vicinity of the well bore 14. For
example, the alarm signal 38 could be transmitted wirelessly to a
cloud-based portal which is in turn in communication with a remote
monitoring center. Still further, the alarm signal 28 could be
transmitted via a wired connection to a monitoring center. Still
further, the alarm signal may be provided via a Bluetooth.RTM.
protocol radio (not shown) integrated into the pump system 10 to a
user's laptop, smartphone, etc. Still further, the alarm signal 28
could be used to set a visual indicator (i.e., LED(s)) at the well
head 16. Still further, the alarm signal 38 could be supplied to a
computer connected to a cellular network to notify a technician via
a text message on the technician's smartphone, or possibly even by
an email message to the technician, of the error condition.
Accordingly, one or more of WiFi, Bluetooth.RTM. protocol, and hard
wired connections may be used to transmit the alarm signal 38 to an
individual or entity as needed by a given application.
[0031] FIG. 2 shows one example of the look-up table 32d which may
be stored in a suitable memory of the electronic controller 32, and
optionally in the memory 32b. This example shows how the two reed
switch 26b and 26c components may be used, but the electronic
controller 32 can be used with just a single reed switch as well.
The use of two reed switches does provide an additional level of
"intelligence" that the electronic controller 32 can use to further
determine/verify the location of the magnet 26a at any given time
during a pump cycle.
[0032] From the look-up table 32d, it can be seen that when the
reed switch 26b has not generated a "1" logic level signal after
completion of the predetermined time internal and the overdrive
time interval, the electronic controller 32 knows that an error
condition has arisen, and can generate the alarm signal 38 (FIG.
1). Error conditions may include any of those expressly set forth
above concerning the main air supply valve being stuck open, stuck
closed, the discharge line being blocked, and/or the force main
being blocked. Also, a restricted air supply can cause similar
poppet movements.
[0033] Referring to FIG. 3, a flowchart 100 illustrates operations
that may be performed by the electronic controller 32 during
operation of the pump system 10. At operation 102 the electronic
controller is initially monitoring for a signal indicating that a
fluid discharge cycle is to be initiated (i.e., pump 12 is presumed
to be full). At operation 104 the electronic controller 32 makes a
check to determine if a fluid discharge cycle signal has been
received. If this check produces a "No" answer, then the monitoring
operation for a fluid discharge cycle to start continues as
operation 102 is repeated. If the answer at operation 104 is a
"Yes" answer, then the electronic controller 32 starts counter 1
32e to begin the predetermined time interval for the fluid
discharge cycle. At operation 108 the electronic controller 32 then
sends a signal to the primary valve 20a of the air supply control
valve 20 to begin admitting air into the pump 12 to begin the fluid
discharge cycle. At operation 110 the electronic controller 32
makes a check to determine if the predetermined time interval (T1)
has expired. If this check produces a "No" answer, then operations
108 and 110 are repeated. If the check at operation 110 produces a
"Yes" answer, the electronic controller 32 makes a check at
operation 111 to determine if the primary valve 20a of the air
supply control valve 20 actually remained open for the T1 time
interval. If this check produces a "No" answer, then the electronic
controller 32 makes a determination at operation 126 that an error
has occurred, for example, a Level 2 error, indicating that the
fluid pump 12 did not actually pump for the T1 interval. The
electronic controller 32 will then generate an error signal at
operation 128, will reset all the counters at operation 130, and
the pumping cycle will be terminated at operation 132.
[0034] If the check at operation 111 indicates that the fluid pump
12 did remain open for the T1 interval, then this indicates a good
or successful pump cycle occurred. The electronic controller 32
then sends a signal to the primary valve 20a of the air supply
control valve 20 to close, as indicated at operation 112, which
cuts off the pressurized air supply to the pump 12 to end the fluid
discharge cycle.
[0035] At operation 114 the electronic controller 32 then starts
the second time interval counter 2 32f. The second time interval
counter 2 32f is an "overdrive" counter intended to provide a short
time period to allow the magnet 26a to return to its "home"
position. A failure to return home within the predetermined time
period (e.g., twice the pumping time period) indicates that the
primary air supply valve 20a is hanging open. At operation 116 the
electronic controller 32 makes a check to determine if the
overdrive time interval counter 2 32f has expired. If this produces
a "No" answer, then operations 114 and 116 are repeated. If the
check at operation 116 produces a "Yes" answer, indicating that the
overdrive counter 32f has timed out, then at operation 118 the
electronic controller 32 makes a check to see if a Level "1" level
signal is now being received from the reed switch 26b (i.e., that
the reed switch 26b has returned to its home position). If no Level
"1" signal is being received, then from using the look-up table
32d, this indicates to the electronic controller 32 that
pressurized air is still being received through the cycle counter
26, which indicates that the primary valve 20a of the air supply
control valve 20 is stuck in the open position. At operation 120
the electronic controller 32 generates the error signal 38
indicating this error condition. The predetermined and overdrive
counters 32e and 32f may then be reset, as indicated at operation
122. At this point the electronic controller 32 may command the
secondary valve 20b of the air supply control valve 20 to close, as
indicated at operation 124, to interrupt the pressurized airflow to
the pump 12.
[0036] If the check at operation 118 indicates that a Level "1"
signal is detected after the additional (i.e., overdrive) time
interval has expired, then from the look-up table 32d, this enables
the electronic controller 32 to verify that the primary valve 20a
of the air supply control valve 20 has actually closed after the
pump discharge cycle time has completed, and the next fill cycle is
beginning. The overdrive counter 32f may be then be reset, as
indicated at operation 134, and the method repeats at operation
102.
[0037] The pump system 10 thus makes use of the cycle counter 26
for the dual purpose of 1) counting fluid discharge cycles, and 2)
intelligently using the electrical signals from the cycle counter
26 to determine when the primary valve 20a of the air supply
control valve 20 is stuck in the open position. The pump system 10
advantageously provides this additional feature of detecting when
the air supply control valve 26 is stuck in the open position
without the need for any other hardware components to be integrated
into the pump system 10, and with virtually no additional cost for
the pump system 10. Moreover, the normal control sequence for the
pump system 10 does not need to be modified. The pump system 10
thus provides a highly beneficial feature that enables field
maintenance personnel to be quickly apprised if an air supply
control valve associated with a given fluid pump becomes stuck in
the open position, as well as a secondary airflow valve that is
controlled to interrupt the flow of pressurized air to the pump
under such condition.
[0038] It will also be appreciated that the pump system 10 can be
constructed to use any type of wireless communication, or even a
plug-in hand held controller, for example a gas analyzer, to enable
making changes in configuration to the pump system 10, or to make
notes about the well site like gas quality, vacuum vale setting,
orifice plate used, etc. The data can be stored on the non-volatile
memory 32b of the electronic controller 32 for future use, or even
sent via a desired wireless protocol, (e.g., BLUETOOTH.RTM.
protocol radio, to a smartphone which is in communication with the
a cloud-based subsystem, or by use of a radio communication link
like LoRa to send the data to a local gateway for storage, or to be
sent to the cloud for remote data collection. Those skilled in the
art will appreciate that virtually any means of communicating with
the electronic controller 32, either through a wireless link or a
wired link, may be employed when implementing the pump system.
[0039] 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.
[0040] Example embodiments are provided so that this disclosure
will be thorough, and will fully convey the scope to those who are
skilled in the art. Numerous specific details are set forth such as
examples of specific components, devices, and methods, to provide a
thorough understanding of embodiments of the present disclosure. It
will be apparent to those skilled in the art that specific details
need not be employed, that example embodiments may be embodied in
many different forms and that neither should be construed to limit
the scope of the disclosure. In some example embodiments,
well-known processes, well-known device structures, and well-known
technologies are not described in detail.
[0041] The terminology used herein is for the purpose of describing
particular example embodiments only and is not intended to be
limiting. As used herein, the singular forms "a," "an," and "the"
may be intended to include the plural forms as well, unless the
context clearly indicates otherwise. The terms "comprises,"
"comprising," "including," and "having," are inclusive and
therefore specify the presence of stated features, integers, steps,
operations, elements, and/or components, but do not preclude the
presence or addition of one or more other features, integers,
steps, operations, elements, components, and/or groups thereof. The
method steps, processes, and operations described herein are not to
be construed as necessarily requiring their performance in the
particular order discussed or illustrated, unless specifically
identified as an order of performance. It is also to be understood
that additional or alternative steps may be employed.
[0042] When an element or layer is referred to as being "on,"
"engaged to," "connected to," or "coupled to" another element or
layer, it may be directly on, engaged, connected or coupled to the
other element or layer, or intervening elements or layers may be
present. In contrast, when an element is referred to as being
"directly on," "directly engaged to," "directly connected to," or
"directly coupled to" another element or layer, there may be no
intervening elements or layers present. Other words used to
describe the relationship between elements should be interpreted in
a like fashion (e.g., "between" versus "directly between,"
"adjacent" versus "directly adjacent," etc.). As used herein, the
term "and/or" includes any and all combinations of one or more of
the associated listed items.
[0043] Although the terms first, second, third, etc. may be used
herein to describe various elements, components, regions, layers
and/or sections, these elements, components, regions, layers and/or
sections should not be limited by these terms. These terms may be
only used to distinguish one element, component, region, layer or
section from another region, layer or section. Terms such as
"first," "second," and other numerical terms when used herein do
not imply a sequence or order unless clearly indicated by the
context. Thus, a first element, component, region, layer or section
discussed below could be termed a second element, component,
region, layer or section without departing from the teachings of
the example embodiments.
[0044] Spatially relative terms, such as "inner," "outer,"
"beneath," "below," "lower," "above," "upper," and the like, may be
used herein for ease of description to describe one element or
feature's relationship to another element(s) or feature(s) as
illustrated in the figures. Spatially relative terms may be
intended to encompass different orientations of the device in use
or operation in addition to the orientation depicted in the
figures. For example, if the device in the figures is turned over,
elements described as "below" or "beneath" other elements or
features would then be oriented "above" the other elements or
features. Thus, the example term "below" can encompass both an
orientation of above and below. The device may be otherwise
oriented (rotated 90 degrees or at other orientations) and the
spatially relative descriptors used herein interpreted
accordingly.
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