Ian Nickell
ChampionX
Automation has been used for many years now as a means for oil and gas operators to optimize sucker rod pump wells. Traditional automation for rod pump wells involved operating the well at a fixed speed and idling the well based on a preprogramed time (time clocks) or fillage (pump off control). However, utilizing a Variable Frequency Drive (VFD)is a more sophisticated method to allow operators to increase their runtime by detecting when there is less fluid to produce and slowing the unit down, accordingly. Although utilizing a VFD can provide significant improvements in production and failure reduction, in some cases operators are not able to realize the full advantage of their rod pump wells with VFDs because the VFD setpoints are not optimized. Optimizing VFD setpoints is not necessarily challenging, but in many cases requires many iterations of user intervention which takes time, and with the ever-changing nature of some reservoirs, that job may never be complete for a given well. However, utilizing a host software with algorithms developed by industry experts, VFD setpoint optimization can be done autonomously. Using domain-specific algorithms, the host software can detect deficiencies in VFD operations and iterate through setpoint changes to determine the optimal setpoints. Utilizing host software, the algorithms can constantly check to make sure that the setpoints are keeping the well running optimally, even when reservoir conditions change. By identifying issues like excessive cycling, lost production, unnecessary speed changes, and poor pump fillage, the algorithms implement changes that improve the performance of the well and help operators leverage the full capabilities of their VFD.