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Dynamometers Cards Dynamometers Cards Benefits of High Speed and High Resolution Benefits of High Speed and High Resolution
Data AcquisitionData Acquisition
Lynn RowlanLynn Rowlan
Beam Pumping WorkshopBeam Pumping WorkshopHouston, TexasHouston, Texas
October 4 - 7, 2005October 4 - 7, 2005
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PORTABLE WELL ANALYZER w/ SENSORSPORTABLE WELL ANALYZER w/ SENSORS
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Typical Typical Rod Pump Control SystemRod Pump Control System
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High Speed Data AcquisitionHigh Speed Data Acquisition
1. Data can be acquired at time intervals of 15, 30, 60, 120, 240, 480, or greater samples per second.
2. A high speed laptop computer allows data to be recorded at the optimum resolution of state-of-the-art instrument using sigma-delta analog to digital converters, precision sensors, and shielded cables.
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Older Style Analog to Digital ConvertersOlder Style Analog to Digital ConvertersDO NOT Have Sensitivity for Small SignalsDO NOT Have Sensitivity for Small Signals
C111 C112 - 3584 Ft Deep
0.2 PSI
Acoustic Signal Show Plunger Fall Acoustic Signal Show Plunger Fall Past 111Past 111thth and 112 and 112thth Tubing Collar Tubing Collar
Zoom in on Axis From 40.554 to 0.3 mins
For 30K Load CellFor 30K Load Cell 8 bit - 58 lb/step8 bit - 58 lb/step12 bit – 7 lb/step12 bit – 7 lb/step24 bit – 0.002 lb/step 24 bit – 0.002 lb/step
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Record Surface & Calc. Pump Cards 1)1) Surface Dynamometer cards Surface Dynamometer cards
is the plot of measured is the plot of measured polished rod load at the polished rod load at the various positions various positions throughout a complete throughout a complete strokestroke– Used for for designing Used for for designing
and diagnosing surface and diagnosing surface problems.problems.
2)2) Pump dynamometer card is Pump dynamometer card is a plot of the calculated a plot of the calculated loads at various positions of loads at various positions of pump stroke and represents pump stroke and represents the load the pump applies to the load the pump applies to the bottom of the rod string.the bottom of the rod string. – Used for analysis of Used for analysis of
downhole problems.downhole problems.
Surface Card
Pump Card
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Acquire Load & Acceleration Versus TimeAcquire Load & Acceleration Versus Time
Analyze Stroke #1Analyze Stroke #1
Identify Identify individual individual
strokes and strokes and process process
acceleration acceleration data to get data to get
velocity and velocity and positionposition
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One Stroke of Polished Rod Acceleration One Stroke of Polished Rod Acceleration Integrated to Determine Polished Rod VelocityIntegrated to Determine Polished Rod Velocity
Bottom Bottom
Top
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Polished Rod Velocity Integrated to Polished Rod Velocity Integrated to Determine Polished Rod PositionDetermine Polished Rod Position
Bottom Bottom
Top
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0 312.50 625.00 937.50 1250.00 1562.50 1875.000
25
50
75
100
125
150
175
1 2 3 4 5 6
Pos
ition
(in)
0 12.50 25.00 37.50 50.00 62.50-20
-15
-10
-5
0
5
10
1 2 3 4 5 6
Time (Seconds)
LOA
D (K
lbs)
0 312.50 625.00 937.50 1250.00 1562.50 1875.00-62.50
-31.25
0
31.25
62.50
93.75
1 2 3 4 5 6
Velo
city
(in/
sec)
0 12.50 25.00 37.50 50.00 62.500.78125
0.85938
0.93750
1.01563
1.09375
1.17188
1 2 3 4 5 6
Time (Seconds)
AC
CE
L ( G
)
Acceleration LoadAcceleration Load
Surface Card
Pump CardWave Wave Down Down
To To PumpPump
Integrate onceIntegrate once
Integrate againIntegrate again
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Downward Spike on Pump Card Near Downward Spike on Pump Card Near Bottom, Appears to be Improperly SpacedBottom, Appears to be Improperly Spaced
Bottom Top
POC DataPOC Data
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String Boxes and InclinometersString Boxes and Inclinometers
Error in Error in Position Data Position Data
from from InclinometerInclinometer
1.1. Tends to have poor resolution at Tends to have poor resolution at top and bottom of stroke top and bottom of stroke
2.2. Smoothing of the Position data Smoothing of the Position data required to prevent load spikesrequired to prevent load spikes
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Noise in Position Data Noise in Position Data Requires Filtering of Acquired SignalRequires Filtering of Acquired Signal
POC DataPOC Data
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Spikes on Pump Card Near CenterSpikes on Pump Card Near CenterCaused by Noise in Position DataCaused by Noise in Position Data
POC DataPOC Data
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Averaging Important forAveraging Important for Longer Duration Event Longer Duration Event
1.1. Blue - 20 Samples per Second results in 20 data values acquired Blue - 20 Samples per Second results in 20 data values acquired during event. during event.
2.2. Black – Median Filter without RegressionBlack – Median Filter without Regression3.3. Averaging Smoothes out Peaks and Flattens CurveAveraging Smoothes out Peaks and Flattens Curve
10 Second10 Second
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A 5 Order Best Fit Regression FilterA 5 Order Best Fit Regression FilterSmoothed Out Noise in Pump CardSmoothed Out Noise in Pump Card
POC DataPOC Data
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Sampling Rate Important forSampling Rate Important for 1/10 Sec Duration High Speed Event 1/10 Sec Duration High Speed Event
1.1. Blue - 20 Samples per Second results in 2 data values acquired Blue - 20 Samples per Second results in 2 data values acquired during event. during event.
2.2. Black - 240 Samples per Second results in 24 data values Black - 240 Samples per Second results in 24 data values acquired during eventacquired during event
3.3. Sampling to slow can completely miss occurrence an EventSampling to slow can completely miss occurrence an Event
1 Second1 Second
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Shock Loads Increased Rod Failures:Gunk in Pump Two TVs in Pump
10 Klb
6.5 Klb
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Zero Velocity
Surface Velocity Slows by 6 in/sec
0.6 Seconds
In 0.1 Second 10,000 Lbs Impacts Rods on Upstroke
Two TVs in Pump
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High Speed Sampling Shows Correct Tag Force
TAG
30 Samples/Second 240 Samples/Second
6500 Lb TAG
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Compare Tag Force of 30 & 240 Hz30 Samples/Second
240 Samples/Second6500 Lb TAG
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Stress waves due to “tagging”
+
-Zero Velocity
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High Speed and High Resolution High Speed and High Resolution Data AcquisitionData Acquisition
1.1. Noisy or poor quality data requires Noisy or poor quality data requires special processing/smoothing to special processing/smoothing to prevent false load spikes. prevent false load spikes.
2.2. High speed/high resolution data High speed/high resolution data required to see character of sudden required to see character of sudden impact loads.impact loads.
3.3. High speed/high resolution data is High speed/high resolution data is used to clearly analyze the severity used to clearly analyze the severity of sudden impact loads. of sudden impact loads.
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Questions ?