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RodMax Hydraulic Pumping Optimization Printingcschoenb/UCURposter.pdfcontrolled by a mobile app. •...
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RodMax Hydraulic Pumping Optimization Presenter: Craig Schoenberger Academic Sponsor: John D Hedengren Chemical Engineering Brigham Young University THE PROBLEM Rod pumping is the industry’s top method for producing crude oil from petroleum reservoirs. Conventional rod pumping units only pump at one speed without an adjustable stroke. Because of the lack of control, fluid pound is the leading maintenance cost in the petroleum industry. Fluid pound is where the pump does not fill completely, causing the plunger of the pump to free fall and “pound” the liquid when it hits on the downstroke. This not only damages the pumping system, but also causes a loss in production efficiency. MILESTONES • Milestone 1: Explore how a better controlled hydraulic system can affect reservoir optimization • Milestone 2: Develop a PLC (Programmable Logic Controller) for the Demo RodMax Unit • Milestone 3: Using the new PLC, program a system that detects fluid pound and adjusts the stroke to optimize production and avoid maintenance • Milestone 4: Examine potential energy recovery options available to a hydraulic unit THE PROJECT • BYU paired up with a Utah-based company RodMax Oil & Gas • RodMax had developed a hydraulic rod pumping unit that had the potential of an optimized stroke • BYU agreed to develop a control system for the pump that would detect fluid pound and adjust the stroke • RodMax delivered a demo unit to BYU campus to be worked on • We first examined the impact an adjustable stroke could have on the entire reservoir. Using a CMG simulation, it was discovered that an adjustable stroke on a pumping unit had a considerable effect on the Net-Present Value of a reservoir • Then we shopped for a control system that would be suitable for the RodMax unit, learned how to program it, and created a human machine interface that could be controlled by a mobile app. • After researching different methods, determined the best way to detect fluid pound and integrated that into our programming • Above- RodMax’s Demo Unit being delivered to BYU • On the left- A conventional rod pumping unit • On the Right- The control box BYU created for RodMax and the mobile app reading stroke parameters from the unit RESULTS • Milestone 1: Through industry-grade computer simulations and literature reviews, it was discovered that a reservoir’s (SPE 10) Net-Present Value can be increased by millions of dollars. • Milestone 2: Replaced the existing $20,000 PLC with a new $5,000 PLC that can stream data faster. Also designed an interface platform that can be accessed remotely via mobile app (you can control the pump with your phone). • Milestone 3: Using differential equations, programmed a pump-off controller (detects fluid pound) and adjusted the stroke using a PID loop. • Milestone 4: Still in progress THE SOLUTION TEAM • Academic Advisor- Professor John D Hedengren • RodMax CEO- Dave Krug • Graduate Team Lead- Brigham Hansen • Undergraduates- Craig Schoenberger, Jens Griffen BYU successfully found a control system and programmed it so it detects how full the pump is. These pump fillage calculations are then used to adjust the stroke of the rod to optimize oil production and avoid fluid pound. This control system has been implemented in the demo unit. RodMax is in the process of constructing a full-sized (about 25 ft) beta unit that will be field tested with BYU’s control system on it.
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RodMax Hydraulic Pumping OptimizationPresenter: Craig SchoenbergerAcademic Sponsor: John D HedengrenChemical EngineeringBrigham Young University
THE PROBLEM
Rod pumping is the industry’s top method for producing crude oil from petroleum
reservoirs. Conventional rod pumping units only pump at one speed without an
adjustable stroke. Because of the lack of control, fluid pound is the leading
maintenance cost in the petroleum industry. Fluid pound is where the pump does not
fill completely, causing the plunger of the pump to free fall and “pound” the liquid
when it hits on the downstroke. This not only damages the pumping system, but also
causes a loss in production efficiency.
MILESTONES• Milestone 1: Explore how a better controlled hydraulic system can affect reservoir
optimization
• Milestone 2: Develop a PLC (Programmable Logic Controller) for the Demo RodMax Unit
• Milestone 3: Using the new PLC, program a system that detects fluid pound and adjusts the stroke to optimize production and avoid maintenance
• Milestone 4: Examine potential energy recovery options available to a hydraulic unit
THE PROJECT
• BYU paired up with a Utah-based company RodMax Oil & Gas
• RodMax had developed a hydraulic rod pumping unit that had the potential of an optimized stroke
• BYU agreed to develop a control system for the pump that would detect fluid pound and adjust the stroke
• RodMax delivered a demo unit to BYU campus to be worked on
• We first examined the impact an adjustable stroke could have on the entire reservoir. Using a CMG simulation, it was discovered that an adjustable stroke on a pumping unit had a considerable effect on the Net-Present Value of a reservoir
• Then we shopped for a control system that would be suitable for the RodMax unit, learned how to program it, and created a human machine interface that could be controlled by a mobile app.
• After researching different methods, determined the best way to detect fluid pound and integrated that into our programming
• Above- RodMax’s Demo Unit being delivered to BYU
• On the left- A conventional rod pumping unit
• On the Right- The control box BYU created for RodMax and the mobile app reading stroke parameters from the unit
RESULTS• Milestone 1: Through industry-grade computer simulations and literature reviews,
it was discovered that a reservoir’s (SPE 10) Net-Present Value can be increased by millions of dollars.
• Milestone 2: Replaced the existing $20,000 PLC with a new $5,000 PLC that can stream data faster. Also designed an interface platform that can be accessed remotely via mobile app (you can control the pump with your phone).
• Milestone 3: Using differential equations, programmed a pump-off controller (detects fluid pound) and adjusted the stroke using a PID loop.
• Milestone 4: Still in progress
THE SOLUTION
TEAM• Academic Advisor- Professor John D Hedengren
• RodMax CEO- Dave Krug
• Graduate Team Lead- Brigham Hansen
• Undergraduates- Craig Schoenberger, Jens Griffen
BYU successfully found a control system and programmed it so it detects how full
the pump is. These pump fillage calculations are then used to adjust the stroke of the
rod to optimize oil production and avoid fluid pound. This control system has been
implemented in the demo unit. RodMax is in the process of constructing a full-sized
(about 25 ft) beta unit that will be field tested with BYU’s control system on it.
