System and method for control and optimization of PCP pumped well operating parameters

1. A method of controlling the production efficiency of a well, the method comprising:

determining one or more parameters of a pump model for a progressive cavity pump of the well by measuring well outflow of liquid from the well at a plurality of different pumping speeds of the progressive cavity pump, the one or more parameters of the pump model including cavity fillage, the cavity fillage being determined by a method including:

measuring a first well outflow rate while running the progressive cavity pump at a first speed;

measuring a second well outflow rate while running the progressive cavity pump at a second speed; and

calculating the cavity fillage from a comparison between the first well outflow rate and the second well outflow rate, a comparison between the first speed and the second speed, and a displacement of the progressive cavity pump; and

adjusting a nominal operating pumping speed of the progressive cavity pump based on the one or more parameters of the pump model to maintain a well outflow rate of liquid from the well at a desired level.

2. The method of claim 1 , wherein the desired level is a predetermined fraction of an inflow rate of fluid into a well bore of the well.

3. The method of claim 1 , wherein the one or more parameters of the pump model further includes slippage.

4. The method of claim 2 , further comprising continuously monitoring the pumping speed of the pump and the well outflow rate and, responsive to the well outflow rate being less than a predetermined amount less than an expected well outflow rate, adjusting the pumping speed.

5. The method of claim 3 , wherein the slippage is determined by a method including

calculating the slippage by a comparison of a theoretical pump outflow at the first speed provided by a manufacturer of the progressive cavity pump and the first well outflow rate.

6. The method of claim 3 , further comprising calculating the slippage from the first well outflow rate, the first speed, the cavity fillage, and the displacement of the progressive cavity pump.

7. The method of claim 3 , further comprising increasing the efficiency of the well by adjusting the pumping speed of the progressive cavity pump based on the slippage, the cavity fillage, and the displacement of the pump.

8. The method of claim 3 , further comprising calculating the cavity fillage from a measured well outflow rate at a set pumping speed, the slippage, and the displacement of the pump.

9. The method of claim 3 , further comprising continuously monitoring the pumping speed of the pump and the well outflow rate and, responsive to the well outflow rate being more than a predetermined amount more than an expected well outflow rate, performing a re-calculation of slippage of the pump.

10. The method of claim 5 , further comprising increasing the efficiency of the well by adjusting the pumping speed of the progressive cavity pump based on the slippage and the displacement of the pump.

11. The method of claim 9 , further comprising adjusting the pump speed based on the re-calculation of the slippage of the pump responsive to the well outflow rate being more than the predetermined amount more than the expected well outflow rate.

12. A system for pumping liquid from a well, the system comprising:

a progressive cavity pump disposed in a bore of the well;

a flow meter configured to measure a well outflow rate of liquid from the well; and

a controller in communication with the progressive cavity pump and the flow meter and configured to:

determine one or more parameters of a pump model for the progressive cavity pump by measuring well outflow of liquid from the well at a plurality of different pumping speeds of the progressive cavity pump, the one or more parameters of the pump model including cavity fillage, the controller configured to determine the cavity fillage by a method including:

receiving an indication of a first well outflow from the flow meter while running the progressive cavity pump at a first speed;

receiving an indication of a second well outflow rate from the flow meter while running the progressive cavity pump at a second speed; and

calculating the cavity fillage from a comparison between the first well outflow rate and the second well outflow rate, a comparison between the first speed and the second speed, and a displacement of the fluid progressive cavity pump; and

adjust a pumping speed of the progressive cavity pump based on the one or more parameters of the pump model to maintain the well outflow rate substantially equal to a desired level.

13. The system of claim 12 , wherein the one or more parameters of the pump model further includes slippage.

14. The system of claim 13 , wherein the controller is further configured to calculate the slippage from the first well outflow rate, the first speed, the cavity fillage, and the displacement of the pump.

15. The system of claim 13 , wherein the controller is further configured to continuously monitor the pumping speed of the pump and the well outflow rate and, responsive to the well outflow rate being more than a predetermined amount more than an expected well outflow rate, to perform a re-calculation of the slippage of the progressive cavity pump.

16. The system of claim 13 , wherein the controller is further configured to continuously monitor the pumping speed of the progressive cavity pump and the well outflow rate and, responsive to the well outflow rate being less than a predetermined amount less than an expected well outflow rate, adjust the pumping speed.

17. The system of claim 15 , wherein the controller is further configured to adjust the pumping speed based on the re-calculation of the slippage of the progressive cavity pump responsive to the well outflow rate being more than the predetermined amount more than the expected well outflow rate.

18. A non-transitory computer readable medium having computer executable instructions encoded thereon which, when executed on a controller of a system for pumping liquid from a well, cause the controller to perform a method including:

determining one or more parameters of a pump model for a progressive cavity pump of the well by measuring well outflow of liquid from the well at a plurality of different pumping speeds of the progressive cavity pump, the one or more parameters of the pump model including cavity fillage, the instructions causing the controller to determine the cavity fillage of the progressive cavity pump by a method including:

measuring a first well inflow rate while running the progressive cavity pump at a first speed;

measuring a second well inflow rate while running the progressive cavity pump at a second speed; and

calculating the cavity fillage from a comparison between the first well inflow rate and the second well inflow rate, a comparison between the first speed and the second speed, and a displacement of the progressive cavity pump; and

adjusting a pumping speed of the progressive cavity pump based on the one or more parameters of the pump model to maintain a well outflow rate of liquid from the well at a desired level.

19. The computer readable medium of claim 18 , wherein the instructions further cause the controller to:

calculate a slippage from the first well outflow rate, the first speed, the cavity fillage, and the displacement of the pump; and

adjust the pumping speed based on calculation of the slippage of the progressive cavity pump responsive to the well outflow rate being more than the predetermined amount more than the expected well outflow rate.