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.

What is claimed is: 
     
         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.