US5015151A — Motor controller for electrical submersible pumps

Claim 1

Independent Claim 79 words

A method for measuring differential pump fluid power output comprising: (a) measuring pump motor power consumption at timed intervals; (b) determining a recent pump motor power consumption from the measurements; (c) determining a previous pump motor power consumption from the measurements; (d) deriving the difference between steps (b) and (c), the difference being indicative of differential pump fluid power output; and (e) shutting the pump down when said differential exceeds a predetermined amount for a predetermined length of time.

Claim 2

Independent Claim 79 words

A method for measuring differential pump fluid power output comprising: (a) measuring pump motor power consumption at timed intervals; (b) determining a recent pump motor power consumption from the measurements; (c) determining a previous pump motor power consumption from the measurements; (d) deriving the difference between steps (b) and (c), the difference being indicative of differential pump fluid power output; and (e) shutting the pump down when said differential exceeds a predetermined amount for a predetermined length of time.

Claim 3

Independent Claim 92 words

A method for detecting loss of pump fluid power output comprising: (a) measuring pump motor power consumption at timed intervals; (b) determining a recent pump motor power consumption from the measurements; (c) determining a previous pump motor power consumption from the measurements; (d) deriving the difference between steps (b) and (c), the difference being indicative of loss of pump fluid power output when said difference exceeds a predetermined quantity; and (e) shutting the pump motor down when said difference is detected which exceeds a predetermined quantity for a predetermined length of time.

Claim 4

Independent Claim 92 words

A method for detecting loss of pump fluid power output comprising: (a) measuring pump motor power consumption at timed intervals; (b) determining a recent pump motor power consumption from the measurements; (c) determining a previous pump motor power consumption from the measurements; (d) deriving the difference between steps (b) and (c), the difference being indicative of loss of pump fluid power output when said difference exceeds a predetermined quantity; and (e) shutting the pump motor down when said difference is detected which exceeds a predetermined quantity for a predetermined length of time.

Claim 5

Dependent Claim 92 words

Apparatus for measuring differential pump fluid power output comprising: (a) means for measuring pump motor power consumption at timed intervals; (b) means for determing a recent pump motor power consumption from the measurements; (c) means for determing a previous pump motor power consumption from the measurements; (d) means for deriving the difference between steps (b) and (c), the difference being indicative of loss of differential pump fluid power output when said difference exceeds a predetermined quantity; and (e) means for shutting the pump motor down when said difference exceeds said predetermined quantity.

Claim 6

Dependent Claim 92 words

Apparatus for measuring differential pump fluid power output comprising: (a) means for measuring pump motor power consumption at timed intervals; (b) means for determing a recent pump motor power consumption from the measurements; (c) means for determing a previous pump motor power consumption from the measurements; (d) means for deriving the difference between steps (b) and (c), the difference being indicative of loss of differential pump fluid power output when said difference exceeds a predetermined quantity; and (e) means for shutting the pump motor down when said difference exceeds said predetermined quantity.

Claim 7

Dependent Claim 108 words

(Twice amended) Apparatus for detecting loss of pump fluid power output comprising: (a) means for measuring pump motor power consumption at timed intervals; (b) means for determining a recent pump motor power consumption from the measurements; (c) means for determining a previous pump motor power consumption from the measurements; (d) means for deriving the difference between steps (b) and (c), the difference being indicative of loss of pump fluid power output when said difference exceeds a predetermined quantity; and (e) means for shutting the pump motor down when said loss of pump fluid power output is detected which exceeds a predetermined quantity for a predetermined length of time.

Claim 8

Dependent Claim 108 words

(Twice amended) Apparatus for detecting loss of pump fluid power output comprising: (a) means for measuring pump motor power consumption at timed intervals; (b) means for determining a recent pump motor power consumption from the measurements; (c) means for determining a previous pump motor power consumption from the measurements; (d) means for deriving the difference between steps (b) and (c), the difference being indicative of loss of pump fluid power output when said difference exceeds a predetermined quantity; and (e) means for shutting the pump motor down when said loss of pump fluid power output is detected which exceeds a predetermined quantity for a predetermined length of time.

Claim 9

Dependent Claim 24 words

The apparatus of claim 3 or 4 wherein the pump motor drive is selected from (1) an electric motor and (2) a hydraulic motor.

Claim 10

Dependent Claim 59 words

The apparatus of claim 3 or 4 wherein the pump is utilized with a motor drive selected from one of the following combinations: (1) a centrifugal pump with an electric motor, (2) a centrifugal pump with an hydraulic motor, (3) a positive displacement pump with an electric motor drive, (4) a positive displacement pump with a hydraulic motor drive.

Claim 11

Independent Claim 74 words

A method for detecting electrical submersible pump motor underload, comprising: (a) measuring pump motor loads at timed intervals; (b) determining a recent pump motor load from the measurements; (c) determining a previous pump motor load from the measurements; (d) deriving the difference between steps (b) and (c), the difference being indicative of pump motor underloaded when said difference exceeds a predetermined quantity; and (e) shutting the pump motor down when said under-load is detected.

Claim 12

Independent Claim 74 words

A method for detecting electrical submersible pump motor underload, comprising: (a) measuring pump motor loads at timed intervals; (b) determining a recent pump motor load from the measurements; (c) determining a previous pump motor load from the measurements; (d) deriving the difference between steps (b) and (c), the difference being indicative of pump motor underloaded when said difference exceeds a predetermined quantity; and (e) shutting the pump motor down when said under-load is detected.

Claim 13

Independent Claim 81 words

A method for detecting electrical submersible pump motor underloaded, comprising: (a) measuring pump motor loads at timed intervals; (b) determining a recent pump motor load from the measurements; (c) determining a previous pump motor load from the measurements; (d) deriving the difference between steps (b) and (c), the difference being indicative of pump motor underload when said difference exceeds a predetermined quantity; and (e) shutting the pump motor down when said underload is detected which exceeds a predetermined length of time.

Claim 14

Independent Claim 81 words

A method for detecting electrical submersible pump motor underloaded, comprising: (a) measuring pump motor loads at timed intervals; (b) determining a recent pump motor load from the measurements; (c) determining a previous pump motor load from the measurements; (d) deriving the difference between steps (b) and (c), the difference being indicative of pump motor underload when said difference exceeds a predetermined quantity; and (e) shutting the pump motor down when said underload is detected which exceeds a predetermined length of time.

Claim 15

Dependent Claim 19 words

The method of claim 7 wherein said motor loads are monitored from apparent power utilized by said pump motor.

Claim 16

Dependent Claim 19 words

The method of claim 7 wherein said motor loads are monitored from actual power utilized by said pump motor.

Claim 17

Dependent Claim 19 words

The method of claim 7 wherein said motor loads are monitored from reactive power utilized by said pump motor.

Claim 18

Dependent Claim 19 words

The method of claim 7 wherein said motor loads are monitored from power factor utilized by said pump motor.

Claim 19

Dependent Claim 21 words

The method of claim 7 wherein said recent motor load is an average of measurements computed over a selected time interval.

Claim 20

Dependent Claim 23 words

The method of claim 7 wherein step (d) is based on a computation of the differential of motor load with respect to time.

Claim 21

Dependent Claim 19 words

The method of claim 7 wherein step (d) is based on integration of motor load with respect to time.

Claim 22

Dependent Claim 13 words

The method of claim 7 wherein step (d) is based on statistical analysis.

Claim 23

Dependent Claim 18 words

The method of claim 7 wherein said motor loads are monitored from current utilized by said pump motor.

Claim 24

Dependent Claim 33 words

The method of claim 17 wherein voltage accompanying said current is utilized to screen out corresponding current fluctuations which are the result of voltage spikes or sags and not pumpoff or gas locking.

Claim 25

Dependent Claim 17 words

The method of claim 7 wherein the most recent motor load measurement is used in step (b).

Claim 26

Dependent Claim 19 words

The method of claim 19 wherein said most recent motor load measurement is based on more than one measurement.

Claim 27

Dependent Claim 19 words

The method of claim 7 or 20 wherein said previous motor load is based on more than one measurement.

Claim 28

Dependent Claim 23 words

The method of claim 7 or 13 wherein said previous motor load is an average of measurements computed over a selected time interval.

Claim 29

Independent Claim 88 words

A method for detecting electrical submersible pump motor underload, comprising: (a) measuring motor current at timed intervals; (b) determining the most recent motor current from the measurements; (c) determining a moving average of the previous motor current from the measurements; (d) derving the difference between steps (b) and (c), the difference being indicative of pump motor underload when said difference exceeds a predetermined quantity; and (e) shutting the pump motor down when said difference exceeds one percent and wherein oil is being pumped in a non-gassy pumping condition.

Claim 30

Independent Claim 88 words

A method for detecting electrical submersible pump motor underload, comprising: (a) measuring motor current at timed intervals; (b) determining the most recent motor current from the measurements; (c) determining a moving average of the previous motor current from the measurements; (d) derving the difference between steps (b) and (c), the difference being indicative of pump motor underload when said difference exceeds a predetermined quantity; and (e) shutting the pump motor down when said difference exceeds one percent and wherein oil is being pumped in a non-gassy pumping condition.

Claim 31

Independent Claim 93 words

A method for detecting electrical submersible pump motor underload, comprising: (a) measuring motor current at timed intervals; (b) determining the most recent motor current from the measurements; (c) determining a moving average of the previous motor current from the measurements; (d) deriving the difference between steps (b) and (c), the difference being indicative of pump motor underload when said difference exceeds a predetermined quantity; and (e) shutting the pump motor down when said difference exceeds one percent for more than two seconds and wherein oil is being pumped in a gassy pumping condition.

Claim 32

Independent Claim 93 words

A method for detecting electrical submersible pump motor underload, comprising: (a) measuring motor current at timed intervals; (b) determining the most recent motor current from the measurements; (c) determining a moving average of the previous motor current from the measurements; (d) deriving the difference between steps (b) and (c), the difference being indicative of pump motor underload when said difference exceeds a predetermined quantity; and (e) shutting the pump motor down when said difference exceeds one percent for more than two seconds and wherein oil is being pumped in a gassy pumping condition.

Claim 33

Independent Claim 84 words

An apparatus for detecting electrical submersible pump motor underload, comprising: (a) means for measuring pump motor loads at timed intervals; (b) means for determining a recent pump motor load from the measurements; (c) means for determining a previous pump motor load from the measurements; (d) means for deriving the difference between steps (b) and (c), the difference being indicative of pump motor underload when said difference exceeds a predetermined quantity; and (e) means for shutting the pump motor down when said underload is detected.

Claim 34

Independent Claim 84 words

An apparatus for detecting electrical submersible pump motor underload, comprising: (a) means for measuring pump motor loads at timed intervals; (b) means for determining a recent pump motor load from the measurements; (c) means for determining a previous pump motor load from the measurements; (d) means for deriving the difference between steps (b) and (c), the difference being indicative of pump motor underload when said difference exceeds a predetermined quantity; and (e) means for shutting the pump motor down when said underload is detected.

Claim 35

Independent Claim 91 words

An apparatus for detecting electrical submersible pump motor underload, comprising: (a) means for measuring pump motor loads at timed intervals; (b) means for determining a recent pump motor load from the measurements; (c) means for determining a previous pump motor load from the measurements; (d) means for deriving the difference between steps (b) and (c), the difference being indicative of pump motor underload when said difference exceeds a predetermined quantity; and (e) means for shutting the pump motor down when said underload is detected which exceeds a predetermined length of time.

Claim 36

Independent Claim 91 words

An apparatus for detecting electrical submersible pump motor underload, comprising: (a) means for measuring pump motor loads at timed intervals; (b) means for determining a recent pump motor load from the measurements; (c) means for determining a previous pump motor load from the measurements; (d) means for deriving the difference between steps (b) and (c), the difference being indicative of pump motor underload when said difference exceeds a predetermined quantity; and (e) means for shutting the pump motor down when said underload is detected which exceeds a predetermined length of time.

Claim 37

Dependent Claim 20 words

The apparatus of claim 25 including means for monitoring said motor load from apparent power utilized by said pump motor.

Claim 38

Dependent Claim 19 words

The apparatus of claim 25 including means for monitoring said motor loads from actual power by said pump motor.

Claim 39

Dependent Claim 20 words

The apparatus of claim 25 including means for monitoring said motor loads from reactive power utilized by said pump motor.

Claim 40

Dependent Claim 21 words

The apparatus of claim 25 including means for monitoring said motor loads from a power factor indicated by said pump motor.

Claim 41

Dependent Claim 19 words

The apparatus of claim 25 including means for monitoring said motor loads from current utilized by said pump motor.

Claim 42

Independent Claim 98 words

An apparatus for detecting electrical submersible pump motor underload, comprising: (a) means for measuring motor current at timed intervals; (b) means for determining the most recent motor current from the measurements; (c) means for determining a moving average of the previous motor current from the measurements; (d) means for deriving the difference between steps (b) and (c), the difference being indicative of pump motor underload when said difference exceeds a predetermined quantity; and (e) means for shutting the pump motor down when said difference exceeds one percent and wherein oil is being pumped in a non-gassy pumping condition.

Claim 43

Independent Claim 98 words

An apparatus for detecting electrical submersible pump motor underload, comprising: (a) means for measuring motor current at timed intervals; (b) means for determining the most recent motor current from the measurements; (c) means for determining a moving average of the previous motor current from the measurements; (d) means for deriving the difference between steps (b) and (c), the difference being indicative of pump motor underload when said difference exceeds a predetermined quantity; and (e) means for shutting the pump motor down when said difference exceeds one percent and wherein oil is being pumped in a non-gassy pumping condition.

Claim 44

Independent Claim 34 words

The apparatus of claims 25 or 32 applied as a controller subassembly wired in series with a motor controller, said controller subassembly being functional to augment or replace underload functions of said motor controller.

Claim 45

Independent Claim 29 words

The apparatus of claims 25 or 32 applied as an integrated motor controller package functional to replace underload functions of a motor controller with gas lock/pump off controller functions.

Claim 46

Independent Claim 46 words

The apparatus of claims 25 or 32 applied as an integrated intelligent remote terminal unit functional to excercise motor control functions to include pump off/gas lock control and have capabilities of monitoring electrical submersible pump operation parameters, storing operation data and communication with a central computer.

Claim 47

Independent Claim 103 words

An apparatus for detecting electrical submersible pump motor underload, comprising: (a) means for measuring motor current at timed intervals; (b) means for determining the most recent motor current from the measurements; (c) means for determining a moving average of the previous motor current from the measurements; (d) means for deriving the difference between steps (b) and (c), the difference being indicative of pump motor underload when said difference exceeds a predetermined quantity; and (e) means for shutting the pump motor down when said difference exceeds one percent for more than two seconds and wherein oil is being pumped in a gassy pumping condition.

Claim 48

Independent Claim 103 words

An apparatus for detecting electrical submersible pump motor underload, comprising: (a) means for measuring motor current at timed intervals; (b) means for determining the most recent motor current from the measurements; (c) means for determining a moving average of the previous motor current from the measurements; (d) means for deriving the difference between steps (b) and (c), the difference being indicative of pump motor underload when said difference exceeds a predetermined quantity; and (e) means for shutting the pump motor down when said difference exceeds one percent for more than two seconds and wherein oil is being pumped in a gassy pumping condition.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1994-05-13	1994-11-12	1995-05-14	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1998-05-13	1998-11-12	1999-05-14	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2002-05-13	2002-11-12	2003-05-14	$7700.00	Window Closed / Lapsed

Motor controller for electrical submersible pumps

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