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.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a PCT International Application and claims priority of U.S. Patent Application No. 62/866,977, filed on Jun. 26, 2019. The entire disclosure of the above application is incorporated herein by reference.

FIELD

The present disclosure relates to fluid pumps for use with wells, and more particularly to electronically controlled pump systems for use in dewatering a wellbore of a well or in well gas extraction applications, and enabling control over fluid discharge and admission cycles of a pump component while interpreting information from a well-head based component to ensure that pump cycling is being carried out in accordance with controller generated fluid discharge and fluid admission cycle commands.

BACKGROUND

This section provides background information related to the present disclosure which is not necessarily prior art.

With fluid pumps such as groundwater sampling pumps, a cycle counter has often been included as a subsystem of the pump for counting the number of cycles that the pump cycles on and off. Typically these pulse counter subsystems have involved the use of a non-mechanical counter, or in some instances the use of a magnetic sensing component, such as a Hall effect switch (HES) or a Ratiometric Hall effect Sensor, which works together with a linearly movable component, often referred to as a “shuttle”. The shuttle typically includes a magnet, and the magnet is typically positioned in a center of the shuttle. The shuttle typically uses a spring which applies a spring force to the shuttle which biases the shuttle towards a home location. The shuttle includes an air passage that is able to receive an air flow signal, and when the air flow signal is acting on the shuttle, an air pressure differential is created. The air flow differential creates pressure that pushes the shuttle to an equilibrium position. The reed switch (e.g., HES) generates a first signal when the shuttle is in its home position, and a different second signal when the shuttle has been moved out of the home position in response to a pressurized airflow signal.

One drawback is that once a controller initiates a fluid discharge cycle by commanding an air supply solenoid valve to open and admit compressed air into the pump, there is no way for the controller to determine if an error condition has arisen, where the error condition is preventing termination of the fluid discharge cycle. For example, if the air supply solenoid valve becomes stuck in the open position, compressed air will be supplied continuously through the air supply solenoid valve into the interior of the pump, even though the controller may have removed the “open” signal being applied to the air supply solenoid valve. Since the controller will typically allow the compressed air to be applied to the pump for a predetermined time to carry out a fluid discharge cycle (e.g., five seconds), once the signal from the controller is removed from the air supply solenoid valve, the controller would not be apprised that compressed air is still being injected into the pump. Put differently, the controller will “assume” that the air supply solenoid valve has closed, and that the next fill cycle is commencing. This condition of the air solenoid valve being stuck in the “open” position, admitting pressurized air into the pump interior, will delay the next “fill” cycle for the pump, which in turn may allow the fluid level in the wellbore to rise to an unacceptably high level before it is recognized that a problem exits with the air supply solenoid valve.

Another error mode which can arise is when the pump controller sends a signal to open the air valve to start a pumping (i.e., fluid discharge) cycle. If the air valve fails to open, the fluid ejection which is supposed to occur during the pumping cycle will not happen.

Still another error mode which can arise is when the pump controller sends a signal to open the air valve to start a pumping (fluid discharge) cycle. The air valve opens but the air water separator or air supply line to the pump is plugged or blocked; in this instance the fluid ejection that is supposed to occur during the pumping cycle will not happen.

Still another error mode which can arise is when the pump controller sends a signal to open the air valve to start a pumping cycle. The air valve opens but the fluid discharge line is blocked; so the fluid ejection that is supposed to occur during the pumping cycle will not happen.

Still another error mode which can arise is when the pump controller sends a signal to open the air valve to start a pumping cycle. The air valve opens, but Force Main is blocked; in this instance the fluid ejection which is supposed to occur during the pumping cycle will not happen. The Force Main plugging is a common occurrence which can be seasonally created when leachate in a wellbore freezes in the force main, and particles obstruct the line. In any of these later conditions, the cycle counter will not be able to index to keep an accurate cycle count.

SUMMARY

This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

In one aspect the present disclosure relates to a pump system for use in a well bore of a well. The system comprises a pneumatically actuated fluid pump, an electronic controller for controlling operation of the fluid pump; an air supply control valve; and a sensing component. The air supply control valve is 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, and interrupting the pressurized airflow to the fluid pump when a second command is received from the electronic controller. The sensing component is in communication with the air supply control valve for counting a number of fluid discharge cycles carried out by the fluid pump. 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 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. The electronic controller may be 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.

In another aspect the present disclosure relates to a pump system for use in a well bore of a well. The system may comprise 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 a cycle counter. The cycle counter may be 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 may include 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 generates 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. The electronic controller may be 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.

In another aspect the present disclosure relates to a method for forming a pumping system for use in a well bore of a well. The method may comprise providing a pneumatically actuated fluid pump disposed in the well bore, using an electronic controller to control operation of the fluid pump; using an air supply control valve 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, and interrupting the flow of the pressurized airflow to the fluid pump when a second command is received from the electronic controller. The method may further include 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 may include 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. The sensing component may be used to generate 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 further used to generate 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. The method may further comprise 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.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

FIG. 1 is a high level illustration illustrating an intelligent pump system which is able to detect when an air supply solenoid valve has become stuck in the open position;

FIG. 2 is one example of a look-up table which may be used by the electronic controller of the pumping system of FIG. 1 to help determine when an error condition involving the solenoid valve exists, based on information supplied by the cycle counter shown in FIG. 1; and

FIG. 3 is a high level flowchart illustrating operations in accordance with one example of a method carried out by the electronic controller of FIG. 1 to detect when an error condition has arisen with operation of the air supply solenoid valve.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference to the accompanying drawings.

The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Referring to FIG. 1 there is shown a pump system 10 in accordance with one embodiment of the present disclosure. The pump system 10 in this example may include a pump 12 disposed in a well bore 14 for pumping fluids collecting within the well bore 14. The pump 12 is in communication with a wellhead 16.

The system 10 also includes a compressed air source 18, an air supply solenoid control valve 20 (hereinafter simply “air supply control valve 20”) having a primary valve 20a and a redundant valve 20b, an air valve 22, an optional quick exhaust valve 24, a cycle counter subsystem 26, a quick exhaust valve 28, and a water separator 30. An electronic controller 32 is included which may include a processor 32a, a non-volatile memory 32b (RAM, ROM, etc.), an input/output communication system 32c, a look-up table 32d, a first counter 32e and a second (“overdrive”) counter 32f. The input/output subsystem may include one or more of a BLUETOOTH® protocol radio, a LORA radio, a plug-in controller component, or any other form of wired or wireless communication subsystem/circuit/device, etc., which enables either one-directional or bi-bi-directional communications with the electronic controller.

The electronic controller 32 may generate a signal to turn on the compressed air source to begin a fluid discharge cycle for the pump 12, and to cause the compressed air source to be turned off as well by removing the turn-on signal. The electronic controller 32 also communicates with the air supply control valve 20 and applies commands to open and close the air supply control valve 20, in this example, specifically, the primary air supply control valve 20a. It is an important feature of the pump system 10 that the electronic controller 32 also receives signals from the cycle counter 26, from which it uses the received signals to monitor for and detect an error condition arising with the air supply control valve 20, that being that the primary air supply control valve 20a does not close, in which case the electronic controller 32 can command the secondary air supply control valve 20b to close to block the flow of pressurized air to the pump 12.

This important feature will be discussed in greater detail in the following paragraphs. The cycle counter 26 is a standard cycle counter for counting pump cycles which employs a magnet 26a and at least one reed switch, for example a well-known HES, a well-known Ratiometric sensor, etc., which will be referred to throughout the following discussion simply as “reed switch” 26b, and where the magnet is movable axially in response to the compressed air flowing through the cycle counter during a fluid discharge cycle. Optionally, a second reed switch 26c may be used, although the pump system 10 may operate with just one reed switch in the cycle counter 26.

The reed switch 26b senses a position of the magnet 26a and generates signals in accordance therewith. The magnet 26a moves from a first or “home” position, when no compressed air is flowing through the cycle counter 26, to a second or “End of Travel” (“EOT”) position when compressed air is flowing through the cycle counter. The reed switch 26b senses this movement of the magnet 26a and generates electrical signals in accordance with the sensed position of the magnet. If the second reed switch 26c is used, then the electronic controller 32 will receive signals from both reed switches 26b and 26c indicating the position of the magnet (e.g., one by reed switch 26b outputting a “0” signal, indicating the magnet is not present at a first location, while the second reed switch 26c outputs a “1” signal, indicating that the magnet is present at the second location, and vice versa). These electrical signals are transmitted to the electronic controller 32. The magnet/reed switch based cycle counter 26 is well known in the industry, and as such further details will not be provided. The precise location of the cycle counter 26 may vary from that shown in FIG. 1, but in any event it needs to be located at some point between the air supply control valve 20 and the pump 12, in other words in the path of the pressurized air flowing between air supply control valve 20 and the pump 12.

The quick exhaust valves 24 and 28 enhance operation of the system 10 but are not absolutely required for satisfactory operation of the system. The quick exhaust valve 28 operates automatically to vent either to atmosphere or to a vacuum line connected to its “Vent” port, when a predetermined lower limit of air pressure is reached within the quick exhaust valve 28. Optional quick exhaust valve 24 operates in the same manner, and collectively, the two quick exhaust valves 24 and 28 enable rapid venting of the interior of the pump 12 after a fluid discharge cycle is completed, which helps to facilitate the immediate start of another fill cycle. Similarly, the water separator 30 is not essential for operation of the system 10, but nevertheless is desirable for removing water and moisture from the compressed air stream injected into the pump 12, and thus helping to prolong the life of valving components exposed to the compressed air stream.

A significant problem that can arise is if the primary valve 20a of the air supply control valve 20 becomes stuck in the open position after a fluid discharge cycle is initiated by the electronic controller 32. In that instance, compressed air will flow through the air supply control valve 20, to open and allow the air supply valve 22 to communicate air from the cycle counter 26, thru the air valve, through the quick exhaust valve 28, and through the water separator 30 before entering an airflow line 34 which leads into a pump casing 12a of the pump 12. The compressed air stream is used to eject fluid which has collected within the pump casing 12a out through a fluid discharge line 36. While flowing through the cycle counter 26, the magnet 26a will be held in its “EOT” position, and this position will be detected by the reed switch 26b. After a predetermined fluid eject cycle time (e.g., 3-10 seconds), the electronic controller 32 will remove the signal to the air supply control valve 20, but because the primary valve 20a of the air supply control valve 20 will have become stuck in the “open” condition, compressed air will continue to be admitted to the interior of the pump casing 12a, and the electronic controller 32 would ordinarily have no way of knowing that this condition has arisen.

The pump system 10 addresses the above condition where the primary valve 20a of the air supply control valve 20 has become stuck in the “open” position by monitoring the signals received from the cycle counter 26. Ordinarily, these signals would just be used by the electronic controller 32 to maintain an on-going count of pump cycles, and possibly to save the count in the memory 32b for use in a future evaluation of pump performance and/or to determine when periodic pump maintenance is needed, or for other diagnostic or maintenance purposes. However, the pump system 10 also uses the electronic controller 32 to analyze the cycle counter 26 signals in relation to when expected transitions of the magnet 26a position within the cycle counter 26 should be occurring.

In one aspect the electronic controller 32 intelligently determines that at the end of a fluid discharge cycle, which for example may last for a predetermined time period, a change in position of the magnet 26a should trigger a corresponding signal from the reed switch 26b of the cycle counter 26. In other words, the reed switch 26b should be generating an electrical signal in accordance with the “home” position of the magnet 26a, in this example a Level “1” signal. If the “home” signal from the reed switch 26b is not detected, that is, if the signal being received is still a Level “0” signal, then the electronic controller 32 knows that compressed air is still flowing through the cycle counter 26 and into the pump 12. In this event, the electronic controller 32 may then use its input/output communications subsystem 32c to generate an alarm signal 38. In one example, the alarm signal 38 may be a wireless signal which is received by a monitoring station in a vicinity of the well bore 14, but it need not necessarily be in the vicinity of the well bore 14. For example, the alarm signal 38 could be transmitted wirelessly to a cloud-based portal which is in turn in communication with a remote monitoring center. Still further, the alarm signal 28 could be transmitted via a wired connection to a monitoring center. Still further, the alarm signal may be provided via a Bluetooth® protocol radio (not shown) integrated into the pump system 10 to a user's laptop, smartphone, etc. Still further, the alarm signal 28 could be used to set a visual indicator (i.e., LED(s)) at the well head 16. Still further, the alarm signal 38 could be supplied to a computer connected to a cellular network to notify a technician via a text message on the technician's smartphone, or possibly even by an email message to the technician, of the error condition. Accordingly, one or more of WiFi, Bluetooth® protocol, and hard wired connections may be used to transmit the alarm signal 38 to an individual or entity as needed by a given application.

FIG. 2 shows one example of the look-up table 32d which may be stored in a suitable memory of the electronic controller 32, and optionally in the memory 32b. This example shows how the two reed switch 26b and 26c components may be used, but the electronic controller 32 can be used with just a single reed switch as well. The use of two reed switches does provide an additional level of “intelligence” that the electronic controller 32 can use to further determine/verify the location of the magnet 26a at any given time during a pump cycle.

From the look-up table 32d, it can be seen that when the reed switch 26b has not generated a “1” logic level signal after completion of the predetermined time internal and the overdrive time interval, the electronic controller 32 knows that an error condition has arisen, and can generate the alarm signal 38 (FIG. 1). Error conditions may include any of those expressly set forth above concerning the main air supply valve being stuck open, stuck closed, the discharge line being blocked, and/or the force main being blocked. Also, a restricted air supply can cause similar poppet movements.

Referring to FIG. 3, a flowchart 100 illustrates operations that may be performed by the electronic controller 32 during operation of the pump system 10. At operation 102 the electronic controller is initially monitoring for a signal indicating that a fluid discharge cycle is to be initiated (i.e., pump 12 is presumed to be full). At operation 104 the electronic controller 32 makes a check to determine if a fluid discharge cycle signal has been received. If this check produces a “No” answer, then the monitoring operation for a fluid discharge cycle to start continues as operation 102 is repeated. If the answer at operation 104 is a “Yes” answer, then the electronic controller 32 starts counter 1 32e to begin the predetermined time interval for the fluid discharge cycle. At operation 108 the electronic controller 32 then sends a signal to the primary valve 20a of the air supply control valve 20 to begin admitting air into the pump 12 to begin the fluid discharge cycle. At operation 110 the electronic controller 32 makes a check to determine if the predetermined time interval (T1) has expired. If this check produces a “No” answer, then operations 108 and 110 are repeated. If the check at operation 110 produces a “Yes” answer, the electronic controller 32 makes a check at operation 111 to determine if the primary valve 20a of the air supply control valve 20 actually remained open for the T1 time interval. If this check produces a “No” answer, then the electronic controller 32 makes a determination at operation 126 that an error has occurred, for example, a Level 2 error, indicating that the fluid pump 12 did not actually pump for the T1 interval. The electronic controller 32 will then generate an error signal at operation 128, will reset all the counters at operation 130, and the pumping cycle will be terminated at operation 132.

If the check at operation 111 indicates that the fluid pump 12 did remain open for the T1 interval, then this indicates a good or successful pump cycle occurred. The electronic controller 32 then sends a signal to the primary valve 20a of the air supply control valve 20 to close, as indicated at operation 112, which cuts off the pressurized air supply to the pump 12 to end the fluid discharge cycle.

At operation 114 the electronic controller 32 then starts the second time interval counter 2 32f. The second time interval counter 2 32f is an “overdrive” counter intended to provide a short time period to allow the magnet 26a to return to its “home” position. A failure to return home within the predetermined time period (e.g., twice the pumping time period) indicates that the primary air supply valve 20a is hanging open. At operation 116 the electronic controller 32 makes a check to determine if the overdrive time interval counter 2 32f has expired. If this produces a “No” answer, then operations 114 and 116 are repeated. If the check at operation 116 produces a “Yes” answer, indicating that the overdrive counter 32f has timed out, then at operation 118 the electronic controller 32 makes a check to see if a Level “1” level signal is now being received from the reed switch 26b (i.e., that the reed switch 26b has returned to its home position). If no Level “1” signal is being received, then from using the look-up table 32d, this indicates to the electronic controller 32 that pressurized air is still being received through the cycle counter 26, which indicates that the primary valve 20a of the air supply control valve 20 is stuck in the open position. At operation 120 the electronic controller 32 generates the error signal 38 indicating this error condition. The predetermined and overdrive counters 32e and 32f may then be reset, as indicated at operation 122. At this point the electronic controller 32 may command the secondary valve 20b of the air supply control valve 20 to close, as indicated at operation 124, to interrupt the pressurized airflow to the pump 12.

If the check at operation 118 indicates that a Level “1” signal is detected after the additional (i.e., overdrive) time interval has expired, then from the look-up table 32d, this enables the electronic controller 32 to verify that the primary valve 20a of the air supply control valve 20 has actually closed after the pump discharge cycle time has completed, and the next fill cycle is beginning. The overdrive counter 32f may be then be reset, as indicated at operation 134, and the method repeats at operation 102.

The pump system 10 thus makes use of the cycle counter 26 for the dual purpose of 1) counting fluid discharge cycles, and 2) intelligently using the electrical signals from the cycle counter 26 to determine when the primary valve 20a of the air supply control valve 20 is stuck in the open position. The pump system 10 advantageously provides this additional feature of detecting when the air supply control valve 26 is stuck in the open position without the need for any other hardware components to be integrated into the pump system 10, and with virtually no additional cost for the pump system 10. Moreover, the normal control sequence for the pump system 10 does not need to be modified. The pump system 10 thus provides a highly beneficial feature that enables field maintenance personnel to be quickly apprised if an air supply control valve associated with a given fluid pump becomes stuck in the open position, as well as a secondary airflow valve that is controlled to interrupt the flow of pressurized air to the pump under such condition.

It will also be appreciated that the pump system 10 can be constructed to use any type of wireless communication, or even a plug-in hand held controller, for example a gas analyzer, to enable making changes in configuration to the pump system 10, or to make notes about the well site like gas quality, vacuum vale setting, orifice plate used, etc. The data can be stored on the non-volatile memory 32b of the electronic controller 32 for future use, or even sent via a desired wireless protocol, (e.g., BLUETOOTH® protocol radio, to a smartphone which is in communication with the a cloud-based subsystem, or by use of a radio communication link like LoRa to send the data to a local gateway for storage, or to be sent to the cloud for remote data collection. Those skilled in the art will appreciate that virtually any means of communicating with the electronic controller 32, either through a wireless link or a wired link, may be employed when implementing the pump system.

The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

Claims

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.