Pneumatic Pump Cycle Counter

Abstract

This invention provides pneumatic pump cycle counters, methods for assembling pneumatic pump cycle counters, and methods for obtaining pump counts with the pneumatic pump cycle counters for wells and other systems that are equipped with pneumatic pumps.

1 . A pneumatic pump cycle counter comprising:
 a pneumatic pump comprising an air inlet line in fluid communication with a compressed air feed line, the compressed air feed line in fluid communication with an inline pressure-reducing regulator, the air inlet line in fluid communication with the pressure-reducing regulator and the pneumatic pump, a piezoresistive pressure sensor in operative contact with air within the air inlet line and proximate to the inline pressure-reducing regulator, the piezoresistive pressure sensor configured to continuously or periodically measure, and transmit signals indicative of, air inlet line pressure, and   a processing unit in electronic communication with the piezoresistive pressure sensor, the processing unit configured to receive the signals indicative of air inlet line pressure, and configured either
 a) to continuously or periodically calculate changes in the air inlet line pressure over time, and to extrapolate and transmit signals indicative of a pump cycle count therefrom when the air inlet line pressure change meets or exceeds a pre-selected value; or 
 b) to continuously or periodically calculate a pressure change between the air inlet line pressure and a rolling average of previously measured air inlet line pressures and to continuously or periodically calculate air inlet line pressure changes over time, and to extrapolate, and transmit signals indicative of a pump cycle count therefrom when the air inlet line pressure change meets or exceeds a pre-selected value; 
   wherein the pneumatic pump cycle counter also comprises one or more of the following:
 one or more temperature sensors configured to continuously or periodically measure, and transmit signals indicative of, a measured temperature; 
 a gas extraction well pressure sensor configured to continuously or periodically measure, and transmit signals indicative of, gas extraction well pressure; 
 an atmospheric chemical sensor configured to continuously or periodically measure, and transmit signals indicative of, a concentration for each of one or more chemicals measured by the atmospheric chemical sensor; and/or 
 a gas extraction well chemical sensor configured to continuously or periodically measure, and transmit signals indicative of, a concentration for each of one or more chemicals; and 
 wherein one or more temperature sensors is present; and wherein the one or more temperature sensors measure gas extraction well temperature and/or ambient air temperature; and 
 wherein an atmospheric chemical sensor is present and wherein the atmospheric chemical sensor senses methane. 
   
     
     
         2 - 24 . (canceled) 
     
     
         25 . A method for assembling a pneumatic pump cycle counter, which method comprises:
 connecting an air inlet line to a pneumatic pump to provide fluid communication therebetween;   connecting the air inlet line to a compressed air feed line to provide fluid communication therebetween;   placing a pressure-reducing regulator inline and connecting the pressure-reducing regulator to the compressed air feed line and to the air inlet line to provide fluid communication between the pressure-reducing regulator and the compressed air feed line, and to provide fluid communication between the pressure-reducing regulator and the air inlet line;   placing a piezoresistive sensor in operative contact with air within the air inlet line and proximate to the pressure-reducing regulator, the piezoresistive pressure sensor configured to continuously or periodically measure, and transmit signals indicative of, air inlet line pressure,   connecting a processing unit to the piezoresistive sensor for electronic communication, the processing unit configured to receive the signals indicative of air inlet line pressure, and configured either
 a) to continuously or periodically calculate changes in the air inlet line pressure over time, and to extrapolate and transmit signals indicative of a pump cycle count therefrom when the air inlet line pressure change meets or exceeds a pre-selected value; or 
 b) to continuously or periodically calculate a pressure change between the air inlet line pressure and a rolling average of previously measured air inlet line pressures and to continuously or periodically calculate air inlet line pressure changes over time, and to extrapolate, and transmit signals indicative of a pump cycle count therefrom when the air inlet line pressure change meets or exceeds a pre-selected value; 
   connecting a transmitter to the processing unit to place the transmitter in electronic communication with the processing unit, the transmitter configured to transmit one or more signals; and   connecting a data repository configured to store one or more signals after receipt from the transmitter, wherein the data repository is a cloud-based data storage system and/or the data repository can be accessed via a webpage.   
     
     
         26 - 27 . (canceled) 
     
     
         28 . A method for obtaining pump cycle counts from a pneumatic pump, which method comprises:
 generating pump cycle counts from a pneumatic pump cycle counter comprised of i) a pneumatic pump comprising an air inlet line in fluid communication with a compressed air feed line, the compressed air feed line in fluid communication with an inline pressure-reducing regulator, the air inlet line in fluid communication with the pressure-reducing regulator and the pneumatic pump, a piezoresistive pressure sensor in operative contact with air within the air inlet line and proximate to the inline pressure-reducing regulator, the piezoresistive pressure sensor configured to continuously or periodically measure, and transmit signals indicative of, air inlet line pressure, and ii) a processing unit in electronic communication with the piezoresistive pressure sensor, the generating comprising:
 measuring the air inlet line pressure with the piezoresistive sensor to produce a signal indicative of air inlet line pressure, 
   transmitting the signal indicative of air inlet line pressure from the piezoresistive sensor to the processing unit,   receiving the signals indicative of air inlet line pressure in the processing unit, the processing unit continuously or periodically calculating either
 a) changes in the air inlet line pressure over time, and extrapolating and transmitting signals indicative of a pump cycle count therefrom when the air inlet line pressure change meets or exceeds a pre-selected value; or 
 b) a pressure change between the air inlet line pressure and a rolling average of previously measured air inlet line pressures and continuously or periodically calculating air inlet line pressure changes over time, and extrapolating and transmit signals indicative of a pump cycle count therefrom when the air inlet line pressure change meets or exceeds a pre-selected value; 
   transmitting one or more signals via a transmitter, the transmitter configured to transmit the one or more signals; and   storing signals in a data repository configured to store signals after receipt from the transmitter, wherein the data repository is a cloud-based data storage system and/or the data repository can be accessed via a webpage.   
     
     
         29 - 38 . (canceled)