Fluid Levels for Well Controllers

This Fluid Level System is designed to add a fluid level component to third party Well Controllers for any type of artificial lift, whether it be a VSD (Variable Speed Drive) or simply a well pumping cycle controller.

Our focus is providing a solid reliable fluid level for use in properly controlling a well’s pumping rate for maximum production and efficiency, while preventing the destruction of equipment and cost involved with running a fluid level too low. We are a direct fluid reading instrument. We are not a POC, which generally attempts to determine a fluid level, or dry pump condition, with extrapolation of remote factors and assumptions about the often variable fluid composition in a well, with varying success. We often demonstrate this by providing empirical fluid level information on wells utilizing normal Pump Off Controllers without fluid level components.

If an existing well controller has excess computing ability and memory capable of running Windows Mobile, XP, Vista or 7, a 1GHz processor, 10 MB of disk space, 10 MB of ram and 2 USB ports, our WSDAQ program may be embedded in your present equipment design at very minimal cost to add a fluid level component.

The heart of the system is our AGR (Acoustic Generator Receiver), which has multiple patents, and patents pending, on a series of unique devices and concepts which, in combination, create a fluid level reading device like no other in the world.

This AGR may be placed up to 50 feet or more from the wellhead on an active casing gas line. We prefer to be within ten feet, and this may be required in difficult circumstances, but the normal well up to about 8,000 feet has little limitation.

We prefer that the AGR be installed facing downward on a riser loop to minimize liquids accumulating in the head of the AGR and facilitate the self cleaning action of the AGR. A valve is placed above the loop and below the AGR for safe and easy installation. We request that the field operator install this service loop in their system, and we can then place the AGR and do final system testing in about an hour.

In some cases, a valve to shut in the gas line for about 30 seconds during a sounding is recommended. We can provide a pneumatic valve which is operated and controlled by our system when necessary. A pre-installation well survey with our portable Surveyor III can determine the requirements for reliable fluid level results.

Nothing is placed within the well, or in any way interacts with the well, except for a very small amount of Nitrogen gas to create a pressure wave, which in turn creates pressure variance echos for recording. We only use safe and inert Nitrogen Gas, and avoid having contact with the unstable, and often corrosive well gasses and treatment chemicals, which can be dangerous and might even react with stainless steel. See our discussion page on pressure sources.

Our system may be isolated from the well gas system instantly with the one valve directly under the AGR. There is no need to make any special preparations for well workovers or other well entry. On rare occasions, when a large amount of recirculated fluids, sometimes used to carry chemicals, are entering the top of the well, these may also need to be halted for 30 to 60 seconds during a survey. The well may be monitored every second of every day, and any number of pressure, temperature, or electric anomalies may trigger a fluid level reading at any time. An acoustic anomaly detection system is available which listens to the well continually for any change from the normal.

The number of readings required, or desired, determines the pressurization source, if one is required. If enough suitable well pressure gas is available for a solid sounding, there is no need for any outside pressure source. For a number of reasons, this is not usually the case, even when several hundred PSI is available, so we have provided a section discussing pressure options.

Although a sounding is possible, continuously every minute or two with our Patent Pending high pressure Nitrogen Generation system, a simple bottle may be the most practical pressure source, and may last for a year or more before a $20 refill is required. Remember, any unusual monitored indicator may trigger a fluid level at any time as the reliable final word on whether a problem needs to be addressed, and the urgency of the action required or performed automatically.

On pressure and fluid build up surveys, in a week of gradually spreading timed soundings, starting every 5 minutes, we have never used more than the larger 200 cu. ft. bottle. Barring these test scenarios, a very few soundings daily are usually all that are required to monitor the pumping rate, in normal circumstances. Once the pumping rate is dialed in, very small rate adjustments are usually required, and the main function becomes one of monitoring the well for undesirable trends. We have held wells in a ten foot range, about 100 feet above the pump, with one sounding daily for months.