Progressive cavity pump system having reverse mode

A progressive cavity pump (PCP) system comprising:

• a PCP comprising a rotor rotatably disposed within a hollow stator, the PCP configured to be disposed downhole in a borehole of a well;
• a permanent magnet motor (PMM) configured to be disposed at a surface of the well;
• a sucker rod coupled to the rotor of the PCP via a connection and operatively coupled to the PMM, wherein in use, the PMM drives rotation of the sucker rod to rotate the rotor;
• and
• a control system configured to control operation of the PCP system, the control system configured to:
• operate the PCP system in a production mode, wherein in the production mode the PMM drives rotation of the sucker rod coupled to the rotor to rotate the rotor in a first direction to pump a fluid from a reservoir in an uphole direction through the PCP;
• and
• perform a pump shutdown of the PCP system, wherein a column of the fluid is above the PCP and the pump shutdown comprises:
• operating the PCP system in a reverse mode, wherein in the reverse mode the PMM drives the rotation of the sucker rod coupled to the rotor to rotate the rotor in a second direction opposite the first direction to pump the column of the fluid in a downhole direction through the PCP;
• monitoring a torque of the PCP;
• and
• stopping the rotation of the rotor of the PCP while operating in the reverse mode to shut down the PCP in response to determining the PCP is approaching a run dry condition to avoid the run dry condition, wherein determining the PCP is approaching the run dry condition includes determining torque has reached a predetermined setpoint.

A control system for a progressive cavity pump (PCP) system including a PCP, the control system comprising:

• a display screen;
• one or more user interfaces;
• and
• a processor configured to:
• operate the PCP system in a production mode, wherein in the production mode a motor of the PCP system drives rotation of a sucker rod coupled to a rotor of the PCP to rotate the rotor in a first direction to pump a fluid from a reservoir in an uphole direction through the PCP disposed in a wellbore;
• and
• perform a pump shutdown of the PCP system, wherein a column of the fluid is above the PCP and the pump shutdown comprises:
• operating the PCP system in a reverse mode, wherein in the reverse mode the motor drives the rotation of the sucker rod coupled to the rotor to rotate the rotor in a second direction opposite the first direction to pump the column of the fluid in a downhole direction through the PCP;
• monitoring if a torque of the PCP reaches a predetermined setpoint;
• and
• stopping the rotation of the rotor of the PCP while operating in the reverse mode to shut down the PCP in response to determining the PCP is approaching a run dry condition to avoid the run dry condition, wherein determining the PCP is approaching the run dry condition includes determining the torque of the PCP has reached the predetermined setpoint.