This disclosure relates generally to operations and equipment utilized in conjunction with a subterranean well and, in an example described below, more particularly provides an artificial lift system, a rod rotator and associated methods for use with a well.
Reservoir fluids can sometimes flow to the earth's surface when a well has been completed. However, with some wells, reservoir pressure may be insufficient (at the time of well completion or thereafter) to lift the fluids (in particular, liquids) to the surface. In those circumstances, technology known as “artificial lift” can be employed to bring the fluids to the surface (or other desired location, such as a subsea production facility or pipeline, etc.).
Various types of artificial lift technology are known to those skilled in the art. In one type of artificial lift, a downhole pump is operated by reciprocating a string of “sucker” rods deployed in a well. An apparatus (such as, a walking beam-type pump jack or a hydraulic actuator) located at the surface can be used to reciprocate the rod string.
Therefore, it will be readily appreciated that improvements are continually needed in the arts of constructing and operating artificial lift systems. Such improvements may be useful for lifting oil, water, gas condensate or other liquids from wells, may be useful with various types of wells (such as, gas production wells, oil production wells, water or steam flooded oil wells, geothermal wells, etc.), and may be useful for any other application where reciprocating motion is desired.
Representatively illustrated in
In the
The rod string 18 is made up of individual sucker rods connected to each other. The rod string 18 communicates reciprocating motion of the hydraulic actuator 14 to the downhole pump 20.
The downhole pump 20 is depicted in
The wellbore 28 is depicted in
In the
As depicted in
In the
The annular seal housing 44 includes an annular seal (not shown) about a piston rod of the hydraulic actuator 14. The piston rod (described more fully below) connects to the rod string 18 below the annular seal, although in other examples a connection between the piston rod and the rod string 18 may be otherwise positioned. A conventional stuffing box may be used for the annular seal housing 44 in some examples.
The hydraulic pressure source 12 may be connected directly to the hydraulic actuator 14, or it may be positioned remotely from the hydraulic actuator 14 and connected with, for example, suitable hydraulic hoses or pipes. The hydraulic pressure source 12 controls pressure in the hydraulic actuator 14, so that the rod string 18 is displaced alternately to its upper and lower stroke extents.
Referring additionally now to
In the
The pressure source 12 applies increased pressure to an annular chamber 54 formed radially between the cylinder 50 and the piston rod 52, in order to displace the piston 48 longitudinally upward (as viewed in
A rod rotator 60 is used with the hydraulic actuator 14. The rod rotator 60, in this example, causes the piston 48, the piston rod 52 and the attached rod string 18 to rotate periodically, and can thereby enhance longevity of the rod string by evening out wear of the rod string in the well.
The rod rotator 60 of
As depicted in
Note that the mandrel 62 has an external helical profile 68 formed thereon. The helical profile 68 is in the shape of a helical external spline formed on the mandrel 62 (see
Note, also, that the mandrel 62 is received in the piston 48 and piston rod 52. The piston 48 and piston rod 52 are suitably configured for insertion of the mandrel 62 therein, as described more fully below.
Referring additionally now to
In the
The insert 70 has an internal profile 74 formed therein which is complementarily shaped relative to the external profile 68 on the mandrel 62. The insert 70 cooperatively and slidingly engages the mandrel 62 as the piston 48 and piston rod 52 reciprocate in the cylinder 50. Note that it is not necessary for the internal profile 74 to be helical, but the internal profile 74 and the external profile 68 are preferably cooperatively shaped, so that the insert 70 is caused by the engagement of the profiles 68, 74 to rotate as it displaces longitudinally relative to the mandrel 62.
In this example, the engagement between the insert profile 74 and the mandrel profile 68 will cause the insert 70 to rotate in one rotational direction (clockwise, or in a right-hand direction, as viewed from above) relative to the mandrel 62, as the insert 70, piston 48 and piston rod 52 displace downward in the cylinder 50. The insert 70 will rotate in an opposite rotational direction (counter-clockwise, or in a left-hand direction, as viewed from above) relative to the mandrel 62, as the insert 70, piston 48 and piston rod 52 displace upward in the cylinder 50. In other examples, the insert 70 could rotate otherwise relative to the mandrel 62.
It is advantageous in this example for the insert 70, along with the piston 48, the piston rod 52 and the attached rod string 18 to rotate in the clockwise or right hand direction as the rod string descends in the wellbore 28. There are no buckling loads induced in the mandrel 62 due to downward displacement of the piston 48 and piston rod 52, and friction loads against the casing 32 are reduced when the rod string 18 descends in the wellbore 28, as compared to when the rod string ascends. However, the scope of this disclosure is not limited to any particular direction of piston 48 and rod 52 longitudinal displacement when these components rotate in any particular rotational direction.
The one-way clutch 72 permits the insert 70 to rotate in the counter-clockwise or left hand direction as the piston 48 and piston rod 52 ascend in the cylinder 50. The piston 48 and piston rod 52 do not rotate when they ascend in the cylinder 50, due to friction between the piston (or seals thereon) and the cylinder. However, in some examples, an anti-rotation device or friction enhancer may be used to prevent rotation of the piston 48 and piston rod 52 in the counter-clockwise direction relative to the cylinder 50.
Note that the cylinder connector 64 and mandrel attachment 66 are differently configured in the
When the mandrel 62 is suspended in the cylinder 50 by the cylinder connector 64 and attachment 66, the mandrel is received in an internal bore 78 extending longitudinally in the piston 48 and rod 52. Thus, the mandrel 62 is “telescoped” within the piston 48 and rod 52 during operation of the actuator 14.
In the
The torque may be applied continuously, periodically, as the piston 48 ascends in the cylinder 50, or as the piston descends in the cylinder. Operation of the rotary actuator 88 may be controlled by the control system 12.
A sensor 86 may be used to measure torque in the mandrel 62. Torque in the mandrel 62 may be due to the rotation imparted by the profile 68 to the piston 48 and attached rod string 18 via the insert 70 and one-way clutch 72. Torque in the mandrel 62 may also be due to operation of the rotary actuator 88.
The torque in the mandrel 62 can vary based on a variety of different factors. A condition of the rod string 18 as it relates to movement in the tubing string 30 (including, for example, build-up of scale in the tubing string, wear on rod guides, etc.) can affect the torque needed to rotate the rod string within the tubing string.
The sensor 86 can be connected to the control system 12 for recording and evaluation of the torque measurements. The condition of the rod string 18 and the tubing string 30, and the efficiency of the pumping operation, can be determined based on the torque measurements.
Referring additionally now to
Other shapes for the profile 68 may be used, in keeping with the scope of this disclosure. In this example, the profile 68 extends an entire length of the mandrel 62, but in other examples the external profile may be formed on only a portion of the mandrel.
Referring additionally now to
The one-way clutch 72 prevents the insert 70 from rotating in the clockwise or right-hand direction relative to the piston 48 and rod 52 as the piston and rod displace downward in the cylinder 50. Thus, the piston 48 and rod 52 are constrained to continuously rotate with the insert 70 in the clockwise or right-hand direction as the piston and rod descend. The rod string 18 also rotates with the insert 70, piston 48 and rod 52.
The one-way clutch 72 permits the insert 70 to rotate in the counter-clockwise or left-hand direction relative to the piston 48 and piston rod 52 as the piston and rod displace upward in the cylinder 50. Thus, the piston 48, piston rod 52 and rod string 18 do not rotate with the insert 70 as the piston and piston rod ascend.
As a result, right-hand or clockwise rotation is imparted to the rod string 18 continuously as the piston 48 and piston rod 52 displace downward, and the rod rotator 60 does not impart any rotation to the rod string as the piston and piston rod displace upward. In other examples, the rod string 18 could be rotated as the piston 48 and rod string 52 displace upward, or the rod string could be rotated as the piston and rod string displace in both longitudinal directions.
Referring additionally now to
The inner component 80 is secured to the insert 70 (such as, by welding, bonding, press-fitting, etc.), so that the insert and the inner component displace rotationally and longitudinally together. In some examples, the insert 70 and the inner component 80 could be integrally formed (e.g., with the profile 74 formed in the inner component).
The outer component 82 is secured to the piston 48 (such as, by welding, bonding, press-fitting, etc.), so that the outer component, the piston, the piston rod 52 and the rod string 18 displace rotationally and longitudinally together. In some examples, the outer component 82 could be secured directly to the piston rod 52, or could be integrally formed with the piston 48 or piston rod 52.
A suitable device that may be used for the one-way clutch 72 is known to those skilled in the art as a sprag bearing or sprag clutch. Such devices have “sprags” positioned between inner and outer races. The sprags permit relative rotation between the races in one direction, but prevent relative rotation between the races in an opposite direction. However, other types of one-way clutches (such as, ratchets, etc.) may be used, in keeping with the scope of this disclosure.
Note that, in operation, the one-way clutch 72, insert 70 and mandrel 62 are positioned within the cylinder 50. This prevents dirt and debris from fouling the rod rotator 60, and protects it from damage due to inadvertent impacts, mishandling, etc.
It may now be fully appreciated that the above disclosure provides significant advancements to the art of constructing and operating artificial lift systems. In one example described above, a hydraulic actuator 14 can be used with a rod rotator 60 that incrementally rotates a rod string 18 as a piston 48 reciprocates in a cylinder 50 of the actuator. The rod rotator 60 rotates the rod string 18 continuously as the piston 48 displaces in at least one longitudinal direction. Active components of the rod rotator 60 are disposed in the cylinder 50.
The above disclosure provides to the art an artificial lift system 10 for use with a subterranean well. In one example, the system 10 comprises an actuator 14 operable to reciprocate a rod string 18 in the well, the actuator 14 including a piston 48 reciprocably disposed in a cylinder 50, and a piston rod 52 connected to the piston 48. A rod rotator 60 continuously rotates the piston rod 52 relative to the cylinder 50 as the piston 48 displaces in a first longitudinal direction relative to the cylinder 50.
The first longitudinal direction comprises a downward direction. In other examples, the first longitudinal direction could be an upward or other direction.
The rod rotator 60 may produce no rotation of the piston rod 52 relative to the cylinder 50 as the piston 48 displaces in a second longitudinal direction (e.g., upward) opposite to the first longitudinal direction.
The rod rotator 60 may include a mandrel 62 having a helical first profile 68. The first profile 68 may comprise a helical external spline formed on the mandrel 62. The mandrel 62 may be disposed within the cylinder 50.
The mandrel 62 may be slidingly engaged with a second profile 74 that reciprocates with the piston 48 and piston rod 52. The second profile 74 may be prevented from rotating in a first rotational direction relative to the piston 48 and/or piston rod 52, and the second profile 74 may be permitted to rotate in an opposite second rotational direction relative to the piston 48 and/or piston rod 52.
A one-way clutch 72 of the rod rotator 60 may prevent rotation of the second profile 74 in a first rotational direction relative to the piston 48 and/or piston rod 52. The one-way clutch 72 may permit rotation of the second profile 74 in an opposite second rotational direction relative to the piston 48 and/or piston rod 52. The second profile 74 may be disposed within the cylinder 50.
The above disclosure also provides to the art a method of rotating a rod string 18 in a subterranean well. In one example, the method can include: connecting the rod string 18 to a piston rod 52 of an actuator 14; longitudinally reciprocating the piston rod 52 relative to a cylinder 50 of the actuator 14 and a mandrel 62 of a rod rotator 60; and rotating the piston rod 52 relative to the mandrel 62 in response to the reciprocating, the mandrel 62 being disposed at least partially within the piston rod 52 during the rotating.
The reciprocating step can include slidingly engaging an internal profile 74 with the mandrel 62, the internal profile 74 reciprocating with the piston rod 52. The internal profile 74 may slidingly engage a helical external profile 68 on the mandrel 62.
The rotating step can include preventing rotation of the internal profile 74 relative to the piston rod 52 in a first rotational direction in response to displacement of the rod string 18 in a first longitudinal direction, and rotating the internal profile 74 in a second rotational direction opposite to the first rotational direction relative to the rod string 18 in response to displacement of the rod string 18 in a second longitudinal direction opposite to the first longitudinal direction.
The rotating step may include rotating the piston rod 52 in a first rotational direction relative to the mandrel 62 in response to displacement of the rod string 18 in a first longitudinal direction, and preventing rotation of the piston rod 52 in a second rotational direction opposite to the first rotational direction relative to the mandrel 62. The rotation preventing step may include engaging a one-way clutch 72 that prevents rotation of the piston rod 52 relative to the mandrel 62 in the second rotational direction.
The method may include positioning the mandrel 62 within the cylinder 50. The method may include positioning the mandrel 62 at least partially within a piston 48 that reciprocates with the piston rod 52.
The rotating step may include rotating the piston rod 52 continuously as the piston rod 52 displaces relative to the mandrel 62. The piston rod 52 may rotate continuously as the piston rod 52 displaces in the first longitudinal direction relative to the mandrel 62.
A rod rotator 60 for rotating a rod string 18 in a subterranean well is also described above. In one example, the rod rotator 60 can include an elongated mandrel 62 having a helical external profile 68, the mandrel 62 being configured to attach to a cylinder 50 of a hydraulic actuator; an internal profile 74 complementarily shaped relative to the external profile 68; and a one-way clutch 72 including first and second components 80, 82. The first component 80 is rotatable with the internal profile 74, and the second component 82 is configured for attachment to a piston 48 and/or a piston rod 52 of the hydraulic actuator 14. The one-way clutch 72 prevents the first component 80 from rotating in a first rotational direction relative to the second component 82, but permits rotation of the first component 80 relative to the second component 82 in a second rotational direction opposite to the first rotational direction.
The internal profile 74 may rotate relative to the mandrel 62 in the first rotational direction in response to displacement of the internal profile 74 relative to the mandrel 62 in a first longitudinal direction. The one-way clutch 72 may permit relative rotation between the internal profile 74 and the mandrel in a second rotational direction in response to displacement of the internal profile 74 relative to the mandrel 62 in a second longitudinal direction opposite to the first longitudinal direction.
The rod rotator 60 may include a cylinder connector 64 configured to suspend the mandrel 62 within the cylinder 50.
The helical external profile 68 may comprise a helical spline formed on the mandrel 62.
Although various examples have been described above, with each example having certain features, it should be understood that it is not necessary for a particular feature of one example to be used exclusively with that example. Instead, any of the features described above and/or depicted in the drawings can be combined with any of the examples, in addition to or in substitution for any of the other features of those examples. One example's features are not mutually exclusive to another example's features. Instead, the scope of this disclosure encompasses any combination of any of the features.
Although each example described above includes a certain combination of features, it should be understood that it is not necessary for all features of an example to be used. Instead, any of the features described above can be used, without any other particular feature or features also being used.
It should be understood that the various embodiments described herein may be utilized in various orientations, such as inclined, inverted, horizontal, vertical, etc., and in various configurations, without departing from the principles of this disclosure. The embodiments are described merely as examples of useful applications of the principles of the disclosure, which is not limited to any specific details of these embodiments.
In the above description of the representative examples, directional terms (such as “above,” “below,” “upper,” “lower,” “upward,” “downward,” etc.) are used for convenience in referring to the accompanying drawings. However, it should be clearly understood that the scope of this disclosure is not limited to any particular directions described herein.
The terms “including,” “includes,” “comprising,” “comprises,” and similar terms are used in a non-limiting sense in this specification. For example, if a system, method, apparatus, device, etc., is described as “including” a certain feature or element, the system, method, apparatus, device, etc., can include that feature or element, and can also include other features or elements. Similarly, the term “comprises” is considered to mean “comprises, but is not limited to.”
Of course, a person skilled in the art would, upon a careful consideration of the above description of representative embodiments of the disclosure, readily appreciate that many modifications, additions, substitutions, deletions, and other changes may be made to the specific embodiments, and such changes are contemplated by the principles of this disclosure. For example, structures disclosed as being separately formed can, in other examples, be integrally formed and vice versa. Accordingly, the foregoing detailed description is to be clearly understood as being given by way of illustration and example only, the spirit and scope of the invention being limited solely by the appended claims and their equivalents.
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Number | Date | Country | |
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20190071956 A1 | Mar 2019 | US |