The present invention relates to safety brake assemblies and, in particular, to safety brake assemblies for drive strings, which store reactive torque by reason of being under torsion.
Certain drive systems are subject to torsional stresses which are stored as reactive torque in a drive train. When drive power to the system is interrupted, the reactive torque is released as backspin and, if an uncontrolled release of torque occurs, personal injury and/or property damage can result. For example, deep well submersible pumps such as progressing cavity pumps driven by sucker rod strings are commonly used to pump oil from deep wells. The drive strings for these submersible pumps usually have a relatively small diameter of ¾ to 1⅛ inches. Such drive strings are commonly used in wells that vary from 1,500′ to 6,000′ in depth, 3,000′ being a common average.
Progressing cavity pumps include a stator, which is attached to a production tubing at the bottom of a well, and a rotor which is attached to a bottom end of the drive string. Due to the rotational resistance of the pump and the weight of the fluid being pumped, the drive sting is torsionally deformed. Progressing cavity pumps are frequently used to pump viscous crude oil, which is often laden with sand or other impurities. As a result, the elongated drive string is subject to considerable torsional force. This torsional force is stored in the elongated drive string as reactive torque. In a 3,000 foot string, as many as several hundreds of revolutions of torsion can be stored in the string if viscous sand laden crude oil is being pumped. The deeper the well and the heavier the liquid being pumped, the larger the torsional force. Upon release, the larger the torsional force, the faster the backspin. Excessive backspin speeds will occur unless a backspin braking system is used to maintain the backspin speed below a safe limit while absorbing and dissipating the energy. The safe speed is determined by the speed rating of the drive head, the power transmission system, or the prime mover.
Commonly, pulleys and belts are used to transmit power from the prime mover to the drive head. If pulleys rotate fast enough, such as during uncontrolled backspin, they will shatter due to tensile stresses in the rim resulting from centrifugal forces. Fragments from shattered sheaves are very dangerous to operating personnel. This is particularly true if an electric motor is used as a power source because such motors offer almost no resistance to reverse rotation.
Brakes which simply prevent the release of reactive torque stored in the drive string are unsatisfactory for two reasons. First, it is preferable that in the case of an electric motor drive, the motor be able to restart unattended when power is restored. In order to ensure a successful unattended restart, the motor must start without load. If the reactive torque in the drive string is not released prior to restart, the motor may not be capable of restarting and the motor may be damaged as a result. Second, if pump repair or replacement is required any unreleased torque in the drive string can be extremely dangerous for unaware workmen. Severe personal injury can result from the unintentional release of reactive torque in such drive strings.
Consequently, braking systems have been developed in an effort to prevent overspeed rotation of the shaft. Centrifugal as well as fluid brake systems are known for backspin control.
Fluid brake systems include a pump engaged only during backspin, which pump circulates hydraulic fluid or lubricating oil from a reservoir to a bearing case through a restricted orifice or valve. The resistance of the fluid created by the restriction serves to control the release of reactive torque. In other fluid brake systems, the circulated fluid is used only during backspin to operate a disc brake mounted on the shaft (see U.S. Pat. No. 5,358,036 by Mills). Fluid brake systems have the disadvantage that the stored energy dissipated by the brake heats the fluid and, thus, may break down the fluid, damage seals and degenerate the lubricating quality of the fluid, which may damage bearings and gears in the pump or the brake system. Of course, leakage of the fluid may lead to catastrophic failure of the system.
U.S. Pat. No. 4,797,075 by Edwards et al. describes a centrifugal brake system including a plurality of circumferentially distributed and leaf spring mounted brake shoes. The centrifugal force acting on the brake shoes overcomes the resetting force of the leaf spring at excessive rotation speeds. However, the brake is not unidirectional and fatigue in the leaf springs may lead to the brake being at least partially engaged even during forward rotation. Moreover, very cold temperatures may lead to excess stiffness of the leaf springs and consequently excessive speeds of the shaft. Other centrifugal brake systems are disclosed in U.S. No. 4,216,848 of Toyohisa Shiomdaira, and U.S. Pat. No. 4,993,276 of Edwards.
U.S. Pat. No. 6,079,489 by Edwards discloses another type of centrifugal brake mechanism which acts on a brake housing to provide a backspin retarder. The housing serves as a stationary brake member. The mechanism has weighted movable brake members, which are spring biased toward an inner inactive or disabled position, and which, during forward rotation of the drive shaft, are mechanically locked in the inner position. During reverse rotation of the drive shaft, the brake members are unlocked and permitted to move radially outwardly under the influence of the centrifugal force to engage with the brake housing. In addition, cams are provided for urging the movable brake members during reverse rotation into more intimate contact with the brake housing.
U.S. Pat. No. 6,079,489 by Hult et al. and US2008/0296011 disclose further centrifugal brake systems wherein the brake shoes are spring biased towards a disengaged position and moved to an active, braking position by the centrifugal force and movable cams. In this type of centrifugal braking system, the biasing of the movable brake members toward the inner disabled position reduces the maximum braking force achievable and requires the use of the additional cam members. However, the use of additional mechanical parts may increase manufacturing costs and increase the chance of mechanical failure. Also, the use of cams may lead to the brake locking up which is undesirable whenever the stored reactive torque in a shaft is to be completely released. Thus, an improved centrifugal brake system, more particularly a backspin braking system is desired which overcomes at least one of the disadvantages of prior art systems and can preferably be incorporated into the drive head of a progressing cavity pump.
In one embodiment of the invention, a centrifugal brake system for retarding backspin of a shaft is provided, which includes a brake drum for mounting in a stationary supporting structure concentrical with the shaft, a hub attachable to the shaft for co-rotation with the shaft concentrically in the brake housing and two or more brake shoes distributed circumferentially about the hub and mounted on the hub for selective braking engagement with the brake drum. The selective braking engagement is achieved with a pivot pin positioned in each brake shoe and engaging a pin slot provided in the brake hub for each brake shoe. The mechanical interaction between the pivot pin and the pin slot transfers the braking force generated by the braking engagement from the brake shoes to the hub and, thus, the shaft. The pivot pin is movably received in the pin slot for allowing the pivot pin to move in the pin slot between deactivated and activated positions, whereby the pin slot is shaped for maintaining the brake shoe in a radially inward, disengaged position when the pivot pin is in the deactivated position and for permitting the brake shoe to move to a radially outward, engaged position wherein the brake shoe is in braking engagement with the brake drum, when the pivot pin is in the activated position. Movement of the pivot pin in the pin slot is achieved through frictional drag between the brake shoe and the brake drum. For generating that frictional drag, each brake shoe has first and second ends located on opposite sides of the pin slot, the brake shoe is pivotable about the pivot pin and a biasing means is provided for each brake shoe for pivoting the brake shoe about the pivot pin and biasing the first end of the brake shoe against the brake housing to generate friction between the brake shoe and the drum. The resulting frictional drag causes a rotational shift between the hub and the brake shoe whereby the pivot pin moves along the pin slot into the deactivated position upon rotation of the shaft in a forward direction and into the activated position upon rotation of the shaft in a backwards direction. The biasing means is preferably a spring mounted between the hub and the brake shoe. The spring is preferably either a compression spring connected to the brake shoe at the first end, or a tension spring connected to the brake shoe at the second end.
In a preferred embodiment, the brake system further includes a counterbiasing structure for counteracting, at elevated forward rotation speeds of the shaft, the biasing of the first end of the brake shoe and for pivoting the first end away from the brake drum. Preferably, the counterbiasing means is a counterweight attached to the brake shoe. Most preferably, the counterweight is connected to the second end when the spring is a compression spring and to the first end when the spring is a tension spring.
The pin slot is preferably shaped as a curved slot with a radius of curvature concentrical with a wall of the brake drum and at the second end has a radially outward enlargement for receiving the pivot pin. Most preferably, the pin slot maintains the brake shoe at a distance A from the brake drum when the pivot pin is in the first position and the enlargement has a radial depth at least equal to A.
In another preferred embodiment, the brake system further includes a backstop for each brake shoe for limiting the pivoting of the first end away from the brake drum to prevent engagement of the second end with the brake drum when the pivot pin is in the first position. Preferably, the backstop is a tab mounted to the brake shoe for engagement with a shoulder on the hub, most preferably a tab mounted to the first end of the brake shoe for engagement with a shoulder on the hub. Thus, the backstop prevents the shoe from dragging on the counterweighted side of the shoe during fast forward speeds.
The invention also provides a method for retarding backspin of a rotatable shaft in a brake system having a stationary brake drum concentrical with the shaft, a hub mounted on the shaft for co-rotation with the shaft in the brake drum and two or more brake shoes distributed circumferentially evenly about the hub and pivotally mounted on the hub, which method includes the steps of pivoting each brake shoe on the hub for biasing an end of the brake shoe against the brake drum for generating a frictional drag between the brake shoe and the brake drum; and using the frictional drag for shifting the brake shoes relative to the hub between a radially inward, disengaged position wherein the brake shoe is not in braking engagement with the brake housing, and a radially outward, engaged position wherein the brake shoe is in braking engagement with the brake drum.
Preferably, the method includes the further step of creating a counterbalancing force for pivoting the end of the brake shoe away from the brake housing at elevated forward rotation speeds of the shaft. More preferably, the method includes the further step of limiting the pivoting of the first end under the influence of the counterbalancing force away from the brake drum to prevent engagement of the second end with brake drum when the brake shoe is in the disengaged position.
The invention will now be further described by way of exemplary embodiments only and with reference to the attached drawings, wherein
The backspin brake assembly in accordance with the invention is useful for controlling the backspin of elongated drive strings which store reactive torque due to torsional stress, such as the sucker rod strings used to drive submersible down hole pumps. The brake assembly is not limited to that application and may be used in conjunction with any shaft which transmits reactive torque that must be safely and controllably released. For purposes of illustration only, the brake assembly in accordance with the invention is described in conjunction with a mounting suitable for use with a sucker rod string typically used to drive a submersible downhole pump such as a progressive cavity pump.
In operation, the output shaft 109 in the drive head 101 rotates in a forward direction until the prime mover 102 is shut off. Torque applied into the rod string 110 by the prime mover 102 during forward rotation causes the rod string 110 to store elastic energy in the form of torsional energy. Additional energy is stored in the form of potential energy in the produced fluid due to the difference between a fluid height at the wellhead drive 102 and the fluid level in the annulus 119 between the production tubing 115 and the casing 116. As soon as the prime mover 102 is shut off, torque input into the rod string ceases and the stored torsional energy causes the rod string 110 to stop and commence to spin backward. Due to the high amount of torsional energy stored with deep well arrangements, the backspin speed will increase rapidly to excessive speeds if not retarded or inhibited by a braking arrangement. Further, as the fluid level equalizes between the annulus 119 and the inside of the tubing string 115, the fluid drives the pump rotor 111 in reverse and additional energy is imparted into the rod string 110. Generally a backspin brake is built into the wellhead drive 102 to retard the backspin speed and absorb and dissipate the stored energy. The present invention is directed toward a braking system which is suited to retard the backspin of any rotating shaft, but is particularly suited for use in the drive head 101 of a PCP installation as shown in
As shown in
The connection between the brake hub 30 and each brake shoe 28 for transfer of the braking force generated by the selective braking engagement to the brake hub 30 and the output shaft 109 is achieved with a pivot pin 29 extending through the brake shoe 28 and through a pin slot 32 provided in the brake hub 30 (see
As will be apparent from
Shifting of the brake shoes 28 relative to the brake hub 30 is achieved by selectively creating frictional drag between the brake shoes 28 and the brake drum 22 at low speeds, in either forward or backward spin direction. The frictional drag is created as follows. Each brake shoe 28 has first and second ends 28a, 28b, located on opposite sides of the pivot pin 29 and is therefore pivotable about the pivot pin 29.
For each brake shoe 28, a biasing structure, in the illustrated embodiment a tension spring 40 is mounted between the brake hub 30 and the second end 28b of the brake shoe 28 to pivot the brake shoe 28 about the pivot pin 29 and bias the first end 28a of the brake shoe into engagement with the brake drum 22 (see
It is apparent, that the desired frictional drag and shifting of the hub 30 relative to the brake shoes 28 can also be achieved by mounting the pivot pins 29 on the hub 30 and providing the pin slot 32 in the brake shoes.
In a preferred embodiment, the backspin brake further includes a counterbiasing structure for counteracting, at elevated forward rotation speeds of the shaft 109, the biasing of the first end 28a of the brake shoe 28 and causing a pivoting of the first end 28a away from the brake drum 22. When the biasing structure is a spring 40, the counterbiasing structure is preferably a counterweight 42 bolted to the brake shoe 28. Most preferably, the counterweight is bolted to the second end 28b when the spring 40 is a compression spring (not shown) and to the first end 28a when the spring 40 is a tension spring (see
In the preferred embodiment, the pin slot 32 is shaped as a curved slot with a radius of curvature parallel to the wall 24 of the brake drum 22 and at the activated end 32b has a radially outward extending enlargement 35 for receiving the pivot pin 29. Preferably, the pin slot 32 is positioned to maintain the brake shoe 28 at a selected spacing from the brake drum 22 when the pivot pin 29 is in the deactivated position and the enlargement 35 has a radial depth at least equal to the selected spacing.
In another preferred embodiment, the backspin brake system includes a backstop 37 on the brake hub for each brake shoe 28 for limiting the pivoting of the first end 28a away from the brake drum in order to prevent engagement of the second end 28b with brake drum 22 when the pivot pin is in the deactivated position 29a. The backstop 37 can also be provided on the brake shoe 28 for engagement with a circumferential shoulder of the brake hub 30. In the preferred embodiment, the backstop 37 is a separately machined part which is installed on the hub 30, one backstop 37 being provided for each brake shoe 28 and the backstops being circumferentially evenly distributed about the axis of rotation of the hub, for rotational balancing.
The operation of a preferred embodiment of the backspin brake of the invention as illustrated in the drawings will now be discussed in detail with reference to
As the forward spin speed increases (see
Once power to the prime mover 102 is interrupted, the forward spin of the shaft 109 decreases rapidly and the direction of rotation of the shaft 109 eventually reverses. As the forward speed approaches zero, the biasing force of the spring 40 exceeds the centrifugal force acting on the counterweight 42 and the first end 28a of the brake shoes 28 once again engages the brake drum 22 (see
As the backspin speed builds (see
Braking ceases when the backspin speed subsides below the point where the force of the biasing spring 40 exceeds the centrifugal force acting on the associated second end 28b of the brake shoe 28. This ensures that no reactive torque is locked in the drive train, and constitutes an important safety feature of the invention. The re-engagement of the first end 28a of the brake shoes 28 when the backspinning shaft 109 approaches standstill also ensures that upon reenergizing of the prime mover the backspin brake is switched back to the deactivated condition (see
It will be readily understood by those skilled in the art that changes and modifications to the above-described embodiments may be made without departing from the scope of the invention. The scope of the invention is therefore intended to be limited solely by the scope of the appended claims.
The present application claims priority to U.S. Provisional Application Ser. No. 61/718,971, entitled Centrifugal Backspin Brake, filed Oct. 26, 2012, the contents of which are incorporated herein by reference in their entirety.
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