The present disclosure relates to a plunger catcher mechanism that receive, holds and releases a plunger used in oil and gas wells. More specifically, the present disclosure relates to a choke mechanism that can be used to ensure that when a plunger arrives at a wellhead, the plunger is fully seated in the catcher mechanism.
The accompanying drawings are part of the present disclosure and are incorporated into the specification. The drawings illustrate examples of embodiments of the disclosure and, in conjunction with the description and claims, serve to explain various principles, features, or aspects of the disclosure. Certain embodiments of the disclosure are described more fully below with reference to the accompanying drawings. However, various aspects of the disclosure may be implemented in many different forms and should not be construed as being limited to the implementations set forth herein.
The present disclosure is concerned with plunger catcher mechanism that is configured to hold and release a plunger used in oil and gas wells. As is well known to those of skill in the art, a manifold can be mounted on top of an oil or gas well, and a plunger catcher mechanism is then mounted on top of the manifold. Oil or gas produced by the well is routed through the manifold to a production line that typically leads to a collection tank.
When the downhole pressure of an oil or gas well is no longer high enough to force oil to gas to the surface at a satisfactory flow rate, one can employ a plunger to help bring oil or gas to the surface. A plunger is a device that is configured to freely descend and ascend within a well bore. The plunger operates to restore production to a well having insufficient pressure to lift the fluids to the surface. Some embodiments are configured as a “bypass” plunger, which may include a self-contained valve—also called a “dart” or a “dart valve”—to control the descent and ascent. Typically the valve is opened to permit fluids in the well to flow through the valve and passages in the plunger body as the plunger descends through the well. Upon reaching the bottom of the well, the valve is closed, converting the plunger into a piston by blocking the passages that allow fluids to flow through the plunger. With the plunger converted to a piston, blocking the upward flow of fluids or gas, pressure in the fluid below the bypass plunger gradually increases until the pressure is sufficient to lift the plunger and the column of fluid in the well bore located above the bypass plunger to the surface. As fluid above the bypass plunger arrives at the surface, the fluid is routed by the manifold to a production line. While the above description applies to bypass plungers, other types of plungers can also be used to help restore production to an oil or gas well.
When a plunger arrives at the surface, it passes through the manifold and into a plunger catcher mounted on top of the manifold.
As illustrated in
As illustrated in
As illustrated in
Fluid exiting the well bore is deliberately provided with this return circuit so that as a plunger leaves the well bore, passes through the manifold 110 and then travels up into the hollow receiving bore 153 of the plunger catcher 150, the fluid located above the plunger will be able to travel through the return circuit and into the production outlet line 130. If the return circuit were not provided, there would be nowhere for the fluid above the plunger to go, which would mean the plunger would be prevented from entering the hollow receiving bore 153 of the plunger catcher 150. In addition, by ensuring that there is a steady flow of fluid through this return circuit, the momentum of the fluid combined with the upward momentum of the plunger itself ensures that the plunger travels all the way up into the plunger catcher 150.
A holder mechanism 151 of the plunger catcher 150 is used to hold and release a plunger that travels up into the plunger catcher 150. A handle 156 of the holder mechanism 151 could be used to manually operate or adjust the plunger holder 151.
As illustrated in
As the upper end 194 of the plunger 192 arrives at the top of its travel, the upper end 194 of the plunger 192 hits the shoulder 175 of the reset rod 174. The shoulder 175 of the reset rod 174 bears against the lower end of the arrival bumper spring 172. The arrival bumper spring 172 operates to help arrest upward movement of the plunger 192 in a controlled matter, limiting any potential damage to the plunger 192 or the plunger catcher 150 due to the impact of the plunger 192 when it arrives and stops inside the plunger catcher 150.
In a well that has little pressure, which is the type of well where plungers are employed, the upward flow of the fluid may not be sufficient to cause the plunger 192 to move upward enough to fully seat in the plunger catcher 150. This can result in a stuck condition, where the plunger 192 blocks the flow of fluid out of the production passageway 118 of the manifold. Also, because the plunger 192 does not travel sufficiently far enough upward into the plunger catcher 150, the reset rod 174 cannot operate to push the valve dart 198 into the reset position. As a result, the passageways through the interior of the plunger 192 are not opened and the plunger 192 cannot travel back down to the bottom of the well bore.
The present application discloses a choke mechanism that is mounted on the manifold 110 and which operates to increase the flow rate of fluid through the return circuit that travels through the hollow receiving bore 153 and return line 160 of the plunger catcher 150. The increased the flow rate of fluid through this return circuit helps to preserve the upward momentum of the plunger 192 when it arrives at the top of the well bore, thereby helping the plunger 192 to move fully upward into the plunger catcher 150.
In a first embodiment as illustrated in
When the distal end 149 of the choke member 147 protrudes into the production passageway 118, partially blocking the production passageway 118, more of the fluid exiting the well bore is routed through the return circuit that passes through the plunger catcher 150. As perhaps best seen in
If the flow rate of fluid leaving the well bore is not sufficient to cause a plunger to fully seat in the plunger catcher 150, one can advance the distal end 149 of the choke member 147 into the production passageway 118, thereby partially blocking the production passageway 118. This serves to increase the flow rate of fluid through the return circuit, which helps to ensure that the plunger will travel fully up into the plunger catcher 150. If pressure in the well increases such that the normal flow rate of fluid leaving the well bore is sufficient to cause the plunger to fully seat in the plunger catcher 150, the choke member 147 can be fully withdrawn from the production passageway 118, which helps to maximize flow out of the well into a collection tank.
The manifold 110 and/or the plunger catcher 150 may include one or more sensors that are used to determine the location and movements of a plunger. For example, an arrival sensor 202 may be mounted on the manifold 110. The arrival sensor 202 would output an arrival signal when a plunger emerges from the well bore and passes into the plunger passageway 116 of the manifold 110. Likewise, an arrival sensor 204 may be provided on the plunger catcher 150. The arrival sensor 204 on the plunger catcher 150 outputs an arrival signal when a plunger is located partway in the hollow receiving bore 153. Further, a seated sensor 206 could be located near the upper end of the hollow receiving bore 153 of the plunger catcher. The seated sensor 206 outputs a seated signal when a plunger is fully seated in the plunger catcher 150.
A controller coupled to the arrival sensors 202, 204 and the seated sensor 206 could determine whether a plunger is not fully seating in the plunger catcher 150 upon arriving at the surface. For example, if the controller notes that the seated sensor 206 did not output a seated signal shortly after one or both of the arrival sensors 202, 204 output an arrival signal, this would likely mean that the flow rate of fluid out of the well head and through the return circuit passing through the plunger catcher 150 was not sufficient to carry the plunger up into a fully seated position within the plunger catcher 150. This would be an indicate that the choke mechanism should be reset to advance the distal end 149 of the choke member 147 further into the production passageway 118 of the manifold 110 to increase the flow rate of fluid through the return circuit passing through the plunger catcher 150.
A proximal end 434 of the choke member 430 is covered by a cam follower 440. A return spring 414 urges the choke member 430 into a retracted position, and also serves to keep the cam follower 440 pressed against a rotatably mounted cam 450. The cam 450 is located in a cam housing 410 and the cam 450 is mounted onto a rotating shaft 412 of an electric motor of the electrically operated actuator 400. When the motor rotates the cam 450, the surface of the cam 450 pushes the cam follower 440 and the choke member 430 further into the manifold 110 so that the distal end 432 of the choke member 430 protrudes into the production passageway 118 of the manifold 110. Thus, selectively operating the motor of the electrically operated actuator 400 allows one to control the extent to which the distal end 432 of the choke member 430 blocks the production passageway, and thus the flow rate of fluid through the return circuit passing through the plunger catcher 150.
In some embodiments, a controller coupled to an arrival sensor 202/204 and a seated sensor 206 could be used to automatically adjust the position of the choke member. If the controller does not receive a seated signal from the seated sensor 206 immediately after receiving an arrival signal from an arrival sensor 202, 204, this would indicate that the flow rate of fluid through the return circuit passing through the plunger catcher 150 was not sufficient to cause the plunger to fully seat in the plunger catcher 150. Under those conditions, the controller could send a signal to an actuator of a choke mechanism to cause a distal end of a choke member to protrude further into the production passageway 118 of the manifold 110. This would serve to increase the flow rate of fluid through the return passageway, thereby aiding the plunger in fully seating in the plunger catcher 150.
Conditional language, such as, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain implementations could, but do not necessarily, include certain features and/or elements while other implementations may not. Thus, such conditional language generally is not intended to imply that features and/or elements are in any way required for one or more implementations or that one or more implementations necessarily include these features and/or elements. It is also intended that, unless expressly stated, the features and/or elements presented in certain implementations may be used in combination with other features and/or elements disclosed herein.
The specification and annexed drawings disclose example embodiments of the present disclosure. Detail features shown in the drawings may be enlarged herein to more clearly depict the feature. Thus, several of the drawings are not precisely to scale. Additionally, the examples illustrate various features of the disclosure, but those of ordinary skill in the art will recognize that many further combinations and permutations of the disclosed features are possible. Accordingly, various modifications may be made to the disclosure without departing from the scope or spirit thereof. Further, other embodiments may be apparent from the specification and annexed drawings, and practice of disclosed embodiments as presented herein. Examples disclosed in the specification and the annexed drawings should be considered, in all respects, as illustrative and not limiting. Although specific terms are employed herein, they are used in a generic and descriptive sense only, and not intended to the limit the present disclosure.
This application is a continuation of U.S. patent application Ser. No. 18/128,784, filed Mar. 30, 2023, the content of which is incorporated herein by reference.
Number | Date | Country | |
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Parent | 18128784 | Mar 2023 | US |
Child | 18775704 | US |