This patent generally pertains to oil wells with sucker rods and tubing and more specifically pertains to means for disintegrating sludge and flushing the resulting grit up out of the well while mitigating corrosion and wear of tubing and rod strings.
Oil wells are vital components of the petroleum industry, allowing for the extraction of crude oil from deep beneath the Earth's surface. The process involves a combination of sophisticated machinery and engineering techniques. One of the most common methods used in onshore oil production involves the use of a pumpjack, which operates on the principle of reciprocating motion.
The pumpjack is a large mechanical device situated above the wellhead. It consists of a beam supported by an A-frame structure, with a counterweight on one end and a pump assembly on the other. The pumpjack is powered by a motor or an engine, which drives the beam up and down in a continuous pumping motion. This movement creates the necessary force to bring the oil to the surface.
At the bottom of the well, there is a submerged downhole pump, also known as a sucker rod pump or a nodding donkey pump. This pump is a positive displacement device that utilizes a piston-like mechanism to lift the oil.
The pump is connected to the pumpjack by a rod string, which is a series of long, slender rods (sucker rods) interconnected by internally threaded rod couplings (rod boxes). The motion of the pumpjack is transmitted through rod string to the downhole pump, causing it to move up and down within the wellbore.
To ensure the efficiency and safety of the oil well, tubing and casing are essential components. Casing is a series of steel pipes that are cemented into the wellbore after the hole is drilled to provide structural integrity, prevent the collapse of the surrounding rock formation, and isolate the various strata of formations. After the casing is set, selective zones are opened with various completion techniques to allow specific formations to flow to into casing.
Inside the casing, there is a tubing string, which is a series of smaller diameter pipes interconnected by internally threaded couplings. The tubing string runs from the surface down to the production zone. The tubing provides a conduit for oil and gas to flow to the surface. Once the formation ceases to flow to the surface, a downhole pump is run inside the tubing to artificially lift the fluids from the formation through the tubing to the surface.
As the pumpjack operates, the reciprocating motion of the beam causes the sucker rods to push and pull the downhole pump. During the downstroke, the pump cavity between two valves reaches extreme pressures and forces the fluid into the tubing above the pump. On the upstroke, one of the valves closes and the pump pushes the fluids upward through the tubing, eventually reaching the surface. During the upstroke, formation pressure refills the cavity of the pump for the process to be repeated. The reciprocating motion of the pump can be repeated thousands of times per day.
The relative motion between the rods and the tubing creates a multitude of contact points between the rods string and the tubing. The forces and stresses at each of these points of contact vary based on the configuration of the pumping system, the operating practices, the degree of inclination at any point in the well from the original drilling operations, and the solids that are entrained in the produced fluids. The current industry practice typically uses combinations of steel in the rods, the rod couplings, and the tubing where at least one of the components is softer than the grit in the production. The current industry practices do not provide an alternative method to instantaneously protect the steel surfaces from corroding when the corrosion inhibitor is scraped off the steel surfaces.
Upon reaching the surface, the oil is collected in a storage tank, while the associated natural gas is separated and often sent for further processing. Advanced sensors and control systems are employed to monitor the well's performance, ensuring optimal oil production rates and identifying any potential issues that may require attention.
In the examples illustrated in
The tubing string 24 extends down through the casing 18 and supports the pump 22 near the bottom of the well 14. The tubing string 24 provides a conduit for conveying the production fluid 16 up through the well 14. Some examples of the tubing string 24 comprise a plurality of tubing sections 30 interconnected by a plurality of threaded tube couplings 25. In some examples, the plurality of tubing sections 30 includes one or more main tubing sections 30a and/or one or more hardened tubing sections 30b. The hardened tubing sections 30b have a greater surface hardness than the more conventional main tubing sections 30a.
The rod string 26 connects the pumpjack 20 to the downhole pump 22. The pumpjack 20 actuates the pump 22 by moving the rod string 26 cyclically up and down within the generally stationary tubing string 24. The pump 20 draws the production fluid 16 from underground and forces the fluid 16 up through the tubing string 24 to the surface. The motion of the rod string 26 creates a complex pattern of wear and friction between the tubing string and the rod string.
With further reference to
Since the production fluid 16 comes from the ground, the fluid 16 is often contaminated with grit 34, as shown in
The milling rod guide system 12, which includes the milling rod guide 10, helps disintegrate the sludge and reduce the grit particle size. The flow of production fluid 16 can carry the fine lighter grit 34 away from the downhole pump 22 and up through the tubing string 24 to where the production fluid 16 with entrained grit 34 eventually exits the well 14. The milling rod guide 10 can be installed near the downhole pump 22 and/or wherever grit 34 might tend to accumulate or create problems. In some examples, one or more milling rod guides 10 are installed partway up the well 14 or at an intermediate location along the length of a horizontal or otherwise deviated well 14 (
Referring to
In some examples, the first and second milling heads 44a and 44b have internal threads 50 for screwing onto the rod's first and second rod ends 36a and 36b, respectively. The first and second milling heads 44a and 44b respectively have a first head outer diameter 52 and a second head outer diameter 54.
In some examples, each of the first and second head outer diameters 52 and 54 have a surface hardness of at least 60 Rc (Rockwell Scale-C) for crushing and grinding common examples of grit 34. In some examples, the milling heads 44a and 44b have a surface hardness exceeding 69 Rc for crushing and grinding particularly hard examples of grit 34, such as sand and iron sulfide.
Some example means for hardening the surface of the milling heads 44a and 44b include boriding (boronizing), coating with DLC (diamond-like carbon), sprayed metal coating (e.g., Class-SM spray metal), and various combinations thereof. In some examples, each of the milling heads 44a and 44b are a Class-SM coupling with an overcoat of DLC. In some examples, providing milling heads 44a and 44b with a surface hardness exceeding 69 Rc is achieved by known boriding methods of treating steel.
In some examples, milling heads 44a and 44b provide a dual purpose of serving as means for milling grit 34 and means for coupling a milling rod guide 10 to a sucker rod 26′ or another milling rod guide 10. In some examples a first milling head 44a is shared by two adjoining milling rod guides 10. Running more milling rod guides 10 creates more milling points of contact with the tubing 24.
The sacrificial anode 46, in some examples, is a generally cylindrical mass with an anode outermost diameter 56. In some examples, the anode outermost diameter 56 is substantially equal to the first and second head outer diameters 52 and 54, which provides a maximum amount sacrificial anode material without obstructing the flow of production fluid 16 past the milling rod guide 10. The term, “substantially equal,” means that the anode outermost diameter 56 is within twenty percent of the first and second head outer diameters 52 and 54. So, for example, if the first and second head outer diameters 52 and 54 are 1.0 inch, then the anode outermost diameter 56 is 0.8 to 1.2 inches. In some examples, the first and second head outer diameters 52 and 54 are 1.7 inches, and the anode outermost diameter 56 is 1.36 to 2.04 inches.
In some examples, the sacrificial anode 46 defines a plurality of grooves 58 running lengthwise between a first end 46a and a second end 46b of the sacrificial anode 46. The plurality of grooves 58 have a radial depth 60 that defines an anode minor diameter 62 that is greater than a throat outer diameter 64 of a throat area 66 extending axially between the sacrificial anode 46 and shoulders 40 and 42. The grooves 58 of such length and depth provide a pathway for production fluid 16 to flow past the milling rod guide 10. In some examples, the grooves 58 curve (e.g., helical) about the longitudinal axis 38. The grooves 58 being curved, rather than straight, create a pathway for grit 34 around the circumference of the anode 46 to help prevent the sacrificial anode 46 from wearing a groove or slot into the sidewall of the tubing 30.
The sacrificial anode 46 is sized and positioned to create one throat area 66 between the first shoulder 40 and the sacrificial anode 46 and another throat area 66 between the second shoulder 42 and the sacrificial anode 46. In some examples, each throat area 66 has a throat outer diameter 64 that is less than the anode outermost diameter 56. The throat areas 66 provide clearance for a known elevator tool to grab the rod 36 during installation or removal of a tubing string 24.
In some examples, the milling rod guide 10 is relatively short with a slenderness ratio of less than 40, wherein the slenderness ratio is defined as the rod's overall length 48 divided by the anode outermost diameter 56. The term, “relatively short,” means that the milling rod guide 10 is shorter than most of the sucker rods 26′ in the same rod string 26. With milling rod guide 10 being relatively short with a slenderness ratio of less than 40, it is less likely that the rod's central section 36c will adversely scrape against any tubing sections 30. Further, the milling heads 44a and 44b can more easily protect the anode 46 of the milling rod guide 10 from excessive flexure.
In some examples, the sacrificial anode 46 is softer than the surface hardness of the milling heads 44a and 44b. Until the anode 46 section wears down to the diameter of the milling heads 40a and 40b, the anode 46 acts as a rod guide with passive galvanic protection. Grinding and milling action is minimal during this phase of the usage. When the anode diameter reaches the diameter of the milling heads 40a and 40b, grinding and crushing of the grit 34 begins at the milling heads 40a and 40b. The remaining anode material no longer interferes with milling operations while the maximum contact area of the anode 46 with the tubing 30 is achieved. The sacrificial anode 46 is attached in intimate contact with the rod's central section 36c to help protect the rod 36 and the nearby surrounding tubing string 24 from galvanic corrosion.
The term, “sacrificial anode” refers to any metal material that is less noble than iron. Some example materials of the sacrificial anode 46 include aluminum, magnesium, zinc, and various alloys thereof. Although some examples of the sacrificial anode 46 are made of pure aluminum, oxides tend to build up on pure aluminum, and oxides can inhibit cathodic protection. To minimize oxidation, some examples of sacrificial anode 46 are comprised of an aluminum alloy, wherein only most of the alloy consists of aluminum by weight. Some example aluminum alloys have a portion of indium, wherein the indium makes up 0.014 to 0.200 percent by weight of the aluminum alloy. Some example aluminum alloys have a portion of gallium, wherein the gallium makes up 0.092 to 0.110 percent by weight of the aluminum alloy. Such proportions have been found to be effective and fall within a US military specification known as MIL-DTL-24779.
As shown in
In some examples, the milling rod guide 10 scrapes corrosion inhibitor film 70 off the inner surface 68 of the tubing 30. When this happens, the flow of production fluid 16 carries away the scraped-off physical barrier film (film 70′), leaving exposed metal (bare sections 72) to be attacked and corroded by the fluids 16. Until additional inhibitor is applied, the sacrificial anode 46 provides an alternative method of protection for the exposed metal. The metal loss from the galvanic cell comes from the anode material rather than the exposed steel. The term, “corrosion inhibitor film” refers to any material coating that acts as a physical barrier between metal surfaces. Galvanic protection refers to an electrolytic protection between exposed metal surfaces that preferentially allows metal ions to be lost from sacrificial material rather than from the metal being protected. In some examples, the corrosion inhibitor film 70 is a solid. In some examples, the corrosion inhibitor film 70 is a non-solid. In some examples, the scraped-off film 70′ is in the form of flakes or specks. In some examples, the scraped-off film 70′ is in the form non-solid substance. Various corrosion inhibitors are well known to those of ordinary skill in the art.
In some examples, the inner surface of the conventional tubing (main tubing section 30a) or hardened tubing section 30b is harder than the sacrificial anode 46. The sacrificial anode surface will wear until the diameter of the anode is the diameter of the hardened milling heads 44a and 44b of the milling rod guide 10. In some examples, the inner surface 68 of the tubing section 30b is harder than rod 36, as it is important that the rod 36 be rugged and not brittle.
In some examples, the hardened inner surface 68 is more noble than the rod 36, and the rod 36 is more noble than the sacrificial anode 46. This allows the sacrificial anode 46 to cathodically protect both the rod 36 and the tubing 24.
In the example shown in
Still referring to
The well configuration shown in
In examples where the tubing string 24 includes both hardened tubing sections 30b and more conventional main tubing sections 30a, the hardened tubing sections 30b are arranged such that the plurality of milling rod guides 10 (e.g., series of milling rod guides 10) are adjacent to the plurality of hardened tubing sections 30b, and the plurality of sucker rods 26′ are adjacent to the plurality of main tubing sections 30a. In the examples shown in
A box 86 in
A box 101 in
Although certain example methods, apparatus and articles of manufacture have been disclosed herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus and articles of manufacture fairly falling within the scope of the claims of this patent.
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