Patent Application
20180187673
The field of the disclosure relates generally to oil and gas downhole pump assemblies and, more specifically, to actuators for use in downhole pump assemblies.
At least some known rod pumps are used in oil and gas wells, for example, to pump fluids from subterranean depths towards the surface. In operation, a pump assembly is placed within a well casing, well fluid enters the casing through perforations, and mechanical lift forces the fluids from the subterranean depths towards the surface. For example, at least some known rod pumps utilize a downhole pump with complicated geometries, which by reciprocating action of a rod string, lifts the well fluid towards the surface.
Oil and gas well pump systems feature reciprocating pumps that go underground to pump fluid from a well. This is traditionally accomplished by way of a motor that operates hydraulic pistons, which utilize reciprocating motion to pump fluid to the surface. A complex system of hydraulic circuits, valves, cables and electronic controls are often required to create the reciprocating motion of the piston. The utilization of switching valves and controls to cause the piston to reciprocate in traditional hydraulic circuits require additional components such as electronics, control systems, and cables connecting to those controls. This is often challenging and costly due to the space required for the components and the harsh conditions encountered beneath the surface, where the required length of the cables can be as long as 10,000 meters (m) (32,808 feet (ft)). The complexities of the systems combined with harsh conditions encountered during operation may result in a decrease of the reliability of the system and its components, which may lead to increased maintenance costs and down time over the service life of the pump system.
In one aspect, an actuator for use with a fluid transfer device is provided. The actuator includes a piston cylinder having a longitudinal axis and defining a piston chamber having both a piston chamber head end and a longitudinally opposite piston chamber base end. The actuator further includes a piston disposed within the piston chamber. The piston movable between a first piston position proximate the piston chamber head end and a second piston position proximate the piston chamber base end. The piston includes a piston head end having a first indexing mechanism, a first piston seal, and at least one first feed hole. The piston further includes a base end longitudinally opposite the head end. The piston base end includes a second indexing mechanism, a guide tooth, a second piston seal, and at least one second feed hole. The piston defines a plurality of channels. The plurality of channels extend from proximate the first piston seal to proximate the second piston seal.
In another aspect, a fluid transfer system is provided. The fluid transfer system includes, a motor, a fluid transfer device coupled to the motor, and an actuator. The actuator includes a piston cylinder having a longitudinal axis and defining a piston chamber having both a piston chamber head end and a piston chamber base end. The piston chamber base end is longitudinally opposite the piston chamber head end. The actuator further includes a piston disposed within the piston chamber. The piston is movable between a first piston position proximate the piston chamber head end and a second piston position proximate the piston chamber base end. The piston includes a piston head end having both a first indexing mechanism and a first piston seal. The piston head end having at least one first feed hole. The piston further includes a piston base end longitudinally opposite the piston head end. The piston base end includes a second indexing mechanism, a guide tooth, and a second piston seal. The piston base end having at least one second feed hole. The piston defines a plurality of channels. The plurality of channels extend from proximate the first piston seal to proximate the second piston seal.
In yet another aspect, a resource recovery system is provided. The resource recovery system includes, a wellhead, a production location coupled to the wellhead and configured to receive resources from the wellhead, and a fluid transfer system. The fluid transfer system includes a motor, a fluid transfer device coupled to the motor, and an actuator. The actuator includes a piston cylinder having a longitudinal axis and defining a piston chamber having both a piston chamber head end and a piston chamber base end. The piston chamber base end is longitudinally opposite the piston chamber head end. The actuator further includes a piston disposed within the piston chamber. The piston movable between a first piston position proximate the piston chamber head end and a second piston position proximate the piston chamber base end. The piston includes a piston head end having a first indexing mechanism and a first piston seal. The piston head end having at least one first feed hole. The piston further includes a piston base end longitudinally opposite the piston head end. The piston base end includes a second indexing mechanism, a guide tooth, and a second piston seal. The piston base end having at least one second feed hole. The piston defines a plurality of channels. The plurality of channels extend from proximate the first piston seal to proximate the second piston seal.
These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
Unless otherwise indicated, the drawings provided herein are meant to illustrate features of embodiments of the disclosure. These features are believed to be applicable in a wide variety of systems comprising one or more embodiments of the disclosure. As such, the drawings are not meant to include all conventional features known by those of ordinary skill in the art to be required for the practice of the embodiments disclosed herein.
In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings.
The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.
“Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not.
Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about”, “approximately”, and “substantially”, are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and/or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.
Embodiments of self-reciprocating linear hydraulic actuators described below facilitate increased reliability, reduced complexity, and reduced cost of a pump system for oil and gas applications. Specifically, the self-reciprocating linear hydraulic actuator eliminates the need for switching valves. More specifically, the self-reciprocating linear actuator reciprocates without the need for an external valve by utilizing a combination of feed holes, indexing mechanisms, a guided tooth, and channels along the length of the piston. The elimination of valves subsequently reduces the need for the electronic controls required to operate those valves. A reduction in the components required to reciprocate the piston results in an overall reduction in the cost of the pump system in addition to a decrease in the cost of the system due to a reduction in its complexity.
In the exemplary embodiment, longitudinal axis 218 of piston cylinder 200 extends through piston cylinder 200 in the direction of travel of piston 208. In the exemplary embodiment, a transverse axis 220 extends in a plane substantially parallel to piston chamber base end 206 and normal to longitudinal axis 218. A vertical axis 222 extends in a direction that is normal to longitudinal axis 218 and normal to transverse axis 220. Longitudinal axis 218, transverse axis 220, and vertical axis 222 are orthogonal to each other. A longitudinal centerline 224 extends axially through actuator 126, and is positioned to define the radial center of actuator 126. Longitudinal centerline 224 is substantially parallel to longitudinal axis 218, and common to actuator 126, piston rod 132, piston cylinder 200, piston chamber 202, and piston 208. Thus, longitudinal centerline 224 is positioned to also define the radial center of piston rod 132, piston cylinder 200, piston chamber 202, and piston 208.
In the exemplary embodiment, piston 208 includes a piston head end 226, and a longitudinally opposite piston base end 228. In the exemplary embodiment, piston rod 132 is coupled to piston 208 proximate piston base end 228 and extends axially along longitudinal centerline 224 from proximate piston base end 208 through piston chamber base end 206 to facilitate coupling piston 208 of actuator 126 to pump 122 (shown in
In the exemplary embodiment, piston head end 226 includes a first indexing mechanism 230, a first piston seal 231, and two first feed holes 232 (shown in
In the exemplary embodiment, piston 208 defines a plurality of channels 246. In the exemplary embodiment, channels 246 include a first channel 247 adjacent to a second channel 248, and a third channel 249, adjacent to second channel 248 extends axially along longitudinal centerline 224 from proximate first piston seal 231 to proximate second piston seal 240. Channels 247, 248, and 249 are spaced radially apart with respect to centerline 224, and are substantially parallel to centerline 224. In the exemplary embodiment, channels 247, 248, and 249, define therein a first opening 250, second opening 251, and third opening 252 respectively. First and third openings 250 and 252 are proximate piston base end 228, and second opening 251 is proximate piston head end 226. In the exemplary embodiment, channels 247, 248, and 249 are in fluid communication with piston chamber 202 through openings 250, 251, and 252 respectively. In some alternative embodiments, openings 250, 251, and 252 may be proximate ends 226, 228, and 226, respectively.
In the exemplary embodiment, Line 5-5 intersects actuator 126 at a point on longitudinal axis 218 defined between first piston position 210 and piston chamber head end 204. Line 6-6 intersects actuator 126 at a point on longitudinal axis 218 defined between first piston position 210 and second piston position 212. Line 7-7 intersects actuator 126 at a point on longitudinal axis 218 defined between second position 212 and piston chamber base end 206.
In the exemplary embodiment, piston 208 defines a plurality of channels 246. Channels 246 include a first channel 247 adjacent to a second channel 248, and a third channel 249, adjacent to second channel 248. Channels 246, 247, and 248, extend axially along longitudinal centerline 224 from proximate first piston seal 231 to proximate second piston seal 240 (shown in
In the exemplary embodiment, second channel 248 is in fluid communication with piston chamber 202 (shown in
In some alternative embodiments, piston head end 226 may include greater or fewer quantities of first feed holes 232. Additionally, in some embodiments, more than one feed hole 232 may define a flow angle 234. In some alternative embodiments, piston head end 208 may be configured such that, fluid flows into or out of a different channel 247, 248, or 249. Additionally, in some alternative embodiments, indexing mechanism 230 is configured to interact with piston chamber head end 204 (shown in
In the exemplary embodiment, piston 208 defines a plurality of channels 246. Channels 246 include a first channel 247 adjacent to a second channel 248, and a third channel 249, adjacent to second channel 248. Channels 247, 248, and 249, extend axially along longitudinal centerline 224 from proximate first piston seal 231 (shown in
In the exemplary embodiment, first channel 247 and third channel 249 are in fluid communication with piston chamber 202 (shown in
In some alternative embodiments, piston base end 210 may include greater or fewer quantities of second feed holes 242. Additionally, in some embodiments, more than one feed hole 242 may define a flow angle 244. In some alternative embodiments, piston base end 210 may be configured such that, fluid flows into or out of a different channel 247, 248, or 249. Additionally, in some alternative embodiments, indexing mechanism 236 is configured to interact with piston chamber base end 206 (shown in
Referring to
In the exemplary embodiment, Piston 208 includes a guide tooth 238 and defines a plurality of channels 246. Channels 246 include channels 247, 248, and 249, extending axially along longitudinal centerline 224 from proximate first piston seal 231 (shown in
In the exemplary embodiment, piston chamber 202 defines a plurality of guide slots 600. Guide slots 600 extend both radially outward from proximate piston 208 into piston chamber 202, and longitudinally from proximate first piston position 210 (shown in
In operation, motor 120 is coupled to and activates pump 122. Pump 122 is coupled to actuator 126 by piston rod 132. Pump inlet 128 is in fluid communication with actuator 126, and pump outlet 130 is fluid communication with accumulator 124 and actuator 126. In operation, oil flows from pump outlet 130 and mixes with oil from accumulator 124 before flowing into actuator 126.
In operation, piston cylinder 200 becomes pressurized by a mixture of oil from pump outlet 130 and accumulator 124. Initially, piston 208 is in second piston position 212, such that piston base end 228 is proximate piston chamber base end 206. Second channel 248 is initially aligned with pump outlet 130, and third channel 248 is initially aligned with pump outlet 130, such that, oil flows into flows into opening 251 of second channel 248, proximate piston head end 226.
Also, in operation, as oil enters second channel 248 it flows toward piston base end 228. As oil reaches piston base end 228, it flows through second feed hole 242 at a flow angle 244, into piston chamber base end 206. The flow of oil into piston chamber base end 206 facilitates moving piston 208 in the direction of piston chamber head end 204, while filling piston chamber base end 206 with oil. As piston 208 moves toward head end 204, guide tooth 249 rides within a guide slot 600 to substantially inhibit piston 208 from rotating due to the inertia induced by oil flowing from second feed hole 242 at flow angle 244. Additionally, in operation, piston seals 231 and 240, facilitate a reduction in oil flowing past piston ends 226 and 228, into piston chamber ends 204 and 206, respectively
Also, in operation, once piston 208 has reached the end of its stroke length 214, guide slots 600 merge into a free slot 700, and first indexing mechanism 230 adjacent piston head end 208 interacts with piston chamber head end 204. The interaction of first indexing mechanism 230 in combination with the torque induced by flow angle 244, and the increased range of movement provided by free slot 700 facilitates rotating piston 208 within a range between and including approximately 5 degrees and approximately 30 degrees. As piston 208 rotates, second channel 248 becomes aligned with pump inlet 128, and first channel 247 becomes aligned with pump outlet 130.
Simultaneously, in operation, piston chamber base end 206 has become the low pressure side of piston chamber 202 and oil begins to flow from out of second channel 248, through second feed hole 242, into pump inlet 128. Simultaneously, in operation, oil from pump outlet 130 flows into opening 250 of first channel 247. Oil then flows through first channel 247 toward piston head end 208. Oil then flows from first channel 247 through first feed hole 232 into piston chamber head end 204 at flow angle 234.
Additionally, in operation, the flow of oil out of piston chamber base end 206 in combination with the flow of oil into piston chamber head end 204 facilitates moving piston 208 in the direction of piston chamber base end 206, while filling piston chamber head end 204 with oil. As piston 208 moves toward piston chamber base end 206 guide tooth 249 rides within a guide slot 600 to substantially inhibit piston 208 from rotating due to the torque induced by oil flowing from first feed hole 247 at flow angle 234. Also, in operation, once piston 208 has reached the end of its stroke length 214, guide slots 600 merge into a free slot 700, and second indexing mechanism 236 interacts with piston chamber base end 206.
In operation, the interaction of indexing mechanism 236 and piston chamber base end 206, in combination with the torque induced by flow angle 234, and the increased range of movement provided by free slot 700 facilitates rotating piston 208 within a range between and including approximately 5 degrees and approximately 30 degrees. As piston 208 rotates, second channel 248 becomes realigned with pump outlet 130, and third channel 249 becomes aligned with pump inlet 128.
Also in operation, subsequently, piston chamber head end 204 has become the low pressure side of piston chamber 202 and oil begins to flow from out of piston chamber head end 204, into third channel 249 through a corresponding feedhole 232. Oil then flows from opening 252 of third channel 249 into pump inlet 128. As this occurs, oil flows into opening 251 of second channel 248 and flows through second channel 248 toward piston base end 228. Oil then flows through second feed hole 242 into piston chamber base end 206.
Additionally, in operation, the flow of oil out of piston chamber head end 204 in combination with the flow of oil into piston chamber base end 206 facilitates moving piston 208 in the direction of piston chamber head end 204, while filling piston chamber base end 206 with oil. The continuous exchange of oil between piston chamber head end 204 and piston chamber base end 206, results in a reciprocating motion of piston 208. In operation, piston rod 132 is coupled to both pump 122 and piston 208, and facilitates driving pump 122 through the reciprocating motion of piston 208. Once pump 122 is activated, and piston 208 begins to reciprocate, the continuous movement of piston 208 in combination with the flow of oil between pump 122 and actuator 126 allows actuator 126 to reciprocate and drive pump 122 without the need for external valves.
In a method of operation similar to the description above, as piston 810 moves toward a position proximate piston chamber ends 804 and 806, deceleration features 808 interrupt oil flow, facilitating a deceleration of piston 810. As piston 810 moves toward a position proximate piston chamber head end 804, indexing mechanism 814 on piston chamber head end 804 interacts with indexing mechanism 822 on piston head end 818 to facilitate simultaneously rotating both piston chamber 802 and piston 810 a range between and including approximately 5 degrees and approximately 30 degrees relative to each other. The simultaneous motion of piston chamber 802 and piston 810 concurrently closes pump inlet 828 and opens accumulator outlet 830 proximate piston chamber head end 804, while concurrently opening pump inlet 828 and closing accumulator outlet 830 proximate piston chamber base end 806. This causes oil to flow into piston chamber head end 804 and out of piston chamber base end 806.
Additionally, in operation, the flow of oil into piston chamber head end 804 in combination with the flow of oil out of piston chamber base end 806 facilitates moving piston 810 in the direction of piston chamber base end 806. As piston 810 moves toward a position proximate piston chamber base end 806, indexing mechanism 816 on piston chamber base end 806 interacts with indexing mechanism 824 on piston base end 820 to facilitate simultaneously rotating both piston chamber 802 and piston 810 a range between and including approximately 5 degrees and approximately 30 degrees relative to each other. The simultaneous motion of piston chamber 802 and piston 810 concurrently opens pump inlet 828 and closes accumulator outlet 830 proximate piston chamber head end 804, while concurrently closing pump inlet 828 and opening accumulator outlet 830 proximate piston chamber base end 806. This causes oil to flow out of piston chamber head end 804 and into piston chamber base end 806. The flow of oil out of piston chamber head end 804 in combination with the flow of oil into piston chamber base end 806 facilitates moving piston 810 in the opposite direction.
Embodiments of a self-reciprocating linear hydraulic actuator as described herein facilitate increased reliability, reduced complexity, and reduced cost of a pump system for oil and gas applications. Specifically, the self-reciprocating linear hydraulic actuator eliminates the need for switching valves. More specifically, the self-reciprocating linear actuator reciprocates without the need for an external valve by utilizing a combination of feed holes, indexing mechanisms, a guided tooth, and channels along the length of the piston. The elimination of valves subsequently reduces the need for the electronic controls required to run those valves. A reduction in the components required to reciprocate the piston results in an overall reduction in the cost of the pump system in addition to a decrease in the cost of the system due to a reduction in its complexity. Additionally, reductions in the use of electronic controls and the complexity of the valve schemes result in a substantially mechanical linear pump.
An exemplary technical effect of the methods and systems described herein includes at least one of: (a) eliminating the need for valves; (b) eliminating the need for electronic controls for switching valves; (c) reducing cost requirements; (d) reducing space requirements; (e) facilitating pump operation at a constant flow rate; (f) improving the reliability of the pump system; and (g) reducing complexity of the pump system.
Exemplary embodiments of methods, systems, and apparatus for a self-reciprocating hydraulic linear actuator are described above in detail. The apparatus, systems, and methods are not limited to the specific embodiments described herein, but rather, operations of the methods and components of the systems may be utilized independently and separately from other operations or components described herein. For example, the systems, methods, and apparatus described herein may have other industrial or consumer applications and are not limited to practice with components as described herein. Rather, one or more embodiments may be implemented and utilized in connection with other industries.
Although specific features of various embodiments of the technology may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the invention, any feature of a drawing may be referenced or claimed in combination with any feature of any other drawing.
This written description uses examples to disclose the embodiments of the present disclosure, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the embodiments described herein is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
