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Aspects of the disclosure relate to long stroke pumping systems. More specifically, aspects of the disclosure relate to arrangements related to long stroke pumping systems that provide resiliency and side load control.
Long stroke pumping systems are used in a variety of methods and applications in today's society. Such systems may be used, for example, where mechanical pumping is required for movement of fluids. As defined herein, fluids may be liquids or gasses. As the pumping of fluids is an integral part of how machinery operates, having systems that do not degrade over time is important. Degradation can lead to higher running costs, extended downtime and in some applications, worker or passenger safety issues.
While long stroke pumping systems have such a large importance in industry, it would be expected that conventional systems (i.e. systems already produced) would accomplish all of the tasks required. Unfortunately, conventional systems are keenly lacking in some areas, and as such, industry has had to accept consequences such as poor overall performance and repeated breakdown.
To prevent mechanical breakdown of such systems, efforts are put into production of high-quality components as well as conformance checks prior to the installation of the system. It is also known that conventional systems are subject to premature breaking; therefore, regular and early maintenance checking is required for such systems.
There is a need; however, within different industries and applications, for ever higher performance operations without the drawbacks discussed above. One such application is the recovery of hydrocarbons from field deposits. In this industry, failure of long stroke systems can have catastrophic consequences. For example, failure of components may result in halting of production, severely impacting the overall economic return for the project. At other times, according to the failure mode of the systems, field workers can be compromised in their health and wellbeing.
Use of long stroke systems is also becoming more prevalent within the hydrocarbon recovery industry. Generally, long stroke systems are used where “artificial” lift is needed, meaning that the pressure of the fluids below the surface are not great enough to allow extraction without pumping strategies. After 100 years of oil exploration, recoverable deposits of hydrocarbons that will transmit fluids directly to the surface by themselves are becoming exceedingly rare. As a result, the percentage of wellbores that need artificial lift increases. Despite the needs of industry, failures of conventional systems occur on a regular basis. Among the chief concerns/deficiencies with conventional apparatus, consistent management of structural loading of the long stroke systems during operation is especially problematic. Despite the risks described above, it is common practice in the hydrocarbon recovery industry to run long stroke systems until the systems fail in the field.
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There is a need to provide an apparatus and methods to operate long stroke systems that are easier to operate than conventional apparatus and methods.
There is a further need to provide apparatus and methods that do not have the drawbacks discussed above, namely the premature maintenance and breakage of long stroke systems.
There is a still further need to reduce economic costs associated with long stroke operations and apparatus.
So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized below, may be had by reference to embodiments, some of which are illustrated in the drawings. It is to be noted that the drawings illustrate only typical embodiments of this disclosure and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments without specific recitation. Accordingly, the following summary provides just a few aspects of the description and should not be used to limit the described embodiments to a single concept.
In one example embodiment, an arrangement is disclosed. The arrangement may comprise a power unit configured to make power for the arrangement and a pumping unit connected to the power unit. The pumping unit may be configured with a hydraulic cylinder with a piston within the cylinder, wherein the piston is configured to move from a first position to a second position, the hydraulic cylinder configured to operate with a fluid delivered from a fluid system. The pumping unit may also be configured with a structural arrangement configured near the hydraulic cylinder. The pumping unit may also be configured with a sensor package configured to be attached to the structural arrangement, the sensor package configured to measure a feature of the arrangement during operation.
In one example embodiment, a method is disclosed. The method may comprise performing a pumping operation. The method may also further comprise measuring at least one value of a tilt and movement of a component in a pumping arrangement within a hydraulic cylinder. The method may also further comprise comparing the measured at least one value of tilt and movement in the defined plane to a threshold value. The method may also further comprise continuing to perform the pumping operation when the measured value does not exceed the threshold value. The method may also further comprise altering a performance value of the pumping operation when the measured value exceeds the threshold value.
So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the drawings. It is to be noted; however, that the appended drawings illustrate only typical embodiments of this disclosure and are therefore not be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments.
To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures (“FIGS”). It is contemplated that elements disclosed in one embodiment may be beneficially utilized on other embodiments without specific recitation.
In the following, reference is made to embodiments of the disclosure. It should be understood; however, that the disclosure is not limited to specific described embodiments. Instead, any combination of the following features and elements, whether related to different embodiments or not, is contemplated to implement and practice the disclosure. Furthermore, although embodiments of the disclosure may achieve advantages over other possible solutions and/or over the prior art, whether or not a particular advantage is achieved by a given embodiment is not limiting of the disclosure. Thus, the following aspects, features, embodiments and advantages are merely illustrative and are not considered elements or limitations of the claims except where explicitly recited in a claim. Likewise, reference to “the disclosure” shall not be construed as a generalization of inventive subject matter disclosed herein and should not be considered to be an element or limitation of the claims except where explicitly recited in a claim.
Although the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, components, region, layer or section from another region, layer or section. Terms such as “first”, “second” and other numerical terms, when used herein, do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed herein could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.
When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected, coupled to the other element or layer, or interleaving elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no interleaving elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed terms.
Some embodiments will now be described with reference to the figures. Like elements in the various figures will be referenced with like numbers for consistency. In the following description, numerous details are set forth to provide an understanding of various embodiments and/or features. It will be understood; however, by those skilled in the art, that some embodiments may be practiced without many of these details, and that numerous variations or modifications from the described embodiments are possible. As used herein, the terms “above” and “below”, “up” and “down”, “upper” and “lower”, “upwardly” and “downwardly”, and other like terms indicating relative positions above or below a given point are used in this description to more clearly describe certain embodiments.
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The power unit 204, in the non-limiting embodiment, provides controls for the arrangement 200 to enable actuation and operation of the arrangement 200. A power train 206 is provided that includes a swash plate hydraulic pump arrangement 208 that is powered by an electric motor 210. In one non-limiting embodiment, the electric motor 210 may include a magnet, which may be a permanent magnet. A permanent magnet may be used to reduce energy consumption. Such reduced energy consumption provides the arrangement 200 with a superior carbon footprint compared to conventional apparatus 100. In embodiments, the pumping unit 202 is configured with a fluid filled cylinder 600. In embodiments, the fluid filled cylinder 600 may be an oil filled cylinder. In further embodiments, logic valves 216 are provided to control fluid for the fluid filled cylinder 600. A control system 214 is further provided to allow for control of the logic valves 216. The control system 214 may be configured with programming such that real-time monitoring may be accomplished for the wellbore 218, the pumping unit 202 and other associated systems.
In further embodiments, heat exchangers 220 are provided. The heat exchangers 220 are incorporated into the power unit 204. The heat exchangers 220 provide a capability for temperature/climate/environment adjustment to allow the power unit 204 to be installed in various environments.
In embodiments, a filter system 222 is incorporated into the arrangement 200 to allow for straining associated fluid systems of the arrangement 200. In embodiments, filter components of the filter system 222 may be swapped/changed without disrupting production from the arrangement 200. Conventional systems do not provide for such capabilities. As will be understood, the filter system 222 is configured to remove contaminants from the fluid systems, thereby preventing premature wearing of metallic surfaces. This filtering, accompanied with side load controls instituted by the control system 214 allows for prevention of destructive run times, enhancing overall arrangement viability.
In embodiments, the control system 214 is provided with programming to control side load conditions that often plague systems. Such programming may include, but not be limited to, reducing run speed, stopping the arrangement 200, providing a warning light condition to an operator and/or combinations of all of these mitigation features.
In embodiments that use controls for side load conditions, implementation of these features offers significant savings for operators. Operators and/or the control system 214 prevent tearing/wear or abnormal running conditions, thereby preserving the overall arrangement 200. By using these side load control systems with the control system 214, the arrangement 200 may run for over twice the run times of conventional systems. In areas where mobilization and repair of equipment is of concern, the arrangement 200 provides significant advantages on maintenance. Moreover, in such instances, since the arrangement 200 is significantly less prone to breakage, the overall cost of production of hydrocarbons from the wellbore 218 is reduced compared to conventional apparatus. In embodiments described later, the control system 214 may use inputs from various components, such as tilt sensors. The tilt sensors may be installed at vibration prone positions for the arrangement 200. If the amount of tilt measured by a tilt sensor exceeds a predetermined value, it may be concluded that side load forces on the long stroke arrangement 200 exceeds desired levels. Operator action or automatic action may be taken to limit the amount of side load forces once the threshold value is reached.
In embodiments, the stroke length of the arrangement 200 may be varied according to operator preset limits. Additionally, the arrangement 200 may be automatically controlled through programming for the control system 214 to alter stroke length, as needed, obviating the need for operator interaction. Embodiments of the arrangement may be configured up to 40,000 pounds of load capacity. Volume production for the arrangement 200 may be 5000 barrels per day in some non-limiting embodiments. As illustrated, the arrangement 200 is configured with a block 260 that connects to the sucker rod 270. Movement of the block 260 and the connected sucker rod 270 is achieved by movement of a counterweight 280 connected to the block 260 by cables 265 looped over sheaves 268 located at the top of the arrangement 200. When movement of the counterweight 280 is achieved, the sucker rod 270 moves within the wellbore 218, allowing for a lifting action for hydrocarbons inside the wellbore 218.
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In some embodiments, the temperature of operation of the arrangement 200 may be between-20 degrees Celsius and 60 degrees Celsius. The arrangement 200 may have an operational pressure of up to 1600 psi. A maximum pressure for the arrangement 200 may be up to 2500 psi. In further embodiments, the motor may be a 150 hp permanent magnet motor with a voltage of 480 VAC. A full load capability for the motor may be 175 amps. Efficiency of the motor may be 97 percent with a rotating speed of 1500 revolutions per minute. In further embodiments, vibration dampers may be used in conjunction with the motor.
In some embodiments, a data retrieval system may be used. In one embodiment, the data retrieval system may log data from a local positioning of components of the arrangement 200. In another example embodiment, the data retrieval system may send data obtained to a remote location for analysis and/or recording. Such sending of data may be performed through a supervisory control and data acquisition (“SCADA”) system. In other embodiments, a testing system may be provided to automatically test components, such as actuator valves, to allow for quick diagnosis for field personnel. Data from the testing system may be provided in the form of a report that is obtainable by field personnel on an attached computer. Tracking of operating parameters, run times, numbers of cycles and other run data may be maintained within the arrangement 200 which may be accessible by a computer configured to interface with the arrangement 200. The arrangement 200 may also be configured to allow for software revisions, at periodic intervals, to allow for further refinement of operations based on user inputs. Such user inputs may be through successful runs completed in similar operating environments, to allow for efficient running of the arrangement 200.
In embodiments, the arrangement 200 may be equipped with a sensor package, such as the control system 214, to allow for correct field installation. As will be understood, field conditions may vary with slope. Such slope differences may affect the overall position of moving/rotating equipment. To ensure a high-quality installation of the arrangement 200, the sensor package may be equipped with tilt sensors. In one embodiment, two tilt sensors may be used to evaluate two primary planes of action, such as a N/S plane and an EW plane. The sensor package may interact with the control system 214 to provide input for ultimate control of the arrangement 200.
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As will be appreciated, such side load control may be beneficial in not only hydrocarbon removal activities, but also other operations where stroking systems are used. Such systems may be mechanical actuators used in heavy equipment, military vehicles, airplanes, processing equipment or other equipment that exhibit wear from contacts between a piston and a main hydraulic cylinder. As will further be appreciated, such side load control capability is even more helpful in heavy loads and/or during high operational speeds as the impacts of wear of contact between the piston and the cylinder would be greater. As provided above, additionally, in the event of a contact between components where wearing would occur, any wear particles generated would be separated out from the other fluid systems through the previously described filtration system, thereby preventing further degradation.
As will be further appreciated, measurements of the position of the stroke of the piston may be combined with the data obtained by the tilt sensors T1 602, T2 604. To this end, the amount of maximum tilt (and potential wear) may be determined at specific points of travel by the piston within the cylinder 600. Such data obtained may be used in further manufacturing to allow for greater clearance at specific positions of piston travel within the cylinder 600. As will be understood, the position for maximum potential contact may not be at the bottom of the stroke S, as shown, but may be at other positions due to vibrational effects and harmonics experienced during runs.
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Different configurations of the arrangement 200 are possible. Table 1 presents running data of a sample arrangement 200 given different piston diameters in inches. Values for Table 1 are presented for a stroke length of 360 inches.
Table 2 presents running data of a sample arrangement 200 given different piston diameters in inches, for a stroke length of 336 inches.
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In embodiments, aspects of the disclosure provide for control of loads upon long stroke systems so that the systems may operate for longer periods of time without failure compared to conventional units.
As illustrated and described, aspects of the disclosure provide an apparatus and method to operate long stroke systems that are easier to operate than conventional apparatus and methods.
Embodiments described also provide apparatus and methods that do not have the drawbacks discussed above, namely the premature maintenance and breakage of long stroke systems.
The embodiments described above also reduce economic costs associated with long stroke operations and apparatus.
In one example embodiment, an arrangement is disclosed. The arrangement may comprise a power unit configured to make power for the arrangement and a pumping unit connected to the power unit. The pumping unit may be configured with a hydraulic cylinder with a piston within the cylinder, wherein the piston is configured to move from a first position to a second position, the hydraulic cylinder configured to operate with a fluid delivered from a fluid system. The pumping unit may also be configured with a structural arrangement configured near the hydraulic cylinder. The pumping unit may also be configured with a sensor package configured to be attached to the structural arrangement, the sensor package configured to measure a feature of the arrangement during operation.
In another example embodiment, the arrangement may be configured wherein the sensor package is at least one of a tilt sensor, an accelerometer and a position measuring sensor.
In another example embodiment, the arrangement may be configured wherein the sensor package is at least two tilt sensors, wherein each of the tilt sensors is configured to measure a different plane.
In another example embodiment, the arrangement may further comprise a filtration system configured to filter fluid within the fluid system.
In another example embodiment, the arrangement may be configured wherein the power unit is configured with permanent magnets.
In another example embodiment, the arrangement may further comprise a data acquisition system, wherein the data acquisition is configured to obtain data from the sensor package and distribute the data to a user.
In another example embodiment, the arrangement may be configured wherein the data acquisition system is configured with a supervisory control and data acquisition system configured to send the data to a remote location.
In another example embodiment, the arrangement may further comprise at least two logic valves configured within the fluid system, the logic valves configured to alter a fluid flow path of the fluid system.
In another example embodiment, the arrangement may be configured wherein the pumping unit is further configured with at least one heat exchanger.
In another example embodiment, the arrangement may be configured wherein the structural arrangement is configured of at least one rod.
In one example embodiment, a method is disclosed. The method may comprise performing a pumping operation. The method may also further comprise measuring at least one value of a tilt and movement of a component in a pumping arrangement within a hydraulic cylinder. The method may also further comprise comparing the measured at least one value of tilt and movement in the defined plane to a threshold value. The method may also further comprise continuing to perform the pumping operation when the measured value does not exceed the threshold value. The method may also further comprise altering a performance value of the pumping operation when the measured value exceeds the threshold value.
In another example embodiment, the method may be performed wherein the pumping operation is configured to pump hydrocarbons from a wellbore environment to an up-hole environment.
In another example embodiment, the method may be performed wherein the altering the performance value of the pumping operation is altering a speed of the pumping operations.
In another example embodiment, the method may be performed wherein the altering the performance value of the pumping operation is stopping a pumping operation.
In another example embodiment, the method may further comprise notifying an operator of a discrepancy between the measured value and the threshold value.
In another example embodiment, the method may be performed wherein the notifying of the operator is through illumination of a warning light.
In another example embodiment, the method may be performed wherein the notifying of the operator is through a supervisory control and data acquisition system.
In another example embodiment, the method may be performed wherein the at least one measured value is a tilt of a component of the pumping operation.
In another example embodiment, the method may be performed wherein the at least one measured value is a displacement of a component of a pumping arrangement during operations.
In another example embodiment, the method may be performed wherein the movement of the component relates to a component of a hydraulic cylinder.
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
While embodiments have been described herein, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments are envisioned that do not depart from the inventive scope. Accordingly, the scope of the present claims or any subsequent claims shall not be unduly limited by the description of the embodiments described herein.