Cycle-Based Stuffing Box Lubrication for Oilwell Pumping Units
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Solution Overview
Problem
The oil industry lacks an effective solution for autonomous lubrication of hydrocarbon producing wells based on the number of completed pumping cycles, leading to potential seal failures and downtime due to inadequate lubrication.
Innovation Solution
A ratiometric autonomous lubrication system that includes a lubrication pump and a controller with an event sequencer, which automatically controls the lubrication operation by sensing the completion of pumping cycles and adjusting the lubrication accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual lubrication monitoring is used, then operators can detect lubrication needs, but the system lacks autonomous control and requires continuous human intervention
Solution Approach 1:
The lubrication system automatically monitors pumping cycle completion and triggers lubrication delivery without human intervention. The controller counts pumping cycles and autonomously activates the lubrication pump when threshold values are reached, enabling the system to self-regulate lubrication based on actual operational needs.
Solution Approach 2:
The system incorporates feedback mechanisms where the controller continuously monitors pumping cycle completion signals and adjusts lubrication delivery accordingly. This closed-loop control ensures lubrication is provided based on real-time operational status, preventing both over-lubrication and under-lubrication.
2Reliability
If lubrication is applied based on fixed time intervals, then the system is simple to operate, but it does not account for varying pumping cycle rates and operational conditions
Solution Approach 1:
The lubrication control system dynamically adjusts lubrication delivery based on the actual pumping cycle rate. Instead of fixed time intervals, the controller counts pumping cycles and triggers lubrication when a predetermined number of cycles is reached, adapting to varying operational speeds and conditions to ensure reliable seal lubrication.
Solution Approach 2:
The system pre-sets threshold values for pumping cycles that trigger lubrication delivery. By anticipating lubrication needs based on cycle counts rather than waiting for seal degradation, the system proactively maintains seal integrity and prevents failures before they occur.
3Reliability
If lubrication is over-applied, then seal protection is enhanced, but lubricant waste increases and operational costs rise
Solution Approach 1:
The controller receives feedback signals from pumping cycle completion and uses this information to precisely time lubrication delivery. By triggering lubrication only when predetermined cycle thresholds are reached, the system avoids continuous or excessive lubricant application, reducing waste while maintaining adequate seal protection.
Solution Approach 2:
The system changes the lubrication delivery parameter from continuous or fixed-interval application to discrete, cycle-based application. This parameter change aligns lubricant delivery with actual seal wear conditions, optimizing the balance between protection and consumption.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system ensures consistent and appropriate lubrication based on the number of pumping cycles, reducing friction, heat production, and the risk of elastomer failure, thereby enhancing the operational reliability of hydrocarbon producing wells.
Implementation Method 1
The fluid from the lubrication pump provides lubrication for ongoing normal operation of the stuffing box
Implementation Method 2
The lubrication controller may be electrically connected to the well controller to allow the event sequencer to sense the electronic pulse received from the well controller
Data Source
AI summary
A ratiometric system for autonomous lubrication of oilwell production equipment. In one arrangement a lubrication pump is fluidly connected to a stuffing box on an oilwell pumping unit. The interval for lubrication and the duration of lubrication is managed by an event sequencer that is electrically connected to the well controller for the pumping unit. The well controller senses a completed cycle of the pumping unit and produces an electronic pulse that can be counted. The event sequencer counts the pulses as they occur. A lubrication cycle is triggered when the sequencer reaches a count corresponding to a predetermined value. The amount of lubrication supplied is directly related to the number of completed cycles of the pumping unit.