Electronic Auto-Catcher for Oil Well Lubricators
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Solution Overview
Problem
Existing manual and pneumatic catchers for oil and gas well lubricators face challenges such as the need for physical presence, environmental hazards, high installation and maintenance costs, and difficulty in integrating with lubricators requiring different actuation distances due to fixed actuator positions.
Innovation Solution
The development of an improved electronic auto-catcher that incorporates an electronic actuator with a stem adaptor featuring a gap to accommodate varying actuation distances and a catcher spring to dampen movement, allowing for adjustable and adaptive plunger catching and releasing mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pneumatic catchers operate by porting well gas to the atmosphere, then the catcher can function without external power, but it creates environmental hazards and harms ESG ratings
Solution Approach 1:
The patent replaces the pneumatic system (which vents gas to atmosphere) with an electric motor-driven system. The electric motor actuates the catcher mechanism through a gear train and linkages, eliminating the need to vent well gas while maintaining automatic operation capability.
Solution Approach 2:
The patent uses hydraulic or pneumatic actuators driven by an electric motor to control the catcher mechanism. This allows the system to maintain automatic operation without directly venting gas to the atmosphere, as the actuator uses controlled fluid pressure to move the catcher components.
2Ease of operation
If pneumatic catchers use on-site compressors, then gas can be compressed for operation, but installation and maintenance costs increase significantly
Solution Approach 1:
The patent replaces the entire on-site compressor system with a simpler electric motor-driven actuator. The electric motor directly drives the catcher mechanism through mechanical linkages, eliminating the need for expensive compressor installation, operation, and maintenance while maintaining automatic functionality.
Solution Approach 2:
The patent extracts and removes the compressor component from the system entirely, replacing it with a more cost-effective electric motor-driven actuation system. This eliminates the harmful and expensive compressor infrastructure while retaining the essential automatic catcher operation.
3Ease of manufacture
If electronic actuators are set to fixed actuation distances, then the actuator design is simplified, but it becomes difficult to integrate with lubricators requiring different actuation distances
Solution Approach 1:
The patent makes the actuation distance adjustable by incorporating a variable stroke mechanism in the electric actuator. This allows the same actuator design to adapt to different lubricator requirements by changing the actuation distance, maintaining both manufacturing simplicity and system versatility.
Solution Approach 2:
The patent divides the actuation mechanism into separable components with adjustable linkages and connectors. This segmentation allows the actuator to be configured for different stroke lengths and geometries to match various lubricator types while keeping the base actuator design standardized and simple to manufacture.
4Extent of automation
If electronic actuators are used, then automation is improved, but wear in the actuator causes actuation distance to vary over time
Solution Approach 1:
The patent incorporates feedback mechanisms such as position sensors or encoders that monitor the actual actuation distance and provide feedback to the control system. This allows the system to detect and compensate for wear-induced variations, maintaining consistent actuation distance and reliable automatic operation over time.
Solution Approach 2:
The patent includes preliminary adjustment mechanisms or calibration features that allow the actuation distance to be pre-adjusted or compensated for wear. This enables maintenance personnel to restore proper actuation distance without replacing the entire actuator, maintaining reliability while preserving automation.
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 electronic auto-catcher effectively addresses the limitations of manual and pneumatic catchers by providing a reliable, environmentally friendly, and cost-effective solution for catching and releasing plungers in oil and gas well lubricators, with adaptable actuation distances and reduced wear-related issues.
Implementation Method 1
a catcher spring to dampen movement
Implementation Method 2
a catcher spring to dampen movement
Data Source
AI summary
An electronic auto-catcher for catching and releasing a plunger in a lubricator attached to a well. The electronic auto-catcher may include an electronic actuator and an auto-catcher. The electronic actuator may include an actuator that causes lateral movement of an actuator shaft, which causes lateral movement of a stem adaptor, which causes lateral movement of a catcher stem, which causes lateral movement of a ball catching device. The ball catching device holds the plunger in the lubricator and/or releases the plunger from the lubricator so that it may fall down the well. Lateral movement of the actuator shaft is not necessarily equal to lateral movement of the plunger catching device.