Flexible Cable Pumping System for Oilfield Power Reduction
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Solution Overview
Problem
Conventional oilfield pumping units exhibit inferior movement performance, low effective load factors, high power consumption, large dimensions, high weights, and high capital and labor intensities, along with the need for robust foundations and rigid rods.
Innovation Solution
A single-crank, double-stroke, flexible-cable pumping system that eliminates rigid rods and walking beams, utilizing an electric motor, speed reducer, and flexible driving elements to achieve improved movement performance, reduced power consumption, and simplified operations, with a compact design that allows for self-powered tripping operations and easy parameter adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional beam pumping units are used, then pumping capability is achieved, but weight and dimensions increase
Solution Approach 1:
The patent removes the heavy rigid rod from the conventional beam pumping unit structure, retaining only the essential crank mechanism and flexible cable for power transmission. This extraction of the rigid rod eliminates the need for heavy supporting structures while maintaining the core pumping function.
Solution Approach 2:
The patent replaces the rigid rod with a flexible cable that transmits power from the crank to the plunger. This flexible cable significantly reduces the weight and dimensions of the moving components while maintaining the necessary mechanical transmission capability for pumping operations.
2Strength
If rigid rods and walking beams are used, then structural strength is maintained, but power consumption increases
Solution Approach 1:
The flexible cable replaces the rigid rod, reducing the mass of moving parts and consequently the energy required to accelerate and decelerate the system during each stroke cycle. This maintains structural integrity while reducing power consumption.
Solution Approach 2:
The patent employs a dynamic flexible cable system that can adapt to motion requirements, allowing for more efficient energy transfer compared to the static rigid rod system. The flexible cable reduces inertial losses and improves overall energy efficiency.
3Productivity
If conventional pumping units are used, then pumping operation is achieved, but movement performance deteriorates
Solution Approach 1:
The flexible cable enables smoother and more responsive motion transmission compared to the rigid rod, improving the dynamic movement performance of the plunger. This allows for better speed control and more efficient pumping operations.
Solution Approach 2:
The patent segments the power transmission system into a crank mechanism and a flexible cable, allowing for independent optimization of each component. This segmentation enables improved movement performance while maintaining pumping productivity.
4Stability of the object's composition
If large dimensions are used, then structural stability is ensured, but capital investment increases
Solution Approach 1:
By removing the rigid rod and associated heavy supporting structures, the patent significantly reduces the dimensions and material requirements of the pumping unit. This extraction maintains essential structural stability while reducing capital investment in manufacturing and installation.
Solution Approach 2:
The flexible cable enables a more compact design with smaller dimensions compared to rigid rod systems. This reduction in size decreases material costs, manufacturing complexity, and overall capital investment while maintaining adequate structural stability for pumping operations.
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 enhances movement performance, reduces power consumption, decreases unit dimensions and weight, lowers capital investments, and simplifies testing and parameter adjustments, while maintaining high effective load factors and efficient oil well pumping capabilities.
Implementation Method 1
a fixed pulley is fixed on the same plane as the top end of the bracket; the end head of the output shaft of the speed reducer is connected to a crank; the top end head of the crank is connected with one or more movable pulleys that are on the same plane as the fixed pulley; and a flexible driving element vertically hung in the center of the wellhead is successively wound across the fixed pulley, the movable pulleys, and another fixed pulley
Data Source
AI summary
A pumping system is described comprising a bracket being vertically fixed onto the connection end of a pump basement and also connected to a wellhead in order to support multiple fixed pulleys fixed on the same plane as the top end of the bracket), an electric motor and a speed reducer also successively being fixed to a lower end of the bracket. The end head of an output shaft of a speed reducer is connected by means of a crank whose top end head is connected with a movable pulley that is on the same plane as the fixed pulleys. A flexible cable vertically hung in the center of the wellhead is successively wound across the fixed pulleys and the movable pulley and then is locked onto the pump basement. The flexible cable is downwardly connected to a plunger element of an upper wellhead canned pump and also to a plunger element of a downhole oil well pump. This pumping system is characterized by good movement performance, high level of effective load factor, the ability to use the combination of its own driving power and special tools for complementing the characteristics of low power consumption on tripping the plunger of oil well pump, as well as relatively small dimension and low weight of the pumping system relative to conventional oilfield pumping units.