Hydraulic Pump Jack Cylinder Assembly for Weight Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional pump jack systems in the oil and gas industry face challenges such as high weight and size, difficulty in controlling operating parameters, high installation costs, and reduced efficiency due to direct power consumption and limitations in stroke length and seal life, especially in high-speed operations.
Innovation Solution
The proposed pump jack system incorporates a cylinder assembly with drive and balance cylinders, a sheave assembly, and an accumulator system that allows for remote control and efficient power use, featuring fluid communication across pistons and chambers to provide balanced movement of the sucker rod string, reducing weight and size while enhancing control and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional pump jack systems are used, then pumping function is provided, but weight and size are tremendous
Solution Approach 1:
The pump jack system is divided into modular components including a power section with engine and transmission, a walking section with legs and rollers, and a pumping section with beam and counterweights. This segmentation allows each module to be optimized independently for weight reduction while maintaining overall system reliability through modular assembly and replacement capabilities.
Solution Approach 2:
The patent replaces traditional mechanical drive systems with a hydraulic power section that uses fluid power transmission. The hydraulic system provides smoother power delivery, reduces mechanical stress on components, and allows for more compact design compared to conventional mechanical linkages, thereby reducing overall weight while maintaining pumping reliability.
2Loss of energy
If conventional pump jack systems are used, then pumping function is provided, but transportation costs are large
Solution Approach 1:
The modular segmentation of the pump jack system enables individual modules to be transported separately and assembled on-site, significantly reducing transportation costs for heavy equipment while maintaining system reliability through proper modular design that ensures functional integrity after assembly.
Solution Approach 2:
The walking section with movable legs and rollers provides dynamic mobility, allowing the pump jack to be relocated more easily compared to fixed conventional systems. This dynamic capability reduces transportation requirements and costs while maintaining operational reliability at each well location.
3Ease of operation
If conventional pump jack systems are used, then pumping function is provided, but control of operating parameters is difficult
Solution Approach 1:
The hydraulic power section incorporates feedback control systems that monitor operating parameters such as pressure, flow rate, and load conditions. This feedback enables automatic adjustment of pumping parameters to optimize performance and maintain reliable operation across varying well conditions, significantly improving ease of control.
Solution Approach 2:
Replacing manual mechanical adjustment mechanisms with hydraulic control systems allows for precise, remote, and automated control of pumping parameters. The hydraulic system provides smooth, controlled movement of the beam and counterweights without requiring manual intervention, improving both ease of operation and operational reliability.
4Use of energy by moving object
If N2 counterweight systems are used, then energy is saved, but stroke length is reduced
Solution Approach 1:
The counterweight system is designed to perform multiple functions: providing gravitational balance during pumping strokes, storing potential energy during downstrokes, and assisting the hydraulic power section during upstrokes. This multi-functionality allows the system to maintain full stroke length while reducing the energy required from the power section compared to systems that use counterweights solely for balancing.
Solution Approach 2:
The system optimizes the mass distribution and positioning of counterweights to change the gravitational parameter, creating a balanced system that reduces peak power requirements while maintaining the full range of motion. By adjusting counterweight parameters, the system achieves energy savings without compromising stroke length.
5Use of energy by moving object
If N2 counterweight systems are used, then energy is saved, but seal life is reduced
Solution Approach 1:
The hydraulic power section replaces high-speed mechanical linkages with fluid power transmission, which operates more smoothly and with fewer impact loads. This substitution reduces dynamic stresses on seals and sealing surfaces, extending seal life while maintaining the energy-saving benefits of the counterweight system.
Solution Approach 2:
The hydraulic system provides controlled, dampened motion that reduces shock and vibration compared to direct mechanical drive systems. This dynamic control minimizes seal wear and extends service life, while the counterweight system continues to provide gravitational assistance for energy savings.
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
This design reduces the weight and size of the system, improves control and efficiency, and enhances reliability by allowing for remote operation and balanced movement of the sucker rod string, thereby reducing power consumption and installation costs while maintaining stroke length and seal life.
Implementation Method 1
a sheave assembly, and an accumulator system that allows for remote control and efficient power use, featuring fluid communication across pistons and chambers to provide balanced movement of the sucker rod string
Implementation Method 2
balanced movement of the sucker rod string, thereby reducing power consumption
Implementation Method 3
cylinder assembly with drive and balance cylinders... featuring fluid communication across pistons and chambers to provide balanced movement of the sucker rod string
Data Source
AI summary
A pump jack system for vertically reciprocating a downhole pump in an oil and gas well. The pump jack system includes a cylinder assembly having a drive cylinder and two balance cylinders. A piston in the drive cylinder may be used to provide an upstroke of a sucker rod string of a downhole pump. The pistons in the balance cylinders may be used to provide a downstroke of the sucker rod string. Lower chambers in the balance cylinders counterbalance the lifting and lowering of the piston in the drive cylinder. The pump jack system also includes an accumulator for maintaining a relative constant fluid pressure in the lower chambers of the balance cylinders.