Hydraulic Rod Pumping Unit With Long-Stroke Sheave Drive
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Solution Overview
Problem
Existing rod pumping systems experience high frictional wear due to the number of stroke cycles required to produce hydrocarbons, leading to potential tubing damage and inefficiency, and lack the ability to stop or adjust movement dynamically.
Innovation Solution
A rod pumping unit with a horizontal support base, vertical support column, standing and traveling sheaves, and a near-vertical linear actuator that provides a 2:1 amplification of travel, allowing for longer stroke lengths and controlled movement of the polished rod, reducing frictional wear and enhancing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional rod pumping systems use multiple stroke cycles to produce hydrocarbons, then production volume is achieved, but frictional wear on production tubing increases leading to potential damage and inefficiency
Solution Approach 1:
The patent changes the key parameter of stroke length from conventional short strokes to ultra-long strokes exceeding 400 inches. This single parameter change reduces the number of stroke cycles required to produce the same volume of hydrocarbons, thereby minimizing frictional wear on production tubing while maintaining productivity
Solution Approach 2:
The system incorporates a controller that dynamically adjusts the operation of the hydraulic actuator based on real-time conditions. This allows optimization of stroke cycles and timing to achieve production targets with minimal wear, adapting the system behavior to reduce harmful frictional effects while maintaining productivity
2Productivity
If conventional pumping systems operate continuously without adjustment capability, then steady production is maintained, but inability to stop or adjust movement dynamically reduces efficiency and increases wear
Solution Approach 1:
The patent implements a controller that provides dynamic control over the hydraulic actuator, enabling the system to start, stop, pause, and adjust stroke parameters in real-time. This dynamic capability allows the system to optimize efficiency by reducing unnecessary stroke cycles and minimizing wear through intelligent operation management
Solution Approach 2:
The controller receives feedback regarding system operation and production status, using this information to dynamically adjust actuator operation. This feedback mechanism enables the system to respond to changing conditions, optimizing efficiency by adjusting stroke cycles to minimize wear while maintaining productivity targets
3Object-affected harmful factors
If ultra-long stroke length is implemented, then number of stroke cycles is reduced minimizing frictional wear, but system complexity and device structure increase
Solution Approach 1:
The patent employs a hydraulic actuator to generate the forces required for ultra-long stroke operation. This hydraulic system provides the necessary mechanical advantage and force multiplication to achieve the extended stroke length without proportionally increasing structural complexity, as hydraulic systems are well-suited for transmitting force over long distances
Solution Approach 2:
The patent introduces a controller as an intermediary between the power source and the mechanical components. This controller coordinates the operation of the hydraulic actuator and manages the complexity of achieving ultra-long strokes by providing intelligent sequencing and control, reducing the burden on mechanical design while enabling the ultra-long stroke capability
Data Source
AI summary
An oil well pumping unit. The pumping unit has a vertical support column residing adjacent a horizontal support base at a generally transverse orientation. The pumping unit has a standing sheave fixed proximate an upper end of the vertical support column, a carrier bar attached to a polished rod along the front face of the vertical support column, and a traveling sheave configured to move up and down along the vertical support column. A near-vertical actuator resides along the horizontal support base, and is connected to the traveling sheave. Cyclical movement of the linear actuator causes the traveling sheave to reciprocate up and down such that upward movement of the traveling sheave produces a downstroke of the polished rod, while downward movement of the traveling sheave produces an upstroke of the polished rod. The linear actuator remains in tension at all times during movement of the polished rod.