Hydraulic Pumping System Seal and Control
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Solution Overview
Problem
Existing artificial lift systems for subterranean wells face inefficiencies in fluid extraction due to insufficient reservoir pressure, leading to issues like pump-off and pump-pound, which affect flow rates and operational costs.
Innovation Solution
A hydraulic pumping system that utilizes a hydraulic actuator connected to a downhole pump, with a control system regulating pressure and stroke lengths to maintain optimal fluid flow, incorporating an annular seal housing and gas balancing assembly to manage pressure and prevent pump-off and pump-pound conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If reservoir pressure is insufficient to lift fluids to the surface, then artificial lift technology must be employed, but this increases device complexity and operational costs
Solution Approach 1:
The patent replaces traditional mechanical sucker rod pumps with a hydraulic pumping system. A hydraulic actuator positioned in the wellbore directly drives the pump, eliminating the need for surface-mounted pump jacks and rod strings. This substitution reduces mechanical complexity while maintaining reliable fluid extraction in low-pressure reservoirs.
Solution Approach 2:
The patent employs hydraulic pressure delivered through the wellbore to directly actuate the pump mechanism. Hydraulic fluid is pumped down the annulus and into the actuator, providing direct mechanical force to drive the pump piston. This hydraulic approach simplifies the overall system compared to traditional mechanical rod-driven pumps while ensuring reliable operation in insufficient pressure conditions.
2Productivity
If traditional sucker rod pumps are used, then fluid extraction can be achieved, but pump-off and pump-pound conditions reduce productivity
Solution Approach 1:
The patent incorporates sensors that monitor pump operation parameters and provide feedback to a control system. This feedback mechanism detects conditions leading to pump-off (pump running dry) or pump-pound (excessive vibration and impact), allowing the control system to adjust hydraulic pressure and stroke parameters in real-time to maintain optimal operation and prevent these problematic conditions.
Solution Approach 2:
The hydraulic actuator system allows for dynamic adjustment of pump stroke length and frequency based on real-time well conditions. Unlike fixed mechanical rod pumps, the hydraulic system can vary its operation parameters continuously, adapting to changing fluid levels and reservoir pressures to maintain consistent productivity and avoid pump-off or pump-pound conditions.
3Productivity
If hydraulic pressure is increased to maximize flow rates, then productivity improves, but electrical power consumption and peak loading increase
Solution Approach 1:
The hydraulic pumping system operates with periodic hydraulic pressure pulses delivered to the actuator, creating controlled reciprocating motion in the pump. By optimizing the frequency and duration of these pressure pulses, the system achieves efficient fluid displacement without requiring continuous high-power input, thereby maximizing flow rates while managing electrical power consumption during the hydraulic fluid delivery cycle.
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 efficiently regulates fluid extraction, maximizing flow rates while minimizing electrical power consumption and peak loading, thereby enhancing the productivity and economic viability of fluid extraction from subterranean wells.
Implementation Method 1
a hydraulic actuator (14) including a piston rod (54) that reciprocates in response to pressure in the hydraulic actuator
Implementation Method 2
a seal assembly (78) that seals about the piston rod and is exposed to the pressure in the well
Data Source
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AI summary
A hydraulic pumping system can include an actuator including a piston rod that displaces in response to pressure in the actuator, a seal assembly that seals about the piston rod and is exposed to the pressure in the actuator, and another seal assembly that seals about the piston rod, is exposed to pressure in a well and includes multiple separate seal cartridges, each of the seal cartridges including a dynamic seal that slidingly and sealingly engages the piston rod. Another hydraulic pumping system can include an actuator including a piston rod that displaces in response to pressure in the actuator, a seal assembly that seals about the piston rod and is exposed to the pressure in the actuator, and another seal assembly that seals about the piston rod, is exposed to pressure in a well and includes a labyrinth ring comprising multiple ring layers.