Downhole Linear Motor Pump with Gravity Gas Separator
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Solution Overview
Problem
Existing downhole oil-well pumping units face issues with reliability and power performance due to poor design features such as mechanical impurity trapping, lack of impact protection, increased dimensions, weight, and large magnetic gaps leading to power losses.
Innovation Solution
The proposed oil-well pumping unit integrates a fully integrated plunger pump with a gravity gas separator, a downhole linear motor, and a telemetry system with sensors, connected via an insulated three-wire cable, utilizing a stator with double-row sectional coils and laminated iron cores, and filled with high-dielectric fluid for improved reliability and power efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical impurity trapping arrangements are used in the motor cavity, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent combines the motor cavity and pump cavity into a single integrated cavity space, eliminating the need for separate mechanical impurity trapping arrangements in the motor cavity. The unified cavity design allows fluid communication between motor and pump sections while maintaining reliability through simplified structure.
Solution Approach 2:
The patent removes the complex mechanical impurity trapping arrangements from the motor cavity by extracting this function from the motor section and integrating it into the unified cavity system, thereby reducing device complexity while maintaining reliability.
2Power
If the motor cavity is filled with high-dielectric fluid, then power performance is improved, but device complexity increases
Solution Approach 1:
The patent merges the motor cavity and pump cavity into a single unified cavity that is filled with high-dielectric fluid. This integration allows the fluid to serve dual purposes: providing electrical insulation and dielectric properties for the motor while also serving as the pump working fluid, thereby improving power performance without proportionally increasing complexity.
Solution Approach 2:
The high-dielectric fluid serves multiple functions simultaneously: it provides electrical insulation for the motor windings, acts as a cooling medium, and serves as the pump working fluid. This multi-functionality improves power performance while minimizing the increase in device complexity.
3Reliability
If a unified cavity system is used for motor and pump, then reliability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent segments the unified cavity into distinct motor and pump sections using internal partitions and diaphragms. This segmentation allows for standardized manufacturing of individual sections with controlled precision requirements, while maintaining the overall unified cavity structure for improved reliability.
Solution Approach 2:
The patent employs nested structures where the pump mechanism is positioned within the motor cavity, and internal partitions create separate functional zones. This nesting approach maintains unified cavity benefits while allowing each component to be manufactured with appropriate precision tolerances independent of others.
4Power
If linear permanent magnet motor is used, then power performance is improved, but weight increases
Solution Approach 1:
The patent replaces traditional rotary motors with a linear permanent magnet motor that directly drives the plunger pump mechanism. This substitution eliminates the need for crankshafts, connecting rods, and other mechanical transmission components, thereby reducing weight while improving power performance through direct electromagnetic actuation.
Solution Approach 2:
Instead of using a rotary motor with mechanical transmission to drive the pump, the patent inverts the approach by using a linear motor that directly produces linear motion to move the plunger. This inversion eliminates intermediate mechanical components and reduces overall system weight while maintaining or improving power efficiency.
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 solution enhances reliability and power performance by reducing mechanical impurities, providing impact protection, and minimizing power losses through efficient fluid management and advanced sensor control, resulting in improved operational efficiency and longevity.
Implementation Method 1
a three-phase high-frequency inverting controller... connected with the downhole linear motor via an insulated three-wire cable
Implementation Method 2
a downhole linear motor, a downhole telemetry unit fitted with stratum fluid temperature and pressure sensors
Implementation Method 3
filled with high-dielectric fluid for improved reliability and power efficiency
Implementation Method 4
a fully integrated plunger pump with a gravity gas separator
Data Source
AI summary
This invention is an oil-well pumping unit. It may be used for production of stratum fluids from marginal well stock at large depths. The invention increases reliability and improves power performance by including a fully integrated plunger pump fitted with discharge valves and a gravity gas separator, non-return valves, and a coupling for fastening the oil-well pumping unit to flow tubing. The downhole linear motor is mounted below the plunger pump. A slider upstroke damper and a slider down-stroke damper, as well as a telemetry unit, are mounted below the linear motor. The unit is linked to a ground-based control unit through a neutral wire interconnected with linear motor windings. The ground-based control unit may be designed as a three-phase high-frequency inverting controller and output transformer, and is connected to the downhole linear motor through an insulated three-wire cable.