Linear Rod Pump Apparatus for Low-Speed Well Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional walking beam-type pumping mechanisms are large, complex, and costly to install and remove, with limitations in operating at low pumping speeds, requiring frequent shutdowns for maintenance, and obstructing nearby equipment due to their size and height.
Innovation Solution
A linear rod pumping apparatus with a linear mechanical actuator and reversible motor, which provides a compact, efficient, and adjustable solution for pumping fluids by imparting reciprocating motion to a sucker-rod pump, allowing for operation at lower speeds and easier installation and removal, and integrating energy storage and dynamic braking for enhanced efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a walking beam pumping mechanism is used, then pumping function is provided, but the apparatus is large and complex requiring heavy foundation and lengthy installation
Solution Approach 1:
The pumping apparatus is divided into modular components including a power unit, a rod pump, and a fluid handling system that can be independently assembled and configured. This segmentation allows for quicker installation and easier maintenance compared to integrated walking beam systems.
Solution Approach 2:
The patent replaces the complex mechanical walking beam system with a more straightforward motor-driven rod pump system. The mechanical advantage of walking beams is substituted with direct motor power transmission, eliminating the need for heavy foundations and complex counterweight mechanisms.
2Speed
If walking beam mechanism is used, then pumping is achieved, but it cannot operate at speeds below 5 strokes per minute
Solution Approach 1:
The rod pump system incorporates variable speed control capabilities that allow dynamic adjustment of pumping speed according to well conditions. The motor can operate across a wide range of speeds including below 5 strokes per minute, adapting to changing reservoir pressures and fluid viscosities that walking beam systems cannot accommodate.
Solution Approach 2:
The system allows change of operating parameters including stroke rate, stroke length, and motor speed to optimize performance for different well conditions. This parametric flexibility enables operation at low speeds when reservoir pressure is high or fluid viscosity is elevated, extending the viable operating window beyond what fixed-speed walking beam systems provide.
3Reliability
If walking beam mechanism is used, then pumping is provided, but frequent shutdowns are required for maintenance increasing downtime
Solution Approach 1:
The rod pump system incorporates self-diagnostic capabilities and easily accessible components that allow operators to perform routine maintenance and troubleshooting without complete system shutdown. The modular design enables quick replacement of wear components while the rest of the system continues to operate, minimizing downtime.
Solution Approach 2:
The system includes predictive maintenance features that monitor component wear and performance degradation before failure occurs. By detecting early signs of problems such as rod string issues or pump wear, maintenance can be scheduled proactively during planned production interruptions rather than reacting to unexpected failures that cause longer downtime.
4Ease of operation
If walking beam mechanism is used, then pumping function is achieved, but it obstructs nearby equipment due to large size and height
Solution Approach 1:
The rod pump system is configured with a compact vertical arrangement that utilizes the vertical space above the wellhead more efficiently. By eliminating the horizontal spread of walking beam mechanisms and counterweights, the system concentrates its footprint vertically, freeing up horizontal space for other equipment such as fluid handling facilities, monitoring instruments, and access pathways.
Data Source
AI summary
An apparatus and method for pumping fluids, such as water and/or hydrocarbons, from a subterranean formation or reservoir, include a linear rod pump having a mechanical rack and pinion drive arrangement, adapted for attachment to a pumping mechanism, such as the polished rod at the top of a rod string in a hydrocarbon well. The rack gear, of the rack and pinion drive arrangement, is adapted for connection to a cable and pulley arrangement for imparting motion to the polished rod. The pinion gear does not translate with the rack gear, and is driven by a reversible motor for affecting up and down reciprocating motion of the rack gear and pumping mechanism. Some forms of the invention include a compressible gas counter-balance arrangement. Some forms of the invention include an electronic drive configured for dealing with electric power generated by the motor during a portion of the pumping cycle.