Linear Rod Pump Rack and Pinion Drive
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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 significant downtime for maintenance, and obstructing other 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 vertical motion to a sucker-rod pump, allowing for easier installation, operation at lower speeds, and reduced downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a conventional walking beam pumping mechanism is used, then the pumping function is provided, but the apparatus is large, complex, and costly to install and remove
Solution Approach 1:
The pumping apparatus is divided into separate modular components: a motor assembly, a rod string, and a pump barrel assembly. These segments can be independently manufactured, transported, and assembled at the well site, eliminating the need for a single large complex structure and reducing installation/removal costs.
Solution Approach 2:
The motor is extracted from the underground pump assembly and positioned at the surface, connected to the rod string. This separation allows the motor to be easily replaced or maintained without removing the entire pumping apparatus, significantly reducing installation and removal complexity.
2Productivity
If a conventional walking beam pumping mechanism is used, then pumping function is provided, but it cannot operate at pumping speeds much below 5 strokes per minute
Solution Approach 1:
The motor speed is made dynamically adjustable through a variable frequency drive system, allowing the pumping mechanism to operate efficiently across a wide range of speeds from very slow to fast rates. This dynamic control enables adaptation to different well conditions and production requirements that were impossible with fixed-speed walking beam mechanisms.
3Reliability
If a conventional walking beam pumping mechanism is used, then pumping function is provided, but significant downtime is required for maintenance and repairs
Solution Approach 1:
The motor is extracted from the underground assembly and positioned at the surface, allowing it to be easily replaced or maintained without removing the rod string or pump barrel. This significantly reduces maintenance downtime as the motor can be serviced independently while other components remain in place.
Solution Approach 2:
The system includes easily accessible service ports and quick-connect mechanisms that allow operators to perform routine maintenance and repairs without specialized equipment or extensive disassembly, enabling self-service maintenance that minimizes downtime.
4Productivity
If a conventional walking beam pumping mechanism is used, then pumping function is provided, but it obstructs other equipment due to its size and height
Solution Approach 1:
The pumping apparatus is segmented into compact modular components that can be arranged in a space-efficient configuration. The surface motor and control systems occupy minimal space compared to the large walking beam structure, freeing up area for other equipment and operations.
Solution Approach 2:
The motor and drive mechanisms are repositioned from the traditional horizontal walking beam configuration to a vertical arrangement with the motor at the surface and the pump barrel at depth. This dimensional change eliminates the need for large horizontal clearance and reduces the apparatus profile.
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 linear rod pumping apparatus significantly reduces installation and removal costs, enables operation at lower pumping speeds, and minimizes downtime, while being compact enough to coexist with other equipment, enhancing the operational efficiency and longevity of wells.
Implementation Method 1
The linear mechanical actuator arrangement includes a rack and pinion gearing arrangement, with the rack being disposed for operation in a substantially vertical direction for reciprocating motion along a pumping axis. The rack is operatively connected in gear mesh relationship with the pinion.
Implementation Method 2
a motor having a reversibly rotatable element, operatively connected to the substantially vertical member of the linear mechanical actuator arrangement in a manner establishing a fixed relationship between the rotational position of the motor and the vertical position of the vertically movable member
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, and movement with, 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.