Top Plunger Adapter With Cyclonic Sand Control
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Solution Overview
Problem
Existing top plunger adapters in sucker rod pumps are ineffective in preventing clogging from sand and debris, leading to reduced pump efficiency and service life, especially in wells with high sand concentrations, and lack a self-cleaning mechanism to address clogging issues.
Innovation Solution
A top plunger adapter assembly with a collection cage and fluted section that directs sand towards an interior region during upstrokes and uses cyclonic fluid flow to suspend and remove sand, incorporating a rotatable collection cage and o-ring seals to prevent debris from entering the pump barrel, allowing for improved sand control and self-cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional top plunger adapter is used, then the pump can operate with simple structure, but sand and debris cause clogging of the pump components
Solution Approach 1:
The top plunger adapter is segmented into multiple functional components: a collection cage with interior region to trap sand, a fluted section with spiral grooves to direct fluid flow, and a bottom cage with passage for fluid communication. This segmentation allows each component to address specific aspects of sand control while maintaining overall adapter functionality.
Solution Approach 2:
The collection cage acts as an intermediary component between the incoming fluid/sand mixture and the pump plunger. It intercepts sand and debris before they can reach and clog the pump components, while still allowing fluid to pass through to the plunger for normal pumping operation.
2Loss of energy
If the pump operates periodically with shutdowns, then energy consumption is reduced, but sand settles and falls back on pump components during off time
Solution Approach 1:
The collection cage is positioned to intercept sand and debris before they can settle on pump components during shutdown periods. The upper lip of the collection cage creates a barrier that prevents settled sand from reaching critical pump parts, preparing the system in advance for the next startup cycle.
Solution Approach 2:
The fluted section creates cyclonic fluid flow that automatically suspends and removes settled sand during pump operation, without requiring external intervention or additional energy input beyond the normal pumping cycle. The system uses its own operating fluid to clean itself.
3Productivity
If high sand concentration wells are pumped, then petroleum production is maintained, but siltification and clogging of the pump occurs
Solution Approach 1:
The fluted section converts the harmful high-velocity fluid flow that carries sand into a beneficial cyclonic flow pattern. The spiral grooves transform the straight-line flow into rotational motion, which generates centrifugal force to suspend sand particles and prevent them from settling and causing siltification.
Solution Approach 2:
The adapter uses hydraulic principles to create cyclonic flow patterns through the fluted section. The geometry of the flutes directs fluid flow to generate rotational motion, utilizing the kinetic energy of the pumped fluid itself to create a self-cleaning effect that removes sand and prevents clogging.
4Object-affected harmful factors
If sand control features are added to the top plunger adapter, then clogging is reduced, but device complexity increases
Solution Approach 1:
The collection cage, fluted section, and bottom cage are merged into a single integrated adapter assembly that fits within the existing top plunger adapter housing. This consolidation provides comprehensive sand control functionality without requiring multiple separate components or complex assembly procedures.
Solution Approach 2:
The top plunger adapter is designed to perform multiple functions simultaneously: it allows fluid communication to the plunger, traps sand and debris, creates cyclonic flow for self-cleaning, and prevents sand from settling on pump components during shutdowns. This multi-functionality is achieved within a single adapter structure rather than requiring separate devices for each function.
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 adapter effectively reduces clogging, enhances pumping efficiency, and extends the service life of the pump by preventing sand from entering the pump components and using cyclonic fluid flow to suspend and remove sand, ensuring compatibility with existing petroleum production devices.
Implementation Method 1
the flute section is configured to impart a spiral movement in fluid passing through the flute section
Implementation Method 2
the flute section is configured to impart a spiral movement in fluid passing through the flute section
Implementation Method 3
the collection cage having an upper lip configured to direct sand toward the interior region of the collection cage during an upstroke of the pump
Data Source
AI summary
There is provided a top plunger adapter assembly for use in controlling sand fouling of an oil pump system wherein the oil pump system reciprocates between upstrokes and downstrokes within a barrel, and wherein the oil pump system includes as components a sucker rod and a plunger. In one embodiment, the top plunger adapter assembly includes an adapter having a first end configured to receive a sucker rod, wherein the adapter includes a chamber which allows fluid movement therethrough; a collection cage rotatably mounted to the adapter, the collection cage defining an interior region, and the collection cage having an upper lip configured to direct sand toward the interior region of the collection cage during an upstroke of the pump; and a bottom cage attached to the adapter and the bottom cage having a bottom end configured to attach to a pump plunger, wherein the bottom cage includes a passage to allow fluid communication through the bottom cage to the chamber of the adapter. In one embodiment, the adapter is further configured with a flute section configured to allow fluid movement from the chamber through the flute section during a downstroke of the pump and wherein the flute section is configured to impart a spiral movement in fluid passing through the flute section.