Tandem motor linear rod pump
11221002 · 2022-01-11
Assignee
Inventors
- Andrew J. Hilgers (Franklin, WI, US)
- Michael A. MacDonald (Racine, WI, US)
- Benjamin J. Gregory (Racine, WI, US)
- Ronald G. Peterson (Racine, WI, US)
Cpc classification
F04B53/14
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B53/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B51/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B19/22
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B53/1087
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B17/03
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B47/022
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B9/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B9/047
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B49/065
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
E21B43/12
FIXED CONSTRUCTIONS
F04B47/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B9/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B53/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B53/14
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B51/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B49/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B53/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B19/22
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B9/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A method for operating a tandem motor linear rod pumping apparatus that includes first and second linear mechanical actuator systems each having a motor, and also includes a rod for a sucker-rod pump. The method calls for constructing the first and second linear mechanical actuator systems to operate within a single housing, and simultaneously operating each of the two motors in a manner that imparts reciprocating vertical motion to respective-vertically movable members of the first and second linear mechanical actuator systems. Each motor has a reversibly rotatable element that is operatively connected to the vertically-movable member of its respective linear mechanical actuator system, thus establishing a fixed relationship between the rotational position of the rotatable element and the vertical position of its respective vertically-movable member. The simultaneous operation of the two motors imparts a reciprocating vertical motion to the pump rod of the sucker-rod pump.
Claims
1. A method for operating a tandem motor linear rod pumping apparatus that includes first and second linear mechanical actuator systems each having a motor, and further includes a pump rod for a sucker rod pump, the method comprising: constructing the first and second linear mechanical actuator systems to operate within a single housing; simultaneously operating each of the two motors in a manner that imparts reciprocating vertical motion to a vertically-movable member via the first and second linear mechanical actuator systems, each motor having a reversibly rotatable element that is operatively connected to the vertically-movable member, the positions of the two rotatable elements are synchronized to equalize a torque placed on the pump rod thus establishing a fixed relationship between a rotational position of the rotatable elements and a vertical position of the vertically-movable member; wherein the simultaneous operation of the two motors imparts a reciprocating vertical motion to the pump rod of the sucker rod pump.
2. The method of claim 1, wherein the vertically-movable member comprises a rack, and wherein each rotatable element includes a pinion.
3. The method of claim 2, wherein the rack has a first plurality of vertically-adjacent teeth along a first side of the rack and a second plurality of vertically-adjacent teeth along a second side of the rack, the first plurality of vertically-adjacent teeth oriented in a direction 180 degrees, about a pumping axis, from that of the second plurality of vertically-adjacent teeth.
4. The method of claim 3, further comprising disposing the first plurality of vertically-adjacent teeth on a first side of the pump rod, and disposing the second plurality of vertically-adjacent teeth on a second side of the pump rod different from the first side of the pump rod.
5. The method of claim 2, further comprising sensing at least one of a linear position of the rack along a pumping axis, a rotational position of each of the two pinions about a respective pinion axis, a motor torque for each of the two motors, a motor speed for each of the two motors, a motor acceleration for each of the two motors, and a motor input power for each of the two motors.
6. The method of claim 1, further comprising disposing the motor of the first linear mechanical actuator system on a first exterior side of the housing, and disposing the motor of the second linear mechanical actuator system on a second exterior side of the housing opposite the first exterior side.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings:
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(12) While the invention will be described in connection with certain preferred embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications and equivalents as included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
(13)
(14) As shown schematically in
(15) A longitudinally directed channel 130 in the rack 106 extends along the pumping axis 120 from a lower end 134 of the rack 106 to a top end 136 of the rack 106, with the upper end 136 of the rack 106 being adapted for operative attachment thereto of the pump rod 52. Specifically, as shown in
(16) The linear mechanical actuator apparatus 104 of the linear rod pumping apparatus 100 includes an actuator rod 142, having a lower end 144 thereof fixedly attached to the top end of the pump rod 52 by a threaded joint or other appropriate type of coupling. The actuator rod 142 extends upward from the lower end 144, through the channel 130 in the rack 106 and the hole 140 in the top plate 138 of the rack 106, and terminates at and upper end 146 of the actuator rod 142 which is disposed above the bearing surface 141 on the upper surface of the top plate 138 of the rack 136. A rod clamp 148 is fixedly attached below the upper end 146 of the actuator rod 142 and above the upper end 136 of the rack 106. The clamp 148 has a lower load bearing surface thereof adapted for bearing contact with the upper load bearing surface 141 of the upper end 136 of the rack 106, for transferring force between the actuator rod 142 and the upper end 136 of the rack 106 when the lower load bearing surface of the clamp 148 is in contact with the upper load bearing surface 141 on the upper end 136 of the rack 106.
(17) The clamp 148 forms an expanded upper end of the actuator rod 142 having a configuration that is incapable of entry into or passage through the hole 140 in the upper end 136 of the rack 106. It will be further appreciated that, to facilitate installation of the linear rod pumping apparatus 100 on a well head 54, the actuator rod 142 may be allowed to extend some distance beyond the collar 148, to thereby provide some measure of adjustment to accommodate variations in the positioning of the upper end of the pump rod 52, with respect to the lower end of the lower section 118 of the housing of the linear mechanical actuator system 104. The upper section 114, of the housing of the linear mechanical actuator system 104 includes sufficient head space to accommodate a portion of the actuator rod 142 extending above the clamp 148.
(18) To further reduce the size of the linear rod pumping apparatus 100, the gearbox 110 is a right angle gear box having input element 166. In some embodiments, the input element 166 of gearbox 110 and the rotatable shaft 122 of motor 112 are oriented substantially parallel to the pumping axis 120. It will be understood that, in other embodiments of the invention, the motor 112 may be operatively attached to the pinion 108 by a variety of other means and in other relative orientations.
(19) As best seen in
(20) As shown in
(21) It will be noted, however, that in other embodiments of the invention, other arrangements for providing lubrication of the rack 106 in the oil sump 168 may be utilized, wherein it would be desirable to provide a packing between the rod 52, 142 and the lower end of the lower section 118 of the housing of the linear mechanical actuator system 104. In particular embodiments of the invention, it may be desirable to have the cross-sectional area of the oil sump 168 match the cross-sectional area of the rack 106, or a lower end plate 176 closely enough so that immersion of the rack 106 into the oil sump 168 generates hydraulic damping of the movement of the rack 106.
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(23) As shown in
(24) A pump valve mechanism 310 is located in the bottom section 304. The pump valve mechanism 310 feeds oil to the oil return line 306, which may include a filter 308 disposed in the oil sump 168 in the lower section 118 of the housing. The filter 308 acts to filter out solid contaminants from the oil in the oil return line 306. In some embodiments, the filter 308 has a replaceable cartridge to simplify filter maintenance. The oil return line 306 may also include a check valve 309 so that only a flow of oil from the oil sump 168 in the lower section 118 of the housing to the oil-filled pinion box 216.
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(29) Referring again to
(30) In certain embodiments, the urethane bumpers 178, 180 are configured for engaging and applying an upwardly-directed force to the lower end 134 of the rack 106 only when the lower end 134 of the rack 106 has moved beyond a normal lower position of the rack 106 during a pump stroke. Such an arrangement provides a safety cushion to safely bring the rack 106 and rod string 82 (shown in
(31) In other embodiments of the invention, however, the urethane bumpers 178, 180 may be configured in such a manner that they engage and apply an upwardly-directed force to the lower end 134 of the rack 106 during a portion of each pump stroke 84 (shown in
(32) In conventional single-motor downhole pumping systems, when seeking to increase the pumping capacity of the downhole pumping system, there are practical limits to how much one can increase the size of the motor. In single-motor systems, the torque from rotational movement of the motor generates a bending moment on the pump rod, rack, and well casing. As the size of the motor increases, the bending moment on the rack, well casing, and pump rod can cause premature wear of the rack, and in extreme cases failure of the rack. As will be explained below, embodiments of the present invention disclose a tandem motor arrangement which can reduce or eliminate the bending moment on the rack, well casing, and pump rod.
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(34) As in the embodiment described above, the first linear mechanical actuator system 214 has a first pinion 208 operatively connected through a first gearbox 210, which is driven by a first reversible electric motor 212. The second linear mechanical actuator system 215 has a second pinion 209 operatively connected through a second gearbox 211, which is driven by a second reversible electric motor 213. The first pinion 208 engages gears, in the form of a vertically-extending set of teeth 217, on the vertically-extending first rack 206, while the second pinion 209 engages gears, in the form of a similarly vertically-extending set of teeth 218, located on different sides of a vertically-extending second rack 207. The first and second racks 206, 207 may be constructed from a single piece of material, such as steel or a similar metal for example.
(35) In
(36) Each motor 212, 213 has a reversibly rotatable element operatively connected to the first and second pinions 208, 209 which, together, engage the first and racks 206, 207 to establish a fixed relationship between the rotational position of the first and second pinions 208, 209 and the vertical position of the first and second racks 206, 207 to impart vertical motion to the pump rod 252, which is connected to the downhole pump 68 (shown in
(37) With the tandem motor arrangement shown in
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(39) As shown in
(40) The electronic controller 205 operates the first and second motors 212, 213 in a driving mode to urge upward movement of the first and second racks 206, 207 and of the pump rod 252, and operates the first and second motors 212, 213 in a driving or braking mode during downward movement of the first and second racks 206, 207 on a downward portion of the stroke of the pump rod 252. In all forms of the invention, the first and second linear mechanical actuator systems 214, 215 include one or more substantially vertically movable members, such as the first and second racks 206, 207 attached to the pump rod 252 for imparting and controlling vertical motion of the rod string 82 and the sucker-rod pump 68.
(41) In certain embodiments, the electronic controller 205 controls the first and second motors 212, 213 in such a way as to equalize the torque placed on the pump rod 252, for example, by synchronizing the rotatable elements of the first and second motors 212, 213. Specifically, the electronic controller 205 accomplishes this by controlling the rotational positions of the first and second pinions 208, 209 to synchronize the vertical motion imparted to the first and second racks 206, 207, respectively. In alternate embodiments, the electronic controller 205 uses a single connection to control the first and second motors 212, 213. The electronic controller 205 may be configured to control the first and second motors 212, 213 and the rotational positions of the first and second pinions 208, 209 via programming and the use of specially-designed algorithms, or via specialized and dedicated electronic hardware, or via a combination of the two.
(42) When both motors 212, 213 are controlled by the same control signal in this fashion, the first and second motors 212, 213 may be substantially identical, in terms of generated torque, in order to equalize the torque, and thereby reduce or eliminate the net moment, placed on the pump rod 252. Using identical motors allows for a somewhat simplified operation of the tandem motor linear rod pumping system 200. When each motor 212, 213 is capable of producing the same amount of torque, the tandem motor arrangement will optimally produce twice that amount of torque. This arrangement typically prevents damage to the first and second racks 206, 207 and pump rod 252 from overload, because even if the performance of one motor starts to degrade relative to the other motor, the torque outputs of the two motors 212, 213 will be close enough that the net moment on the pump rod 252 and well casing 60 is not sufficient to cause any damage to the system. By reducing the net moment on the pump rod 252 and well casing 60, it may be possible to increase the length of a typical pump stroke 84 of the pumping system 200
(43) In a certain embodiment, the first and second racks 206, 207 extend vertically along the pumping axis 120 such that the first and second racks 206, 207 are substantially parallel with the pumping axis 120. In the embodiments shown, the first rack 206 has the first set of vertically-adjacent teeth 217 along a side of the first rack 206, while the second rack 207 has the second set of vertically-adjacent teeth 218 along a side of the second rack 207 different from the side of the first rack 206. In some embodiments, the set of teeth 217 on the first rack 206 faces away from the set of teeth 218 on the second rack 207, such that the set of teeth 217 on the first rack 206 face a direction that is 180 degrees from the direction faced by the set of teeth 218 on the second rack 207, and where both sets of teeth 218, 218 face directions that are perpendicular to the pumping axis 120.
(44) In a further embodiment, the first motor 212 of the first linear mechanical actuator system 214 is disposed on a first side of the pump rod 252, and the second motor 213 of the second linear mechanical actuator system 215 is disposed on a second side of the pump rod 252 opposite the first side.
(45) In a particular embodiment, the first down-hole pump 68 includes a stationary valve 78, and a traveling valve 80. The traveling valve 80 is attached to a rod string 82 extending upward through the tubing 70 and exiting the well head 54 at the pump rod 52. Those having skill in the art will recognize that the first down-hole pumping apparatus 68, in an exemplary embodiment of the invention, forms a traditional sucker-rod pump arrangement for lifting fluid from the bottom of the well 56 as the first pump rod 252 imparts reciprocal motion to first rod string 82, and the first rod string 82 in turn causes reciprocal motion of the traveling valve 80 through the pump stroke 84. In a typical hydrocarbon well, the rod string 82 may be several thousand feet long and the pump stroke 84 may be several feet long.
(46) All references, including publications, patent applications, and patents cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
(47) The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
(48) Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.