Gas compressor unit for oil wells
11415140 · 2022-08-16
Assignee
Inventors
Cpc classification
F04D27/009
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B39/123
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B35/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D29/70
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B39/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F04D27/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D25/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A compressor unit for oil wells, operating independently from conventional AIB rod pumps, which allows regulated gas extraction to keep the gas pressure constant inside the well and thus allowing the extraction of oil without the inconveniences of traditional pumping systems.
Claims
1. A gas compressor unit for oil wells, the gas compressor unit comprising: a base; a stand element in the base; a rotary drive motor mounted in an upper end of the stand element; an output rotary shaft of said rotary drive motor; a connecting rod having an end affixed to said output rotary shaft to rotate with the output rotary shaft, and an opposite end including a first bearing; at least one compressor cylinder having a first end and a second end, with the second end pivotally connected to a support fixed in the base, and a double-acting piston having a driving shaft with a proximal end that is rotably connected to said opposite end of the connecting rod through the first bearing for moving the double-acting piston with reciprocating movement; at least one first gas inlet/outlet port in the first end of the compressor cylinder; at least one second gas inlet/outlet port in the second end of the compressor cylinder; a valves framework affixed to the base, the valves framework having a first framework port connected by a first flexible conduit to the first gas inlet/outlet port of the compressor cylinder and a second framework port connected by a second flexible conduit to the second gas inlet/outlet port of the compressor cylinder, a discharge branch and a suction branch, the discharge branch having a pair of discharge check valves and a discharge branch port between the discharge check valves, the suction branch having a pair of suction check valves and a suction branch port between the suction check valves; a liquid separator having a first end connected to the suction branch port and a second end connected to a suction hose; and a gas venting tube connected to security valves and between the liquid separator and the discharge branch port, wherein said security valves are a first security valve connected between the liquid separator and the gas venting tube, and a second security valve connected between the gas venting tube and the discharge branch port.
2. The gas compressor unit of claim 1, wherein said second end of the compressor cylinder has a lower arm provided with a second bearing to pivot around a shaft in the support that is stationary affixed to the base.
3. The gas compressor unit of claim 1, wherein said rotary drive motor is connected to a pressure transmitter operatively connected to a pressure switch which in turn is operatively connectable to the well.
4. The gas compressor unit of claim 1, wherein a suction pressure sensor is connected to at least one of the liquid separator and the suction branch port.
5. The gas compressor unit of claim 1, wherein a discharge pressure sensor is connected between the discharge hose and the second security valve.
6. The gas compressor unit of claim 1, wherein the discharge check valves and the suction check valves are unidirectional check valves.
7. The gas compressor unit of claim 1, wherein said rotary drive motor is an electric motor.
8. The gas compressor unit of claim 1, wherein said rotary drive motor is connected to a motor gear reducer.
9. The gas compressor unit of claim 1, further comprising a connection element rotatably connected to said opposite end of the connecting rod through the first bearing.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) For greater clarity and understanding of the object of the present invention, it has been illustrated in several figures, in which the invention has been represented in one of the preferred embodiments, all by way of example, wherein:
(2)
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DESCRIPTION OF THE PREFERRED EMBODIMENTS
(10) Referring now to the figures, it is seen that the invention consists of a new gas compressor unit for oil wells which is an unit independent from the AIB rod pumps that allows regulated extraction of gas to keep the gas pressure constant inside the well and thus allow the extraction of oil without any inconvenience. For exemplary purposes and to further improve the understanding of the present invention,
(11) Thus, and according to
(12) Internally, the compressor cylinder 2 comprises a double-acting piston 9 whose drive shaft 10 passes through the upper cover 4 and has a proximal end that has a connection element 11 provided with a bearing 12 on which a connecting shaft 13 is fixed, said connecting shaft 13 allowing the connection between said driving shaft 10 and a respective connecting rod 14 which is connected to a drive motor 15-reducer 16 by means of the shaft 17 of the latter. The drive motor 10 may be a combustion, hydraulic or electric drive motor, but it is preferably an electric motor which is operatively connected to a pressure switch 18 by a pressure transmitter 41 which is used to control the speed of said motor-reducer, the pressure switch 18 being used to set or establish the start/stop pressure and being operatively connected to the well, more particularly to the annulus space between the casing and the extraction pipe. In this way, the pressure in the well can be programmable without any inconvenience, this not being possible by any of the conventional devices of the prior art since they operate with the beam pump stroke and there is no way of being able to program the pressure required in the well.
(13) The pressure transmitter 41 measures the pressure in the annulus and regulates the rotational revolution of the motor so that the piston moves at a greater or lower speed inside the compressor cylinder. This allows the extraction of gas in accordance with gas pressure existing inside the annulus. By way of example, but not limiting the invention, if the gas pressure existing within the annulus space exceeds the maximum pressure limit necessary to allow the extraction of oil, the pressure transmitter 41 sends a signal to the variable speed drive of the motor so that it rotates at higher revolutions and thus generating a greater speed in the piston movement, consequently extracting a greater amount of gas from the annulus in order to reduce the pressure existing in it. Likewise, the use of the pressure transmitter makes it possible to know the pressure in the annulus and to maintain the ideal pressure therein on a constant basis. In turn, owing to the pressure switch arrangement and the pressure transmitter, the required pressure inside the well can be programmable according to the operating conditions of the moment.
(14) For its part, the connecting rod 14 provides an eccentric movement rectilinear to the drive shaft 10 of the piston 9 which moves longitudinally inside the compressor cylinder 2 to allow the entry of gas as well as, simultaneously, its compression and discharge. When said driving shaft 10 performs a rectilinear eccentric movement, it causes the compressor cylinder 2 to pivot in a tilting manner. To facilitate the tilting movement of the compressor cylinder 2, a pivoting lower end is provided which comprises a lower arm 19 provided with a bearing 20 through which a shaft 21 passes whose ends are fixed to respective lateral support plates (not shown) provided with bearings (not shown) and which are mounted on a frame (not shown) that supports the general structure of the unit of the invention. In this way, pivoting from the lower end is allowed accompanying the eccentric rectilinear movement of the drive shaft 10 and the tilting movement of the cylinder 2.
(15) On the other hand, the invention comprises at least one main gas inlet 22 in connection with the well annulus and at least one main gas outlet 23 in connection with the gas production line and/or related reservoirs. Although, according to the direction illustrated in
(16) The main gas inlet 22 bifurcates and projects into a lower gas inlet 24 which is in connection with the lower gas cylinder inlet/outlet 8 of the lower part 5 of the cylinder 2 through a unidirectional check valve 25, and in a upper gas inlet 26 which is connected to the upper gas cylinder inlet/outlet 7 of the upper part 3 of the compressor cylinder 2 by another unidirectional check valve 27. In turn, the present invention has a lower gas outlet 28 which is connected to the lower gas cylinder inlet/outlet 8 by a unidirectional check valve 29 and an upper gas outlet 30 which is connected to the upper gas cylinder inlet/outlet 7 through another unidirectional check valve 31, both gas outlets 28 and 30 extending and being connected to the main gas outlet 23.
(17) It is noted that projections and bifurcations mentioned above include tubes or pipes 32 as well as bends 33, shut-off valves, connectors, flanges, seals, stuffing boxes, etc., as best illustrated in
(18) By way of example, but not limiting the invention, according to what is illustrated in
(19) On the other hand,
(20) The use of the unidirectional check valves 25, 27, 29 and 31, define the direction of gas flow for both the entry and exit from/to the cylinder, thus avoiding the possible return of the gas. Likewise, both the direction of gas circulation and the main gas inlet and outlet are not limited to what has been described above, but can be adapted for having other configurations without any inconvenience.
(21) According to the embodiment shown in
(22) Another question that the embodiment of
(23) As shown in
(24) Moreover, the invention provides at least one compressor cylinder 110 having a first end 111 and a second end 112, with the second end 112 pivotally connected to a support 113 fixed in the base 101, and a double-acting piston (not shown) inside the cylinder, having a driving shaft 114 which is connected to connection element 109 for moving the double-acting piston with reciprocating movement. It should be understood that the internal configuration of the compressor cylinder 110 is similar to the structural configuration of said compressor cylinder 2 illustrated in
(25) According to the present embodiment, at least one first gas inlet/outlet port 120 in first end 111 of compressor cylinder 110 and at least one second gas inlet/outlet port 121 in second end 112 of compressor cylinder 110, are provided. A valves framework 122 is affixed to base 101, preferably to stand element 102 through respective supports 123 with clamps. A lower branch 149 and an upper branch 149,
(26) Furthermore, the invention provides a discharge branch 128 and a suction branch 129, wherein discharge branch 128 has a pair of discharge check valves 130a, 130b and a discharge branch port 131 between discharge check valves 130a, 130b. Suction branch 129 has a pair of suction check valves 132a, 132b and a suction branch port 133 between suction check valves 132a, 132b. The discharge check valves and the suction check valves are unidirectional check valves, such that they are arranged as illustrated to define a fluid flow circulation, preferably only gas but gas with some humidity degree and even liquid. The sense of circulation will be defined by the movement of the piston inside the cylinder as it will be disclosed below. Connection between valves and ports are made by respective couplings, seals, nipples, conduits or tubing, which are illustrated while not precisely indicated by reference numbers to keep the drawings clear.
(27) On the other hand, the invention provides a liquid separator 134 having a first end 135 connected to suction branch port 133 via respective curved couplings, conduits, tubing, seals, unions or nipples, and a second end 136 connected to a suction hose 137 through a spigot, closing or shutoff valve 138. Suction hose 137 is connected to the well as is hose 40 with suction gas outlet 35 shown in
(28) The present invention further comprises a gas venting tube 141 connected to security valves and between liquid separator 134 and discharge branch port 131. More particularly, said security valves are a first security valve 142 connected between liquid separator 134 and gas venting tube 141, and a second security valve 143 connected between gas venting tube 141 and discharge branch port 131. Furthermore, the invention provides a suction pressure sensor 144 that is connected to at least one of liquid separator 134, as shown, and suction branch port 133, and a discharge pressure sensor 145 that is connected between a discharge hose 146 and second security valve 143. Discharge hose 146 is connected to a shutoff or closing valve 147 which in turn is operatively connected to discharge branch port 131, with discharge pressure sensor 145 being connected between valve 147 and port 131. Connections between said ports, security valves, sensors and gas venting tube 141, are made by respective connectors, nipples, seals, conduits, tubings and the like as it is clearly illustrated.
(29) As shown, the arrangement of the security valves, the sensors and the gas venting tube allows venting of gas and excessive pressure in the event of an unexpected increasing or peak of pressure within the circuit. Thus, the invention remarkably improves the security of the installation and provides a solution to the above mentioned drawbacks relating to the movement of sensible parts in the embodiment of
(30) A shown in
(31) In operation, 1) when the double-acting piston moves downwardly it means that inner chamber (not shown) at upper end of the cylinder is expanding and therefore sucking fluid:
(32) a) the fluid is sucked via hose 125 and suction branch 129, the liquid is separated in separator 134, fluid flows to suction branch port 133 and then to suction check valve 132a. This is because the piston is compressing the fluid downwardly in the lower chamber (not shown) of the cylinder, and the pressure generated in lower branch 148 is higher than in upper branch 149, therefore the fluid coming from separator 134 cannot pass through suction check valve 132b, that is closed, and is directed to suction check valve 132a, that is open;
(33) b) the fluid passes through suction check valve 132a, continues to pass through first framework port 124, and flows by first flexible conduit 125 to first gas port 120 of the compressor cylinder 110 and enters the upper chamber of the cylinder that is expanding, thus gas port 120 operates as an inlet for the fluid;
(34) c) at the other end of the cylinder, with the piston moving downwardly, fluid sucked into the lower chamber (not shown) of compressor cylinder 110 is compressed by the piston and is directed to second gas port 121 that now operates as an exit for the fluid, and the fluid exists via second flexible conduit 127, to discharge branch 128, reaches second framework port 126 and flows to discharge check valve 130b, passes through discharge branch port 131 and is discharged via valve 147 and discharge hose 146.
(35) 2) when the double-acting piston moves upwardly it means that inner chamber (not shown) at lower end of the cylinder is expanding and therefore sucking fluid:
(36) d) the fluid is sucked via hose 127 and suction branch 129, the liquid is separated in separator 134 and the fluid flows to port 133. Since valve 132a is closed, fluid passes through suction check valve 132b, flows through conduit 151, passes through second framework port 126 and continuous by second flexible conduit 127 to enter second gas port 121 to lower chamber of the compressor cylinder. Now, port 121 operates as an inlet port;
(37) e) The piston follows moving upwardly and compresses the fluid that is in the upper chamber which fluid is discharged through first gas port 120, operating now as an exit port. The fluid is directed through first flexible conduit 125, passes through first framework port 124, and continuous to discharge check valve 130a. The fluid passes through valve 130a because it is open while valve 130b is closed. The fluid is finally exited through discharge branch port 131 and discharge hose 146. In any event, hose 146 is connected to any gas collecting installation as is in the case of
(38) These steps are cyclically repeated with the upward and downward movement of the piston. The fluid discharged through the discharge hose, is prevented from returning to liquid separator 134 because of the operation of suction check valves 132a, 132b.
(39) By way of example, but not limiting the invention, some tables are attached showing the results obtained by the compressor unit of the invention:
(40) Discharge flow tables: thousands of cubic feet of gas under standard conditions per day (MSCF/D−thousand standard cubic feet per day)
8.73×10.sup.−5×D.sup.2×L×RPM×Q=PS; Calculation equation:
(41) Calculations should be made with absolute pressures.
(42) TABLE-US-00001 Piston diameter 6″ Piston P net stroke suction Revolution per minute (RPM) in gear box outlet (inches) (psig) 10 20 30 10 0 4.7 9.42 14.1 5 6.3 12.6 18.8 10 7.8 15.7 23.5 15 9.4 18.8 28.3 20 11.0 21.9 32.9 25 12.6 25.1 37.7 30 14.1 28.3 42.4
(43) TABLE-US-00002 Piston diameter 8″ Piston P net stroke suction Revolution per minute (RPM) in gear box outlet (inches) (psig) 10 20 30 16 0 13.4 26.8 40.2 5 17.9 35.8 53.6 10 22.3 44.7 67.0 15 26.8 53.6 80.4 20 31.2 62.5 93.7 25 35.7 71.5 107.2 30 40.2 80.4 120.7
(44) Torque table: (depending on pressure difference, diameter and effective stroke of the piston) Newton-meter
#N−m=4.44×10.sup.−2×D.sup.2×L(Pd−Ps); Calculation equation:
(45) wherein, pressure difference: Discharge pressure−Suction pressure.
(46) TABLE-US-00003 Pressure difference Piston Piston (psi) diameter: 6 inches diameter: 8 inches ΔP 10 12 14 16 10 12 14 16 5 80 96 112 128 142 170 199 227 10 160 192 224 256 284 341 398 454 15 240 287 335 383 426 511 596 681 20 319 383 447 511 568 681 795 909 DETAILS 25 399 479 559 639 710 852 994 1136 APPLICABLE 30 479 575 671 767 852 1022 1193 1363 IN THE 35 559 671 783 894 994 1193 1391 1590 FIELD 40 639 767 894 1022 1136 1363 1590 1817 45 719 862 1006 1150 1278 1533 1789 2044 50 799 958 1118 1278 1420 1704 1988 2272
(47) Well Tests
(48) Prior to the Use of the Compressor Unit of the Invention:
(49) The selected well had a production of 02 BO×0 BW, in October 2016, taking the following physical measurement:
(50) TABLE-US-00004 Production before compressor Current production with compressor P Tbg P Csg P Tbg P Csg Incremental Compressor Well Oil Water (psi) (psi) Manometric Oil Water (psi) (psi) Manometric de Oil Suction Remark BMCG - 4453 2 0 10 3 10-280 psi/ 8 0 20-60 −4 20-300 psi/ 6 −4 psi Operating GMP-09 2 min 40 sec 30 sec. compressor, having no problem Total Production Increase 6
(51) As it can be seen from the table above, the pressure without the compressor or pumping unit was 3 psi, changing to −4 (four negative) psi by using the compressor or pumping unit of the present invention, resulting consequently that, that difference of vacuum pressure allows a greater production.
(52) Using the Compressor Unit of the Invention:
(53) TABLE-US-00005 Fluid level Dynamom- Recommen- Date Battery P.sub.Pipe P.sub.Casing Well details (FLAP) PPRL Torque etric card Remarks dation Oct. October 4537 10 @ 280 2.9 1374′ 36″ 3.58 24 1345′ 29′ 29′ 1,993 15,977 Card has Card has Decrease 22.sup.nd, psi/2′ 40″ fluid fluid working 2016 pound. pound. time to 20 × 4.
(54) One can remarkably observe an increase of the production from 2 BOPD to 8 BOPD, operating 24 hours under the same extraction conditions as those prior to the use of the compressor unit, thus obtaining better manometric tests.
(55) In this way, the compressor unit for oil wells of the present invention is constituted and constructed, which is independent from the operation of the AIB rod pump and in turn, it allows the variation of the piston moving speed to extract a greater or lesser amount of gas in accordance with the existing pressure in the well annulus owing to the novel arrangement of the pressure transmitter and pressure switch. That is to say, the pressure is programmable, this being not possible with any conventional mechanism of the prior art. It is emphasized that the gas extraction cycle is continuous during the period of oil extraction.
(56) Furthermore, some of the advantages of the unit of the present invention lie in:
(57) The use of an external and independent compressor unit instead of a traditional reciprocating gas compressor CGBD (mechanical pumping), allows to further reduce gas pressure in the well annulus since its action is not limited by the geometry of the pumping rod unit, nor the low GPM (<9), wherein independence of frequency of action of the compressor unit allows it to be smaller;
(58) The compressor unit allows maintaining a constant gas pressure in the well, since it has the pressure switch and pressure transmitter that controls the piston speed according to the gas flow to be extracted, pressure being programmable;
(59) Higher gas extraction capacity;
(60) Increases production, with less flowing pressure;
(61) Increase in recoverable reserves (vacuum in annulus);
(62) Easy installation and transfer of the compressor unit;
(63) It does not generate imbalance in alignment and balancing in a mechanical compressor unit;
(64) Totally compact compressor unit (small dimensions) reducing the risk of accidents (there is no work at height);
(65) Easy acquisition of spare parts;
(66) Durability of materials used in its manufacture;
(67) In case of maintenance of the compressor cylinder, it is replaced in approximately 30 minutes by another backup unit;
(68) It is not necessary to stop the AIB rod pump;
(69) The unit of the invention is environment friendly since it does not generate excessive noise;
(70) It is not obstructive as it occupied little physical space in the well's location;
(71) Compact compressor cylinder (fewer parts and flanges with uniform adjustment); improved metallurgy (high quality steel and aluminum), last generation seals (in stuffing box, flanges and piston)
(72) Graphite Teflon seals for greater efficiency and durability;
(73) Compressor accessories (horizontal check valves, bends, tee's, tubes, etc.) designed to work in media with gas flow;
(74) Decrease in manufacturing cost; and
(75) Longer useful life and efficiency of the compressor unit due to less maintenance and repairs, among many other advantages.
(76) Thus, the invention allows varying the piston drive amount according to what we want by means of the variable speed drive that drives the motor and without depending on the frequency of actuation of the mechanical pumping as it occurs with the units of the prior art. In turn, the unit of the invention allows the compressor to be smaller since there being more frequency a smaller compressor is needed, thus allowing regulating the gas pressure of the well as desired owing to the arrangement of the pressure switch and pressure transmitter connected to the casing that, according to the desired programmed pressure, varies the speed of the motor that drives the compressor and therefore extracts more or less gas.