Roller coupling apparatus and method therefor

Abstract

A roller coupling apparatus for securing rods and other threaded components together in a pumping system. The roller coupling apparatus can include a body with a plurality of radially-positioned wheels rotatably coupled to the body. The arrangement of the wheels can uniformly spread the rod load within the interior diameter of the tubing. The body can include flat outer surfaces to facilitate increased fluid flow capacity around the apparatus. In operation, the wheels contact and roll along the interior diameter of the tubing, preventing surface-to-surface wear of the coupling body exterior and tubing interior, thereby prolonging coupling and tubing life. In one embodiment, the wheels can include wear grooves that can indicate wear areas in the wellbore. In one embodiment, the body can include grooves to permit retrieval of the apparatus when needed. Multiple apparatuses can be utilized to form rod strings of various lengths.

Claims

1. A roller coupling apparatus comprising, in combination: a body having a threaded upper end, a threaded lower end, and a plurality of alternating curved outer surfaces and flat outer surfaces; a first plurality of partial circumferential grooves positioned proximate the upper end of the body and a second plurality of partial circumferential grooves positioned proximate the lower end of the body; wherein an upper portion and a lower portion of each of the plurality of flat outer surfaces is T-shaped; and a plurality of wheels rotatably coupled to the body; wherein the wheels are positioned radially around the body; and wherein the wheels are spaced-apart equidistantly from each other.

2. The roller coupling apparatus of claim 1 further comprising a plurality of wheel wells positioned between the upper end and the lower end, wherein each wheel well is configured to receive one of the plurality of wheels.

3. The roller coupling apparatus of claim 1 further comprising: a plurality of aligned pairs of openings in the body; a plurality of inserts, each insert having an opening configured to receive an axle, and wherein each insert is configured to be positioned in an opening in one of the plurality of wheels; a plurality of axles, wherein each axle is configured to be positioned through one of the plurality of aligned pairs of openings in the body and in one of the plurality of inserts.

4. The roller coupling apparatus of claim 1 wherein each wheel of the plurality of wheels comprises: an outer wall; a pair of sidewalls; and an opening wall defining a central opening, wherein the opening wall is configured to receive an insert.

5. The roller coupling apparatus of claim 4 wherein each wheel of the plurality of wheels further comprises a plurality of wear grooves.

6. The roller coupling apparatus of claim 5 wherein the wear grooves are concentric and spaced apart equidistantly from each other.

7. The roller coupling apparatus of claim 1 wherein the plurality of wheels comprises three wheels.

8. The roller coupling apparatus of claim 1 wherein the first plurality of partial circumferential grooves comprises three grooves and the second plurality of partial circumferential grooves comprises three grooves.

9. The roller coupling apparatus of claim 1 wherein the plurality of alternating curved outer surfaces and flat outer surfaces comprises three curved outer surfaces and three flat outer surfaces.

10. A roller coupling apparatus comprising, in combination: a body comprising: a threaded upper end; a threaded lower end; a plurality of alternating curved outer surfaces and flat outer surfaces; a first plurality of partial circumferential grooves positioned proximate the upper end and a second plurality of partial circumferential grooves positioned proximate the lower end; wherein an upper portion and a lower portion of each of the plurality of flat outer surfaces is T-shaped; a plurality of wheel wells positioned between the upper end and the lower end; and a plurality of aligned pairs of openings; a plurality of wheels rotatably coupled to the body; a plurality of inserts, each insert having an opening configured to receive an axle, and wherein each insert is configured to be positioned in an opening in one of the plurality of wheels; a plurality of axles, wherein each axle is configured to be positioned through one of the plurality of aligned pairs of openings in the body and in one of the plurality of inserts; wherein each wheel well of the plurality of wheel wells is configured to receive one of the plurality of wheels; wherein the wheels are positioned radially around the body; and wherein the wheels are spaced-apart equidistantly from each other.

11. The roller coupling apparatus of claim 10 wherein each wheel of the plurality of wheels comprises: an outer wall; a pair of sidewalls; and an opening wall defining a central opening, wherein the opening wall is configured to receive one of the plurality of inserts.

12. The roller coupling apparatus of claim 10 wherein each wheel of the plurality of wheels further comprises a plurality wear grooves.

13. The roller coupling apparatus of claim 10 wherein the plurality of wheels comprises three wheels.

14. The roller coupling apparatus of claim 10 wherein the first plurality of partial circumferential grooves comprises three grooves and the second plurality of partial circumferential grooves comprises three grooves.

15. The roller coupling apparatus of claim 10 wherein the plurality of alternating curved outer surfaces and flat outer surfaces comprises three curved outer surfaces and three flat outer surfaces.

16. A method for protecting pumping system components from wear during pumping operations, comprising the steps of: providing a pumping unit; providing a roller coupling apparatus comprising, in combination: a body having a threaded upper end, a threaded lower end, and a plurality of alternating curved outer surfaces and flat outer surfaces; a first plurality of partial circumferential grooves positioned proximate the upper end of the body and a second plurality of partial circumferential grooves positioned proximate the lower end of the body; wherein an upper portion and a lower portion of each of the plurality of flat outer surfaces is T-shaped; and a plurality of wheels rotatably coupled to the body; wherein the wheels are positioned radially around the body; and wherein the wheels are spaced-apart equidistantly from each other; providing a first threaded component; providing a second threaded component; securing together the first and second threaded components by threadably coupling the upper end of the roller coupling apparatus to a lower end of the first threaded component and threadably coupling the lower end of the roller coupling apparatus to an upper end of the second threaded component to form an assembly; positioning the assembly within tubing of a wellbore; causing the assembly to move up with an upstroke of the pumping unit and down with a downstroke of the pumping unit; and during the movement with the upstroke and the downstroke, causing the wheels of the roller coupling apparatus to contact and roll along an interior diameter surface of the tubing.

17. The method of claim 16 wherein: the first threaded component is one of a sucker rod and pony rod; and the second threaded component is one of a sucker rod, pony rod, and sinker bar.

18. A roller coupling apparatus comprising, in combination: a body having a threaded upper end and a threaded lower end; and a plurality of wheels rotatably coupled to the body, wherein each wheel of the plurality of wheels comprises: a convex outer wall having only one circumferential wear groove, the circumferential wear groove centrally positioned on the outer wall; a pair of sidewalls having a plurality of wear grooves positioned on the sidewalls; and an opening wall defining a central opening, wherein the opening wall is configured to receive an insert; wherein the plurality of wheels are positioned radially around the body; wherein the plurality of wheels are horizontally coplanar with each other; and wherein the plurality of wheels are spaced-apart equidistantly from each other.

19. A method for protecting pumping system components from wear during pumping operations, comprising the steps of: providing a pumping unit; providing a roller coupling apparatus comprising, in combination: a body having a threaded upper end and a threaded lower end; and a plurality of wheels rotatably coupled to the body, wherein each wheel of the plurality of wheels comprises: a convex outer wall having only one circumferential wear groove, the circumferential wear groove centrally positioned on the outer wall; a pair of sidewalls having a plurality of wear grooves positioned on the sidewalls; and an opening wall defining a central opening, wherein the opening wall is configured to receive an insert; wherein the plurality of wheels are positioned radially around the body; wherein the plurality of wheels are horizontally coplanar with each other; and wherein the plurality of wheels are spaced-apart equidistantly from each other; providing a first threaded component; providing a second threaded component; securing together the first and second threaded components by threadably coupling the upper end of the roller coupling apparatus to a lower end of the first threaded component and threadably coupling the lower end of the roller coupling apparatus to an upper end of the second threaded component to form an assembly; positioning the assembly within tubing of a wellbore; causing the assembly to move up with an upstroke of the pumping unit and down with a downstroke of the pumping unit; and during the movement with the upstroke and the downstroke, causing the wheels of the roller coupling apparatus to contact and roll along an interior diameter surface of the tubing.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present application is further detailed with respect to the following drawings. These figures are not intended to limit the scope of the present application, but rather, illustrate certain attributes thereof.

(2) FIG. 1 is a side view of an embodiment of a roller coupling apparatus in accordance with one or more aspects of the present invention, with portions thereof shown in phantom;

(3) FIG. 2 is a side, cross-sectional view of the roller coupling apparatus of FIG. 1, with portions thereof shown in phantom;

(4) FIG. 3 is a bottom perspective view of the roller coupling apparatus of FIG. 1, with portions thereof shown in phantom;

(5) FIG. 4 is an end view of the roller coupling apparatus of FIG. 1, with portions thereof shown in phantom;

(6) FIG. 5A is a perspective view of an illustrative wheel of the roller coupling apparatus of the present invention;

(7) FIG. 5B is a perspective view of an illustrative wheel of the roller coupling apparatus of the present invention;

(8) FIG. 6 is a perspective view of an illustrative insert of the roller coupling apparatus of the present invention;

(9) FIG. 7 is a perspective view of an illustrative axle of the roller coupling apparatus of the present invention;

(10) FIG. 8 is a side view of an embodiment of a roller coupling apparatus in accordance with one or more aspects of the present invention;

(11) FIG. 9 is a side view of another embodiment of a roller coupling apparatus in accordance with one or more aspects of the present invention; and

(12) FIG. 10 is another side view of the roller coupling apparatus of FIG. 9;

(13) FIG. 11 is an end perspective view of an embodiment of a roller coupling apparatus in accordance with one or more aspects of the present invention;

(14) FIG. 12 is a side view of the roller coupling apparatus of FIGS. 11; and

(15) FIG. 13 is an end view of the roller coupling apparatus of FIG. 11 shown positioned in tubing.

DETAILED DESCRIPTION OF THE INVENTION

(16) The description set forth below in connection with the appended drawings is intended as a description of presently preferred embodiments of the disclosure and is not intended to represent the only forms in which the present disclosure may be constructed and/or utilized. The drawing figures are not necessarily drawn to scale and certain figures can be shown in exaggerated or generalized form in the interest of clarity and conciseness. The description sets forth the functions and the sequence of steps for constructing and operating the disclosure in connection with the illustrated embodiments. It is to be understood, however, that the same or equivalent functions and sequences may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of this disclosure.

(17) FIGS. 1-13, together, disclose embodiments of a roller coupling apparatus 10 of the present invention. The roller coupling apparatus 10 is adapted to be used with a pumping system, such as an oil pumping system, that is positioned within a pump barrel. The roller coupling apparatus 10 is configured to securely couple two various threaded components that are placed within the tubing, such as rods, including sucker rods and pony rods, and sinker bars. The roller coupling apparatus 10 provides rolling capability at the threaded connections and thereby prevents subsurface components such as couplings, rods, and sinker bars from being dragged across the interior diameter surface of the tubing during pumping operations, which would cause damage to both the subsurface components and tubing. Although the term “oil” is used herein, it should be understood that the roller coupling apparatus 10 of the present invention may be used in pumping systems that pump fluids other than oil, such as debris-containing water. In describing the structure of the roller coupling apparatus 10 and its operation, the terms “north” and “south” are utilized. The term “north” is intended to refer to that end of the pumping system that is more proximate the pumping unit, while the term “south” refers to that end of the system that is more distal the pumping unit, or “downhole.”

(18) Referring first to FIGS. 1-3, an embodiment of the roller coupling apparatus 10 of the present invention is shown. The roller coupling apparatus 10, which has a substantially cylindrical external configuration, can be divided into the following principal components: a body 12 and a plurality of rollers or wheels 30 (hereinafter wheels 30) which are rotatably coupled to the body 12.

(19) Beginning at the top portion of FIGS. 1-3, the components of the roller coupling apparatus 10 will be described in further detail. In this embodiment, the body 12 comprises a north end 14 having an inlet 16, which is configured to receive a southern end of a rod (not shown). Inlet 16 includes a threaded region 18. Threaded region 18 is configured to permit the roller coupling apparatus 10 to be coupled to a southern end of a rod. As seen in this embodiment, threaded region 18 can originate southward of north end 14 and terminate northward of a plurality of wheel wells 20. While in this embodiment threaded region 18 is shown as comprising female threading, in order to correspond to male pin threading present on the ends of conventional rods, it should be understood that threaded region 18 may comprise either male or female threading, as long as it engages corresponding male or female threading present on the rod to which it may be coupled.

(20) Continuing southward in the drawing figures, as seen in this embodiment, the body 12 further includes a plurality of wheel wells 20, each of which is configured to house one of a plurality of wheels 30, as described further herein. Each wheel well 20 can be substantially semi-circularly shaped and can comprise a concave wall configured to correspond to the shape of each wheel 30. With this configuration, a portion of each wheel 30 can be positioned within each wheel well 20. This configuration helps to protect the wheels 30 from damage that could otherwise be caused by the narrow tolerance between the roller coupling apparatus 10 exterior and tubing interior due to buildup of scale, paraffin or other solids, since the wheels 30 will continue to roll in such solids buildup areas. This is in contrast to presently known wheeled couplings/rod guides, in that the wheels of such couplings/rod guides can seize and become dragged through areas of the tubing having solids buildup, flattening the wheels. Each wheel well 20 can have an overall diameter that is greater than an exterior diameter of each wheel 30. In this way, each wheel 30 can be suspended when positioned in each wheel well 20 without contacting the interior surface of the wheel well 20. As best seen in FIG. 4, in this embodiment, the roller coupling apparatus 10 utilizes a set of three wheel wells 20 (corresponding to three wheels 30) that are positioned in the same horizontal plane. The wheel wells 20 are positioned radially around the body 12 and are spaced-apart equidistantly from each other. In this embodiment, the wheel wells 20 are spaced 120 degrees apart. While in this embodiment three wheel wells 20 are shown, it should be understood that more than three wheel wells 20 (corresponding to more than three wheels 30) may be provided as may be needed for particular well conditions and configurations and depending upon the dimensions of the body 12 of the roller coupling apparatus 10.

(21) Referring now to FIG. 4, the body 12 further includes a plurality of aligned pairs of openings 28. Each opening 28 is configured to receive an end of an axle 50, to permit the wheels 30 to be coupled to the body 12, as described further herein. While in this embodiment three aligned pairs of openings 28 (corresponding to three wheels 30) are shown, it should be understood that more than three aligned pairs of openings 28 (corresponding to more than three wheels 30) may be provided as may be needed for particular well conditions and configurations and depending upon the dimensions of the body 12 of the roller coupling apparatus 10.

(22) Referring again to FIGS. 1-3 and continuing with the bottom portion thereof, in this embodiment, the body 12 further comprises a south end 22 having an inlet 24, which is configured to receive a northern end of a rod (not shown). Similar to inlet 16, inlet 24 includes a threaded region 26. Threaded region 26 is configured to permit the roller coupling apparatus 10 to be coupled to a northern end of a rod or sinker bar. As seen in this embodiment, threaded region 26 can originate northward of south end 22 and terminate southward of wheel wells 20. While in this embodiment threaded region 26 is shown as comprising female threading, in order to correspond to male pin threading present on the ends of conventional rods and sinker bars, it should be understood that threaded region 26 may comprise either male or female threading, as long as it engages corresponding male or female threading present on the rod or sinker bar to which it may be coupled.

(23) In one embodiment, the body 12 can be approximately five inches in length. However, it should be understood that the length of the body 12 may deviate from this dimension, as desired. For example, the roller coupling apparatus 10 could have a length longer than five inches, in order to accommodate additional sets of three wheels 30 each, as described further herein, or as may be required for heavier rod loads, severe deviation of the wellbore configuration, and the like. As another example, the roller coupling apparatus 10 could have a length slightly less than five inches.

(24) Referring now to FIGS. 1-5A, the wheel 30 of the roller coupling apparatus 10 will be discussed in further detail. As seen in this embodiment, wheel 30 includes an outer wall 32 flanked by sidewalls 34. Outer wall 32 can be substantially convex in shape. As best seen in FIG. 5A, each wheel 30 is provided with a central opening 36, defined by opening wall 38, which is configured to receive an insert 40. Wheel 30 can be fabricated from a variety of high-density materials suitable for downhole pumping applications including, by way of example only, various metals, such as stainless steel or alloys such as TOUGHMET alloys by Materion Corporation or high-density thermoplastics or high-density polymers. While in this embodiment three wheels 30 are provided in the roller coupling apparatus 10 (see FIG. 4), it should be understood that more than three wheels 30 may be provided as may be needed for particular well conditions and configurations and depending upon the dimensions of the body 12 of the roller coupling apparatus 10.

(25) Referring now to FIGS. 5B and 8, in one embodiment, wheel 30 includes wear grooves 35. In one embodiment, wear grooves 35 can be concentric and spaced apart equidistantly from each other. In one embodiment, each groove 35 can have a depth ranging from approximately 0.0001 to 0.010 inch. However, it would be possible to vary the depth of grooves 35, as may be needed for particular well conditions and configurations. While in this embodiment seven grooves 35 are provided (with three grooves 35 on each sidewall 34 and one groove 35 on outer wall 32), it should be understood that more or fewer than seven grooves 35 may be provided as desired.

(26) Referring now to FIG. 6, the insert 40 of the roller coupling apparatus 10 will be discussed in further detail. As seen in this embodiment, insert 40 is generally a hollow cylinder in shape. Insert 40 includes a central opening 42 defined by opening wall 44, which is configured to receive an axle 50. Insert 40 can include side surfaces 46 and outer surface 48. Insert 40 can be fabricated from a variety of high-density materials suitable for downhole pumping applications including, by way of example only, various metals, such as stainless steel or alloys such as TOUGHMET alloys. While in this embodiment three inserts 40 are provided in the roller coupling apparatus 10 corresponding to three wheels 30 (see FIG. 4), it should be understood that more than three inserts 40 may be provided depending upon the number of wheels 30 utilized.

(27) Each wheel 30 is rotatably coupled to the body 12 by axle 50, which is inserted through aligned openings 28 and 42 in the body 12 and insert 40, respectively. Referring now to FIG. 7, the axle 50 of the roller coupling apparatus 10 will be discussed in further detail, As seen in this embodiment, axle 50 is generally cylindrical in shape. In one embodiment, axle 50 can be hollow and can include a slit 51 from end to end. When wheel 30 fitted with insert 40 is positioned in wheel well 20, axle 50 may then be positioned through a first opening 28 in body 12, opening 42 in insert 40, and a second opening 28 in body 12. When so positioned, each end of axle 50 may protrude outwardly from insert 40 into aligned pairs of openings 28 in the body 12, thereby securing each wheel 30 in position on the body 12. As seen in FIG. 4, in one embodiment, the ends of each axle 50 may further protrude slightly from an outer diameter of the body 12. Referring to FIG. 2, each axle 50 can further include a plurality of ridges 52, which may grip the opening wall 44 of insert 40, thereby securing axle 50 in place. Ridges 52 can be longitudinal, running along a length of the axle 50. Axle 50 can be fabricated from a variety of high-density materials suitable for downhole pumping applications including, by way of example only, various metals, such as stainless steel, carbon steel, or alloys such as TOUGHMET alloys. While in this embodiment three axles 50 are provided in the roller coupling apparatus 10 (see FIG. 4), it should be understood that more than three axles 50 may be provided depending upon the number of wheels 30 utilized.

(28) As best seen in FIG. 4, in this embodiment, the roller coupling apparatus 10 utilizes a set of three wheels 30 that are positioned in the same horizontal plane. The wheels 30 are positioned radially around the body 12 and are spaced-apart equidistantly from each other. In this embodiment, the wheels 30 are spaced 120 degrees apart. This configuration spreads the rod load more uniformly within the interior diameter of the tubing. In this regard, this configuration allows for 360-degree load weight carrying of the rod to transfer to the wheels 30 which roll inside the tubing, thereby eliminating the surface-to-surface wear of the sucker rod coupling and tubing that can occur during pumping operations, especially in deviated areas of the wellbore. While in this embodiment three wheels 30 are provided in the roller coupling apparatus 10, it should be understood that more than three wheels 30 may be provided as may be needed for particular well conditions and configurations and depending upon the dimensions of the body 12 of the roller coupling apparatus 10. For example, where the body 12 has relatively larger dimensions, it may be desired to provide additional radially-positioned wheels 30. Further, while in this embodiment the wheels 30 are shown positioned inline vertically on the body 12, it should be understood that the wheels 30 can be positioned at various degrees from vertical on the body 12. Such a configuration allows for slight rod rotation during pumping operations which, in turn, allows for more even wear, helping to eliminate premature pumping operation failures related to rod and tubing wear issues.

(29) Referring now to FIGS. 9-10, reference number 100 refers generally to another embodiment of the roller coupling apparatus of the present invention. The roller coupling apparatus 100 is similar to the roller coupling apparatus 10, but includes a body 12 of a length longer than the roller coupling apparatus 10 in order to accommodate an additional set of wheels 30. For this reason, the same reference numbers used in describing the features of the roller coupling apparatus 10 will be used when describing the identical features of the roller coupling apparatus 100.

(30) In this embodiment, the body 12 includes six wheel wells 20, corresponding to six wheels 30 (see FIGS. 9-10, which show opposing sides of the roller coupling apparatus 100). However, it should be understood that more or less than six wheel wells 20, corresponding to more or less than six wheels 30, may be provided as desired. As can be seen from a review of FIGS. 9-10, a first set of three wheel wells 20 is provided proximate the north end 14 of the body 12, while a second set of three wheel wells 20 is provided proximate the south end 22 of the body 12. In one embodiment, the body 12 of the roller coupling apparatus 100 can be approximately seven inches in length. This longer length, compared to the length of the roller coupling apparatus 10 (which, as described above, is approximately five inches in length), is configured to accommodate the second set of three wheel wells 20 and wheels 30. However, it should be understood that the length of the body 12 may deviate from this dimension, as desired. For example, the roller coupling apparatus 100 could have a length longer than twenty-four inches, in order to accommodate yet additional sets of wheels 30. It should be noted that for each additional set of wheels incorporated into the roller coupling apparatus 100, approximately two inches are added to the length of the body 12 in order to accommodate the additional wheel set(s). For example, a roller coupling apparatus 100 with three sets of wheels would have a body 12 length of approximately nine inches, a roller coupling apparatus 100 with four sets of wheels would have a body 12 length of approximately eleven inches, and so on.

(31) As seen from a review of FIGS. 9-10, in this embodiment, the roller coupling apparatus 100 utilizes two sets of three wheels 30 each, including three wheels 30 positioned in a northern wheel region 54, proximate the northern end 14 of the body 12, and three wheels 30 positioned in a southern wheel region 56, proximate the southern end 22 of the body 12, for a total of six wheels 30. The wheels 30 of the northern wheel region 54 are positioned in a first horizontal plane. Further, the wheels 30 of the northern wheel region 54 are positioned radially around the body 12 and are spaced-apart equidistantly from each other. In this embodiment, the wheels 30 of the northern wheel region 54 are spaced 120 degrees apart. Similarly, the wheels 30 of the southern wheel region 56 are positioned in a second horizontal plane that is located southward of the first horizontal plane. Further, the wheels 30 of the southern wheel region 56 are positioned radially around the body 12 and are spaced-apart equidistantly from each other. In this embodiment, the wheels 30 of the southern wheel region 56 are spaced 120 degrees apart. As seen from a review of FIGS. 9-10, the wheels 30 of the northern wheel region 54 are staggered relative to the wheels 30 of the southern wheel region 56, and vice versa, such that each wheel 30 of the northern wheel region 54 is positioned diagonally from each wheel 30 of the southern wheel region 56, and vice versa. As with the roller coupling apparatus 10, the configuration of the wheels 30 in the roller coupling apparatus 100 spreads the rod load more uniformly within the interior diameter of the tubing. In this regard, this configuration allows for 360-degree load weight carrying of the rod to transfer to the wheels 30 which roll inside the tubing, thereby eliminating the surface-to-surface wear of the sucker rod coupling and tubing that can occur during pumping operations, especially in deviated areas of the wellbore. As with the roller coupling apparatus 10, while in this embodiment the wheels 30 are shown positioned inline vertically on the body 12, it should be understood that the wheels 30 can be positioned at various degrees from vertical on the body 12. Such a configuration allows for slight rod rotation during pumping operations which, in turn, allows for more even wear, helping to eliminate premature pumping operation failures related to rod and tubing wear issues.

(32) While non-grooved wheels 30 are shown in the embodiment in FIGS. 9-10, it should be understood that the wheels 30 of the roller coupling apparatus 100 may include wear grooves 35, as shown in FIG. 5B and as discussed above.

(33) Referring now to FIGS. 11-13, reference number 200 refers generally to another embodiment of the roller coupling apparatus of the present invention. The roller coupling apparatus 200 is similar to the roller coupling apparatus 10, but includes a plurality of flat outer surfaces 62 and a plurality of grooves 64. For this reason, the same reference numbers used in describing the features of the roller coupling apparatus 10 will be used when describing the identical features of the roller coupling apparatus 200.

(34) In this embodiment, the body 12 includes a plurality of alternating outer surfaces, including a plurality of curved outer surfaces 60 and a plurality of flat outer surfaces 62. Each surface 60 is longitudinal, running along a length of the body 12, and is juxtaposed between a pair of flat outer surfaces 62. Similarly, each surface 62 is longitudinal, running along a length of the body 12, and is juxtaposed between a pair of curved outer surfaces 60. Each surface 62 is also positioned between a pair of wheels 30. As can be seen from a review of FIGS. 11-12, a portion of each surface 62 proximate the north end 14 and south end 22 of the body 12 may generally be substantially T-shaped. In this way, surface 62 can accommodate end portions of a plurality of grooves 64, as described further herein. While in this embodiment three surfaces 62 are shown, it should be understood that more than three surfaces 62 may be provided as may be needed for particular well conditions and configurations and depending upon the dimensions of the body 12.

(35) This configuration of the roller coupling apparatus 200, with its flat outer surfaces 62, can provide one or more advantages. In this regard, as the roller coupling apparatus 10, 100, or 200 is deployed, over time, the wheels 30 will become worn. Depending upon the amount of wear undergone by the wheels 30, it is possible that various regions of the outer surface of the body 12 could come into contact with the interior surface of the tubing. The roller coupling apparatus 200, with its flat outer surfaces 62, eliminates this concern. As can be seen from a review of FIG. 13, for example, the flat outer surfaces 62 allow for more space between the outer diameter of the roller coupling apparatus 200 and the interior diameter of the tubing 300 proximate the flat outer surfaces 62, as compared to the curved outer surfaces 60, which allow for relatively less space between the outer diameter of the roller coupling apparatus 200 and the interior diameter of the tubing 300 proximate the curved outer surfaces 60. Further, with its combination of alternating curved outer surfaces 60 and flat outer surfaces 62, the outer diameter of the roller coupling apparatus 200 proximate outer surfaces 60 can be configured according to standard coupling outer diameter dimensions, while the outer diameter of the roller coupling apparatus 200 proximate outer surfaces 62 can be configured according to API slim hole specifications, as understood by those of skill in the art. Overall, this configuration allows for greater fluid flow capacity around the roller coupling apparatus 200, particularly in the areas proximate flat surfaces 62, compared to rolling coupling apparatus 10 and 100, as well as compared to presently known wheeled couplings/rod guides, thereby providing improved efficiency during pumping operations.

(36) Referring now to FIGS. 11-12, in this embodiment, the body 12 further includes a plurality of partial circumferential grooves 64 formed in an outer surface of the body 12. Each groove 64 can be positioned along a portion of one of the curved outer surfaces 60 of the body 12 and can be juxtaposed between a pair of flat outer surfaces 62. Opposing end portions of each of the grooves 64 may each terminate at one of the plurality of flat surfaces 62, defining substantially T-shaped regions of the body 12 proximate the north end 14 and south end 22, as noted above. The grooves 64 are configured to permit a tool to be coupled to the roller coupling apparatus 200 so that retrieval of the roller coupling apparatus 200 and/or rods from the wellbore may be accomplished, as further described herein. In this embodiment, three grooves 64 are positioned proximate the north end 14 of the body 12, while three grooves 64 are positioned proximate the south end 22 of the body 12, for a total of six grooves 64. While in this embodiment six grooves 64 are shown, it should be understood that more than six grooves 64 may be provided as may be needed for particular well conditions and configurations and depending upon the dimensions of the body 12.

(37) As described herein, each roller coupling apparatus 10, 100, and 200 is configured to be coupled at its north end 14 to the south end of a rod, and at its south end 22 to the north end of another rod or to a sinker bar, thereby connecting the two rods together, or connecting a rod and a sinker bar together, to form an assembly. Multiple roller coupling apparatuses 10, 100, and 200 may be utilized to connect multiple rods together, thereby forming a rod string of various lengths, as may be needed depending on the depth of the well and length of the wellbore in which the roller coupling apparatuses 10, 100, and 200 are employed.

(38) The roller coupling apparatus 10 or 200 can be installed in the same manner as a conventional rod coupling. In this regard, the roller coupling apparatus 10 or 200 can be installed with hydraulic power tongs on the pulling unit. Such tongs can be set so that an equal amount of torque is applied to each roller coupling apparatus 10 or 200 utilized in a given pumping operation, which can include multiple roller coupling apparatuses 10 or 200 as may be needed. This method of installation is economical, efficient, and provides torque consistency among the rod couplings. Compared to manual installation, this method of installation is faster in that it can require a few seconds to install rod couplings with hydraulic power tongs, as opposed to the minutes that may be required for manual installation.

(39) Unlike the roller coupling apparatus 10 or 200, the roller coupling apparatus 100, with its multiple sets of wheels 30, is not suited for installation with hydraulic power tongs on the pulling unit, due to its longer body length. Instead, the roller coupling apparatus 100 can be installed manually with hand wrenches or other hand tools.

(40) In operation, the roller coupling apparatus 10, 100, or 200, being part of the rod string, will move up with the upstroke of the pumping unit and down with the downstroke of the pumping unit. As the roller coupling apparatus 10, 100, or 200 moves within in the wellbore, wheels 30 make contact with and roll along the interior diameter surface of the tubing. This prevents the body 12 exterior from contacting the tubing interior, preventing surface-to-surface wear of the body 12 exterior and tubing interior, including in deviated areas of the wellbore. In turn, with the wheels 30 contacting the tubing, this helps to keep the rods from contacting the tubing. This prolongs the life of the rod assembly and tubing.

(41) Further, with respect to the roller coupling apparatus 200 with its flat outer surfaces 62, more space is provided between the outer diameter of the roller coupling apparatus 200 and the interior diameter of the tubing 300, as compared to the regions proximate curved outer surfaces 60, as discussed above. This, too, prevents the body 12 exterior from contacting the tubing interior, preventing surface-to-surface wear of the body 12 exterior and tubing interior, including in deviated areas of the wellbore, thereby prolonging the life of the rod assembly and tubing.

(42) The roller coupling apparatus 10, 100, or 200 that includes one or more wear grooves 35 on wheels 30 provides further advantages. In this regard, wear grooves 35 allow the operator to determine the wear undergone by the wheels 30 and provide an indication of when the roller coupling apparatus(es) 10, 100, or 200 should be repaired or replaced. The operator can inspect the wheels 30 for wear along the sidewalls 34, outer walls 32, or both when the well experiences down-time and the downhole pumping system components are retrieved for repair. This will enable the operator to determine the location of the most severe wear areas in the wellbore, by reviewing the wear patterns on the wheels 30 including where the grooves 35 have become worn. The operator can then make an informed decision, based on quantitative data, to place additional roller coupling apparatuses 10, 100, or 200 in the severe wear areas, by replacing single sucker rods with multiple, shorter, pony rods, which would allow for more roller coupling apparatuses 10, 100, or 200 to be installed in wellbore locations experiencing severe wear. Such wear may occur due to such reasons as rod loading in deviated areas of the wellbore or rod buckling due to fluid pounding caused by the pump barrel not completely filling with fluid in between pump strokes. This causes the rods to buckle in the tubing, particularly when the traveling valve passes through an empty space in the barrel and then slams into the fluid area. This results in a large shock throughout the rod assembly, causing damage to the rods and tubing. Utilizing the roller coupling apparatus 10, 100, or 200 in the rod assembly lessens the damage to the rod assembly and tubing.

(43) The roller coupling apparatus 200, with its plurality of grooves 64 provides further advantages. In this regard, as noted above, the grooves 64 are configured to permit a tool to be coupled to the roller coupling apparatus 200 for retrieving the roller coupling apparatus 200 and/or rods from the wellbore. In this regard, in the event that the rods become detached from the roller coupling apparatus 200, the operator can use a tool known as a fishing tool or overshot, which includes inward-facing spring barbs. Once the fishing tool/overshot is slid over the roller coupling apparatus 200, the barbs can latch into the grooves 64, allowing the operator to then retrieve the roller coupling apparatus 200 and rods from the wellbore.

(44) The foregoing description is illustrative of particular embodiments of the invention, but is not meant to be a limitation upon the practice thereof. While embodiments of the disclosure have been described in terms of various specific embodiments, those skilled in the art will recognize that the embodiments of the disclosure may be practiced with modifications without departing from the spirit and scope of the invention.