Note: Descriptions are shown in the official language in which they were submitted.
CA 2919781 2017-04-20
Forged Flange Lubricator
Field
[0001] This
disclosure relates generally to oil and gas well systems, and more
specifically, to
a forged flange lubricator.
Background
[0002] It is well
known that production from oil and gas wells can suffer due to the build-up
of fluids at the bottom of the well. See e.g., U.S. Patent No. 6,148,923.
Various methods and
devices have been developed to remove those fluids so as to improve the well's
productivity.
[0003] One such
device is known as a plunger, of which there are many variants known to
those skilled in the art. For example, an auto-cycling plunger operates as
follows: (1) it is dropped
into the well (at the well's surface), (2) it free-falls down the well until
it stops upon impact with
the bottom of the well, and (3) it thereafter is caused (by pressure in the
well) to travel back toward
the surface of the well, pushing a "load" of liquid above it for removal at
the well's surface by a
lubricator assembly. The plunger then is allowed to repeat that cycle, thereby
ultimately removing
enough fluid from the well to improve its production.
[0004] A number
of problems have arisen from the use of prior art plungers. For example,
due to the typically great distance between the surface and bottom of a well,
and high pressures
within the well system, the plunger travels at a great rate of speed when it
is received by the
lubricator. Impacts between the plunger and the lubricator can be violent;
they often are so violent
that damage occurs (either immediately or over time due to repeated use) to
lubricator. As another
example, the repeated cycling of the plunger causes at least certain of its
parts eventually to wear
out.
[0005] For
example, a prior art lubricator includes a main body configured to receive the
plunger. The main body may include a spring or catcher assembly for dampening
the impact
1
CA 2919781 2017-04-20
between the lubricator and the plunger. Fluids raised by the plunger may be
ejected from the main
body through one or more ports. In prior lubricator assemblies, the ports are
pipes, flanges,
threaded connectors, or the like that are welded over a hole in the main body.
[0006] The lubricator experiences high fluid pressures when the fluids are
compressed at the
lubricator by the plunger because of the violent impacts between the plunger
and the lubricator
assembly. Further, vibrations are experienced by the lubricator and connected
assemblies each
time the plunger impacts the lubricator. Consequently, wear and tear during
nomml operation of
the plunger lift assembly can be experienced by all components of the system,
and in particular by
the lubricator. A common failure point of the lubricator component is the
junctions or welds
between the ports and the main body. The high pressures may cause leaks at the
junctions, or =
vibration may degrade the welds over time, particularly when heavy pipe or
other components are
attached to the ports.
Summary
[0007] Embodiments of a forged flange lubricator and systems incorporating
the same are
described. In an embodiment, the forged flange lubricator may include a main
body configured to
receive fluid raised by a plunger lift assembly from a well. Additionally, the
lubricator may include
a port in the main body configured to conduct fluid as it is received by the
main body, wherein the
main body and the port are a unitary structure devoid of applied junctions.
[0008] A system including a forged flange lubricator is also described. In
an embodiment, the
system includes a well assembly comprising a well bottom, a wellhead, and a
well pipe coupling
the wellhead to the well bottom, a plunger lift assembly configured to lift
fluid from the well
bottom to the wellhead, a bumper assembly disposed proximate to the well
bottom and configure
to catch the plunger lift assembly before reaching the well bottom, and a
lubricator disposed
proximate to the wellhead. In an embodiment, the lubricator includes a main
body configured to
receive fluid raised by the plunger lift assembly from the well assembly, and
a port in the main
body configured to conduct fluid as it is received by the main body, wherein
the main body and
the port are a unitary structure devoid of applied junctions.
2
=
CA 2919781 2017-04-20
Brief Description of the Drawings
[0009] The following drawings form part of the present specification and
are included to
further demonstrate certain aspects of the present invention. The invention
may be better
understood by reference to one or more of these drawings in combination with
the detailed
description of specific embodiments presented herein.
[0010] FIG. 1 is a schematic diagram illustrating one embodiment of a
system having a forged
flange lubricator.
[0011] FIG. 2 is a schematic diagram illustrating one embodiment of a
system having a forged
flange lubricator.
[0012] FIG. 3 is a perspective view diagram illustrating one embodiment of
a forged flange
lubricator.
[0013] FIG. 4 is a top view diagram illustrating one embodiment of a forged
flange lubricator.
[0014] FIG. 5 is a bottom view diagram illustrating one embodiment of a
forged flange
lubricator.
[0015] FIG. 6 is a back view diagram illustrating one embodiment of a
forged flange
lubricator.
[0016] FIG. 7 is a front view diagram illustrating one embodiment of a
forged flange
lubricator.
[0017] FIG. 8 is a side view diagram illustrating one embodiment of a
forged flange lubricator.
[0018] FIG. 9 is a cross-section view diagram illustrating one embodiment
of a forged flange
lubricator.
[0019] FIG. 10 is a perspective view diagram illustrating one embodiment of
a forged flange
lubricator.
3
CA 2919781 2017-04-20
[0020] FIG. 11 is a top view diagram illustrating one embodiment of
a forged flange lubricator.
[0021] FIG. 12 is a bottom view diagram illustrating one embodiment
of a forged flange
lubricator.
[0022] FIG. 13 is a back view diagram illustrating one embodiment
of a forged flange
lubricator.
[0023] FIG. 14 is a front view diagram illustrating one embodiment
of a forged flange
lubricator.
[0024] FIG. 15 is a side view diagram illustrating one embodiment
of a forged flange
lubricator.
[0025] FIG. 16 is a cross-section view diagram illustrating one
embodiment of a forged flange
lubricator.
Detailed Description
[0026] Various features and advantageous details are explained more
fully with reference to
the nonlimiting embodiments that are illustrated in the accompanying drawings
and detailed in the
following description. Descriptions of well-known starting materials,
processing techniques,
components, and equipment are omitted so as not to unnecessarily obscure the
invention in detail.
It should be understood, however, that the detailed description and the
specific examples, while
indicating embodiments of the invention, are given by way of illustration
only, and not by way of
= limitation. Various substitutions, modifications, additions, and/or
rearrangements within the spirit
and/or scope of the underlying inventive concept will become apparent to those
skilled in the art
from this disclosure. =
[0027] The present embodiments include a well system for oil and/or
gas production. In an
embodiment, the well system includes a well assembly comprising a well bottom,
a wellhead, and
a well pipe coupling the wellhead to the well bottom. The system may also
include a plunger lift
= assembly configured to lift fluid from the well bottom to the wellhead.
In an embodiment, the
system includes a bumper assembly disposed proximate to the well bottom and
configure to catch
4
CA 2919781 2017-04-20
the plunger lift assembly before reaching the well bottom. The system may also
include a
lubricator disposed proximate to the wellhead.
[0028] In an embodiment, the lubricator may include a main body configured
to receive fluid
raised by the plunger lift assembly from the well assembly and a port in the
main body configured
to conduct fluid as it is received by the main body. The main body and the
port are a unitary
structure devoid of applied junctions. As used herein, the term "unitary
structure" means a single
piece or part. As used herein the term "applied junction" means union of
separate components
applied together by a secondary process. For example, a port applied to a main
body by an applied
junction would include a port, coupler, or connector welded, bolted,
adhesively applied, or
otherwise applied to the main body in a step that is secondary to initial
formation of the main body.
For example, a lubricator structure that is forged with integrated ports is
devoid of applied
junctions in some embodiments.
[0029] Beneficially, the embodiments described herein allow for a non-
threaded, zero weld
lubricator solution. Upon testing of the described lubricator, an embodiment
was tested up to 15K
psi, rated for pressures up to 10K psi, and did not include a single applied
junction, such as a weld.
A further benefit of the described embodiments is that the secondary steps of
joining the ports to
the main body may be eliminated, or at least significantly reduced. One of
ordinary skill will
recognize additional benefits and advantages of the described embodiments.
[0030] FIG. 1 is a schematic diagram illustrating one embodiment of a
system 100 having a
forged flange lubricator 102. In the depicted embodiment, the system 100
includes a well assembly
having a well bottom 106 and a wellhead 104 coupled together by well pipe 108.
The well pipe
108 may be inserted into a hole formed by the well casing 110. Well casings
110 may be formed
in the ground 112 with concrete or other structurally adequate materials. The
well pipe 108 and
well casing 110 may be of indeterminate length. In some embodiments, the well
may be a vertical
well as shown. In other embodiments, the well may be a horizontal well
configuration, or a hybrid
well configuration, as is recognized by one of ordinary skill in the art.
CA 2919781 2017-04-20
[0031] The system 100 may include a bumper assembly 114 proximate
to the well bottom 106.
In an embodiment, the plunger 116 may be configured to lift fluid 120 from the
well bottom 106
to the wellhead 104. The fluid 120 is received by the lubricator 102 and
expelled through one or
more ports to peripheral components (not shown). In an embodiment, the plunger
116 may engage
with a stopper, such as the ball 118. In some embodiments, the ball 118 may be
a steel sphere
configured to be received by a portion of the plunger 116. The stopper may
restrict flow of fluid
through or around the plunger 116, thereby causing the plunger to rise to the
lubricator 102. The
lubricator 102 may cause the stopper 118 to be released, thereby allowing
passage of fluids through
or around the plunger 116, and causing the plunger 116 to fall back to the
bumper 114. The bumper
114 may dampen the impact forces when the plunger 116 approaches the bottom of
the well 106.
The stopper 118 may be received by the plunger 116 again, and the process may
repeat, thereby
cyclically lifting fluid 120 to be expelled by the lubricator 102.
[0032] FIG. 2 is a schematic diagram illustrating one embodiment of
a system 200 having a
forged flange lubricator 102. As in the embodiment of FIG. 1, the well may
include a well bottom
106 and a wellhead 104 separated by a well pipe 108 and a well casing 110
formed in the ground
112. In the depicted embodiment, the lubricator 102 may include a main body
202. The lubricator
= 102 may also include a plurality of fluid conduit ports 204a-b, and
plurality of instrumentation
port(s) 210a. In addition, the lubricator 102 may include a catcher port 211
configured to receive
a catch assembly (not shown) for catching and releasing the plunger 218 within
the lubricator 102.
Additionally, the lubricator 102 may include an inlet port 206 having an inlet
flange 208 for
coupling the lubricator 102 to the wellhead 104.
[0033] In an embodiment, the system may include a caged dart
plunger 218 having an
= internally captured dart 220 as a sealing member, which replaces the ball
118 of FIG. 1. An
example of a caged dart plunger 218 is described in greater detail in US Pat.
App. Publ. No.
2016/0168963 entitled "Improved Bypass Dart and Assembly." filed on December
15, 2014.
Although the caged dart plunger is one embodiment of a plunger assembly that
may be suitable
for use according to the present embodiments, one of ordinary skill will
recognize alternative
embodiments which may be equally suitable, including for example, the ball
stopper embodiment
describe in FIG. 1.
6
CA 2919781 2017-04-20
[0034] In an embodiment, the progressive rate bumper 222 may include a
progressive rate
spring 224. One example of a progressive rate bumper 222 which may be suitable
for use with the
present embodiments is described in US Pat. App. Publ. No. 2016/0017700
entitled "Bumper
Assembly Having Progressive Rate Spring," filed on July 16, 2014. Although the
progressive rate
bumper 224 is one embodiment of a bumper 114 that may be included with the
present
embodiments, one of ordinary skill will recognize alternative embodiments of
bumpers 114 which
may be equally suitable.
[0035] In the embodiment of FIG. 2, the lubricator 102 may include a spring
assembly 214,
which may further include a catch spring 216 disposed in a spring housing 212.
In an embodiment,
the catch spring 216 may also be a progressive rate spring, as described in
relation to the bumper
spring assembly. Alternatively, the catch spring 216 may be a common constant
rate spring. One
of ordinary skill will recognize various embodiments of a spring/catch
assembly which may be
used in conjunction with the present embodiments of the lubricator 102. The
spring assembly 214
may work in conjunction with the catch assembly (not shown) which is received
by the catch port
211. The catch assembly may include a flange or lever for locking the plunger
218 in place, or for
releasing the plunger 218 back into the well.
[0036] FIG. 3 is a perspective view diagram illustrating one embodiment of
a forged flange
lubricator 102. In an embodiment, the lubricator 102 may include a main body
202 configured to
receive fluid 120 raised by the plunger 116 lift assembly from a well bottom
106. Additionally,
the lubricator 102 may include a plurality of ports 204a-b, 21 Oa and 211 in
the main body 202. In
particular, the main body 202 and the ports 204a-b, 210a, and 211 are a
unitary structure devoid
of applied junctions. For example, the ports 204a-b and/or 210a and 211 may be
forged together
with the main body 202, thereby eliminating the need for welds, fixtures, etc.
between the main
body 202 and the ports 204a-b, 210a, and 211.
[0037] While some ports may be used to conduct fluid from the lubricator,
such as 204b, for
example, other ports may be used for instrument sensors, such as 210a, for
catch assembly
components such as catch port 211, or for fluid injection such as 204a. One of
ordinary skill will
recognize a variety of embodiments which may be suitable for use according to
the present
embodiments. For example, an additional port may include the inlet with inlet
flange 208 or a port
7
CA 2919781 2017-04-20
for the spring assembly 214. In the embodiment of FIGs. 3-9, the ports 204a
and 204b may include
a flange 304a and 304b respectively for attaching one or more peripheral
components.
Additionally, the flanges 304a-b may each include one or more fixation points
306 which may be
used to affix the flange to a peripheral device. For example, the fixation
points 306 may include
holes or slots for receiving screws, bolts, ties, etc. Similarly, flange 208
may also include one or
more fixation points 306 for attaching the lubricator 102 to the wellhead 104.
[0038] In an embodiment, the flanges 304a-b may include sealing member
receivers 308
configured to receive a sealing member to form a seal between the flange 304a-
b and the peripheral
component. For example, a sealing member (not shown) may include an 0-ring, a
gasket, a sealing
compound, grease, or the like. One of ordinary skill will recognize a variety
of sealing members
that may be suitable for use according to the present embodiments.
[0039] In an embodiment, the ports 204a-b may include a support structure
310 formed to
provide structural support around the area of the ports 204a-b. In an
embodiment, the support
structure 310 may be a region of material disposed around the ports 204a-b
that is thicker than the
side wall of the remainder of the main body 202. In a further embodiment, the
support structure
may be shaped to provide increased structural strength to withstand high
pressures and vibration.
For example, the support structure 310 may include rounded edges and/or convex
sides.
[0040] The spring housing 212 may extend from an end of the main body 202
of the lubricator
102. In an embodiment, the lubricator 302 may include a spring housing coupler
302, such as a
nut or collar for connecting the spring housing 212 to the main body 202. In
some embodiments,
the spring housing coupler 302 may be integral with the main body 202. For
example, the spring
housing coupler 302 may be forged together with the main body 202.
[0041] FIG. 4 is a top view diagram illustrating one embodiment of a forged
flange lubricator
102. The embodiment of FIG. 4 illustrates the flange 304b associated with port
204b. As illustrated
the flange 304b may be integral with the main body 202. In an embodiment, the
catch port 211
8
CA 2919781 2017-04-20
may be disposed on a side opposite port 204b. In one such embodiment, catch
port 211 may
comprise an opening configured for receiving components of a catch assembly
configured to catch
the plunger 116 when it is received by the lubricator 102. As shown, in one
embodiment, the
spring housing 212 may be disposed at a top side of the lubricator 102.
[0042] FIG. 5 a bottom view diagram illustrating one embodiment of a forged
flange lubricator
102. FIGs. 4-5 show that the fixation points 306 may extend entirely through
the flange 208 at the
inlet port 502. For example, the fixation points 306 may include holes through
the flange 208 for
receiving bolts used to bolt the flange to the wellhead 104. Additionally, the
flange 208 may
include a sealing member receiver 504, such as a groove or slot for receiving
an o-ring or gasket.
[0043] FIG. 6 is a back view diagram illustrating one embodiment of a
forged flange lubricator
102. As shown in FIG. 6, the support structure 310 may be formed with a curved
profile to provide
additional strength to the ports 204a-b. In an embodiment, the support
structure 310 may be shaped
to conform to an outer profile of the flanges 304a-b. In an embodiment, the
fixation points 306
may not pass all the way through the flange 304b to the back side. Rather, as
shown in FIG. 7, the
fixation points 306 may include threaded holes for receiving a bolt, screw, or
the like. One of
ordinary skill will recognize alternative embodiments. For example, the
fixation points 306 may
include keyed slots for receiving mating portions of a peripheral component.
[0044] FIG. 7 illustrates the sealing member receiver 308 in further
detail. Additionally, as
shown, a portion of the support structure 310 on the front of the lubricator
102 may be tapered to
smoothly transition between the main body 202 and the flanges 304a-b. FIG. 8
is a side view
diagram illustrating one embodiment of a forged flange lubricator 102.
[0045] FIG. 9 is a cross-section view diagram illustrating one embodiment
of a forged flange
lubricator 102. In the embodiment of FIG. 9, the ports 204a-b may include
channels 906a-b
configured to extend through the flange material 908 to the interior cavity
904 of the main body
202. As shown, the material defining the sidewalls 902 of the main body 202
are unitary with the
material defining the body 908 of the flange 304a-b. In such an embodiment,
the lubricator 102
9
CA 2919781 2017-04-20
may be formed by a forging process. In one embodiment, the ports 204a-b, 210a,
and 211 may be
formed during the forging process. In an alternative embodiment, the ports
204a-b, 210a and 211
may be formed in a secondaty machining or drilling process, but in all
embodiments, the main
body 202 and the ports 204a-b are defined by a unitary body that is free from
welds and other
junctions.
[0046] One of ordinary skill will recognize that in various embodiments,
certain peripheral or
secondary components, such as the spring housing 212, sensors (not shown), the
catch mechanism
(not shown), and the like, may be welded or otherwise affixed to the main body
202, but the body
defining the sidewalls 902 and the flanges 908 is a unitary body devoid of
welds or other applied
junctions between the main body 202 and the ports 204a-b, 210a and 211.
[0047] FIG. 10 is a perspective view diagram illustrating one embodiment of
a forged flange
lubricator 102. In the embodiment of FIGs. 10-16, the area defining the ports
204a-b includes
threads 1002 for receiving a peripheral component with a mating threaded
coupler. FIG. 11 is a
top view diagram illustrating one embodiment of the forged flange lubricator
102 and FIG. 12 is a
bottom view diagram illustrating one embodiment of the forged flange
lubricator 102. As shown
in FIG. 12, the inlet flange 208 may be similar in configuration to the inlet
flange 208 of FIGs. 3-
9. For example, the inlet flange 208 may include one or more fixation points
306. In the
embodiment of FIG. 11, the profile of the port threads 1002 is illustrated. In
various embodiments,
the diameter of the catch port 211, and the thread types or sizes may vary
depending upon the
details of the catch assembly.
[0048] FIG. 13 is a back view diagram illustrating one embodiment of the
forged flange
lubricator 102. In the embodiment, the back profile of the support structure
310 may be smaller
than the profile of the embodiment in FIGs. 3-9, because the size of the port
coupler is smaller
than the flange 304a-b. FIG. 14 is a front view diagram illustrating one
embodiment of the forged
flange lubricator 102. In an embodiment, the lubricator 102 includes a sealing
member receiver
1402 configured to receive a sealing member, such as an 0-ring or gasket for
forming a seal
between the port 204a,b and the peripheral component.
CA 2919781 2017-04-20
[0049] FIG. 15 is a side view diagram illustrating one embodiment of the
forged flange
lubricator 102, and FIG. 16 is a cross-section view diagram illustrating one
embodiment of the
forged flange lubricator 102. The cross-section shows that the region 1602
forming the structural
support 310 and the material forming the sidewalls 902 of the main body 202
are a unitary structure
devoid of any applied junctions. Similarly, the channels 906a-b directly
connect the ports 204a-b
to the main channel 904 of the main body 202. In the embodiment of FIG. 15,
the additional sensor
port 214 may be included with the spring housing 212 to sense when the plunger
116 has been
received by the spring/catch assembly 214.
[0050] Although the invention(s) is/are described herein with reference to
specific
embodiments, various modifications and changes can be made without departing
from the scope
of the present invention(s), as set forth in the claims below. Accordingly,
the specification and
figures are to be regarded in an illustrative rather than a restrictive sense,
and all such modifications
are intended to be included within the scope of the present invention(s). Any
benefits, advantages,
or solutions to problems that are described herein with regard to specific
embodiments are not
intended to be construed as a critical, required, or essential feature or
element of any or all the
claims.
[0051] Unless stated otherwise, terms such as "first" and "second" are used
to arbitrarily
distinguish between the elements such terms describe. Thus, these terms are
not necessarily
intended to indicate temporal or other prioritization of such elements. The
terms "coupled" or
"operably coupled" are defined as connected, although not necessarily
directly, and not necessarily
mechanically. The terms "a" and "an" are defined as one or more unless stated
otherwise. The
terms "comprise" (and any form of comprise, such as "comprises" and
"comprising"), "have" (and
any form of have, such as "has" and "having"), "include" (and any form of
include, such as
"includes" and "including") and "contain" (and any form of contain, such as
"contains" and
"containing") are open-ended linking verbs. As a result, a system, device, or
apparatus that
"comprises," "has," "includes" or "contains" one or more elements possesses
those one or more
elements but is not limited to possessing only those one or more elements.
Similarly, a method or
process that "comprises," "has," "includes" or "contains" one or more
operations possesses those
one or more operations but is not limited to possessing only those one or more
operations.
11
