Note: Descriptions are shown in the official language in which they were submitted.
SLANT MOUNTED HYDRAULIC PUMPING SYSTEM
BACKGROUND
This disclosure relates generally to equipment utilized and operations
performed in conjunction with a subterranean well and, in one example
described
below, more particularly provides a hydraulic pumping system.
Reservoir fluids can sometimes flow to the earth's surface when a well has
been completed. However, with some wells, reservoir pressure may be
insufficient (at the time of well completion or thereafter) to lift the fluids
(in
particular, liquids) to the surface. In those circumstances, technology known
as
"artificial lift" can be employed to bring the fluids to the surface (or other
desired
location, such as a subsea production facility or pipeline, etc.).
Various types of artificial lift technology are known to those skilled in the
art. In one type of artificial lift, a downhole pump is operated by
reciprocating a
string of "sucker" rods deployed in a well. An apparatus (such as, a walking
beam-type pump jack or a hydraulic actuator) located at the surface can be
used
to reciprocate the rod string.
Therefore, it will be readily appreciated that improvements are continually
needed in the arts of constructing and operating artificial lift systems. Such
2 5 improvements may be useful for lifting oil, water, gas condensate or
other liquids
1.
CA 2936221 2017-09-13
CA 02936221 2016-07-15
from wells, may be useful with various types of wells (such as, gas production
wells, oil production wells, water or steam flooded oil wells, geothermal
wells,
etc.), and may be useful for any other application where reciprocating motion
is
desired.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a representative partially cross-sectional view of an example of a
hydraulic pumping system and associated method which can embody principles
of this disclosure.
FIG. 2 is a representative cross-sectional view of an example of a
hydraulic actuator that may be used in the system and method of FIG. 1.
FIG. 3 is a representative cross-sectional view of an example piston
position sensing technique that may be used in the system and method of FIG.
1.
FIG. 4 is a representative cross-sectional view of an example lower
portion of the hydraulic actuator and an annular seal housing.
FIG. 5 is a representative top view of an example of a hydraulic pressure
source that may be used in the system and method of FIG. 1.
FIG. 6 is a representative diagram of an example of a gas balancing
assembly that may be used in the system and method of FIG. 1.
FIG. 7 is an example process and instrumentation diagram for the
hydraulic pressure source of FIG. 5.
FIGS. 8A & B are representative examples of load versus displacement
graphs for the system and method of FIG. 1.
FIG. 9 is a representative elevational view of another example of the
hydraulic pumping system and associated method.
2
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DETAILED DESCRIPTION
Representatively illustrated in FIG. 1 is a hydraulic pumping system 10
and associated method for use with a subterranean well, which system and
method can embody principles of this disclosure. However, it should be clearly
understood that the hydraulic pumping system 10 and method are merely one
example of an application of the principles of this disclosure in practice,
and a
wide variety of other examples are possible. Therefore, the scope of this
disclosure is not limited at all to the details of the system 10 and method as
described herein or depicted in the drawings.
In the FIG. 1 example, a hydraulic pressure source 12 is used to apply
hydraulic pressure to, and exchange hydraulic fluid with, a hydraulic actuator
14
mounted on a wellhead 16. In response, the hydraulic actuator 14 reciprocates
a
rod string 18 extending into the well, thereby operating a downhole pump 20.
The rod string 18 may be made up of individual sucker rods connected to
each other, although other types of rods or tubes may be used, the rod string
18
may be continuous or segmented, a material of the rod string 18 may comprise
steel, composites or other materials, and elements other than rods may be
included in the string. Thus, the scope of this disclosure is not limited to
use of
any particular type of rod string, or to use of a rod string at all. It is
only
necessary for purposes of this disclosure to communicate reciprocating motion
of
the hydraulic actuator 14 to the downhole pump 20, and it is therefore within
the
scope of this disclosure to use any structure capable of such transmission.
The downhole pump 20 is depicted in FIG, 1 as being of the type having a
stationary or ''standing" valve 22 and a reciprocating or "traveling" valve
24. The
traveling valve 24 is connected to, and reciprocates with, the rod string 18,
so
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that fluid 26 is pumped from a wellbore 28 into a production tubing string 30.
However, it should be clearly understood that the downhole pump 20 is merely
one example of a wide variety of different types of pumps that may be used
with
the hydraulic pumping system 10 and method of FIG. 1, and so the scope of this
disclosure is not limited to any of the details of the downhole pump described
herein or depicted in the drawings.
The wellbore 28 is depicted in FIG. 1 as being generally vertical, and as
being lined with casing 32 and cement 34. In other examples, a section of the
wellbore 28 in which the pump 20 is disposed may be generally horizontal or
otherwise inclined at any angle relative to vertical, and the wellbore section
may
not be cased or may not be cemented. Thus, the scope of this disclosure is not
limited to use of the hydraulic pumping system 10 and method with any
particular
wellbore configuration.
In the FIG. 1 example, the fluid 26 originates from an earth formation 36
penetrated by the wellbore 28. The fluid 26 flows into the wellbore 28 via
perforations 38 extending through the casing 32 and cement 34. The fluid 26
can
be a liquid, such as oil, gas condensate, water, etc. However, the scope of
this
disclosure is not limited to use of the hydraulic pumping system 10 and method
with any particular type of fluid, or to any particular origin of the fluid.
As depicted in FIG. 1, the casing 32 and the production tubing string 30
extend upward to the wellhead '16 at or near the earth's surface 40 (such as,
at a
land-based wellsite, a subsea production facility, a floating rig, etc.). The
production tubing string 30 can be hung off in the wellhead 16, for example,
using a tubing hanger (not shown). Although only a single string of the casing
32
is illustrated in FIG. 1 for clarity, in practice multiple casing strings and
optionally
one or more liner (a liner string being a pipe that extends from a selected
depth
CA 02936221 2016-07-15
in the wellbore 28 to a shallower depth, typically sealingly "hung off" inside
another pipe or casing) strings may be installed in the well.
In the FIG. 1 example, a rod blowout preventer stack 42 and an annular
seal housing 44 are connected between the hydraulic actuator 14 and the
wellhead 16. The rod blowout preventer stack 42 includes various types of
blowout preventers (BOP's) configured for use with the rod string 18. For
example, one blowout preventer can prevent flow through the blowout preventer
stack 42 when the rod string 18 is not present therein, and another blowout
preventer can prevent flow through the blowout preventer stack 42 when the rod
string 18 is present therein. However, the scope of this disclosure is not
limited to
use of any particular type or configuration of blowout preventer stack with
the
hydraulic pumping system 10 and method of FIG. 1.
The annular seal housing 44 includes an annular seal (described more
fully below) about a piston rod of the hydraulic actuator 14. The piston rod
(also
described more fully below) connects to the rod string 18 below the annular
seal,
although in other examples a connection between the piston rod and the rod
string 18 may be otherwise positioned.
The hydraulic pressure source 12 may be connected directly to the
hydraulic actuator 14, or it may be positioned remotely from the hydraulic
actuator 14 and connected with, for example, suitable hydraulic hoses or
pipes.
Operation of the hydraulic pressure source 12 is controlled by a control
system
46.
The control system 46 may allow for manual or automatic operation of the
hydraulic pressure source 12, based on operator inputs and measurements
taken by various sensors. The control system 46 may be separate from, or
incorporated into, the hydraulic pressure source 12. In one example, at least
part
of the control system 46 could be remotely located or web-based, with two-way
5
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communication between the hydraulic pressure source 12 and the control system
46 being via, for example, satellite, wireless or wired transmission.
The control system 46 can include various components, such as a
programmable controller, input devices (e.g., a keyboard, a touchpad, a data
port, etc.), output devices (e.g., a monitor, a printer, a recorder, a data
port,
indicator lights, alert or alarm devices, etc.), a processor, software (e.g.,
an
automation program, customized programs or routines, etc.) or any other
components suitable for use in controlling operation of the hydraulic pressure
source 12. The scope of this disclosure is not limited to any particular type
or
configuration of a control system.
In operation of the hydraulic pumping system 10 of FIG. 1, the control
system 46 causes the hydraulic pressure source 12 to increase pressure applied
to the hydraulic actuator 14 (delivering a volume of hydraulic fluid into the
hydraulic actuator), in order to raise the rod string 18. Conversely, the
hydraulic
pressure source 12 receives a volume of hydraulic fluid from the hydraulic
actuator 14 (thereby decreasing pressure applied to the hydraulic actuator),
in
order to allow the rod string 18 to descend. Thus, by alternately increasing
and
decreasing pressure in the hydraulic actuator 14, the rod string 18 is
reciprocated, the down hole pump 20 is actuated and the fluid 26 is pumped out
of the well.
Note that, when pressure in the hydraulic actuator 14 is decreased to
allow the rod string 18 to displace downward (as viewed in FIG. 1), the
pressure
is not decreased to zero gauge pressure (e.g., atmospheric pressure). Instead,
a
"balance" pressure is maintained in the hydraulic actuator 14 to nominally
offset a
load due to the rod string 18 being suspended in the well (e.g., a weight of
the
rod string, taking account of buoyancy, inclination of the wellbore 28,
friction, well
pressure, etc.).
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In this manner, the hydraulic pressure source 12 is not required to
increase pressure in the hydraulic actuator 14 from zero to that necessary to
displace the rod string 18 upwardly (along with the displaced fluid 26), and
then
reduce the pressure back to zero, for each reciprocation of the rod string 18.
Instead, the hydraulic pressure source 12 only has to increase pressure in the
hydraulic actuator 14 sufficiently greater than the balance pressure to
displace
the rod string 18 to its upper stroke extent, and then reduce the pressure in
the
hydraulic actuator 14 back to the balance pressure to allow the rod string 18
to
displace back to its lower stroke extent.
Note that it is not necessary for the balance pressure in the hydraulic
actuator 14 to exactly offset the load exerted by the rod string 18. In some
examples, it may be advantageous for the balance pressure to be somewhat less
than that needed to offset the load exerted by the rod string 18. In addition,
it can
be advantageous in some examples for the balance pressure to change over
time. Thus, the scope of this disclosure is not limited to use of any
particular or
fixed balance pressure, or to any particular relationship between the balance
pressure, any other force or pressure and/or time.
A reciprocation speed of the rod string 18 will affect a flow rate of the
fluid
26. Generally speaking, the faster the reciprocation speed at a given length
of
stroke of the rod string 18, the greater the flow rate of the fluid 26 from
the well
(to a point).
It can be advantageous to control the reciprocation speed, instead of
reciprocating the rod string 18 as fast as possible. For example, a fluid
interface
48 in the wellbore 28 can be affected by the flow rate of the fluid 26 from
the well.
The fluid interface 48 could be an interface between oil and water, gas and
water, gas and gas condensate, gas and oil, steam and water, or any other
fluids
or combination of fluids.
7
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If the flow rate is too great, the fluid interface 48 may descend in the
wellbore 28, so that eventually the pump 20 will no longer be able to pump the
fluid 26 (a condition known to those skilled in the art as "pump-off"). On the
other
hand, it is typically desirable for the flow rate of the fluid 26 to be at a
maximum
level that does not result in pump-off. In addition, a desired flow rate of
the fluid
26 may change over time (for example, due to depletion of a reservoir, changed
offset well conditions, water or steam flooding characteristics, etc.).
A "gas-locked' downhole pump 20 can result from a pump-off condition,
whereby gas is received into the downhole pump 20. The gas is alternately
expanded and compressed in the downhole pump 20 as the traveling valve 24
reciprocates, but the fluid 26 cannot flow into the downhole pump 20, due to
the
gas therein.
In the FIG. 1 hydraulic pumping system 10 and method, the control
system 46 can automatically control operation of the hydraulic pressure source
is .. 12 to regulate the reciprocation speed, so that pump-off is avoided,
while
achieving any of various desirable objectives. Those objectives may include
maximum flow rate of the fluid 26, optimized rate of electrical power
consumption, reduction of peak electrical loading, etc. However, it should be
clearly understood that the scope of this disclosure is not limited to
pursuing or
achieving any particular objective or combination of objectives via automatic
reciprocation speed regulation by the control system 46.
As mentioned above, the hydraulic pressure source 12 controls pressure
in the hydraulic actuator 14, so that the rod string 18 is displaced
alternately to its
upper and lower stroke extents. These extents do not necessarily correspond to
.. maximum possible upper and lower displacement limits of the rod string 18
or the
pump 20.
8
CA 02936221 2016-07-15
For example, it is typically undesirable for a valve rod bushing 25 above
the traveling valve 24 to impact a valve rod guide 23 above the standing valve
22
when the rod string 18 displaces downwardly (a condition known to those
skilled
in the art as "pump-pound"). Thus, it is preferred that the rod string 18 be
displaced downwardly only until the valve rod bushing 25 is near its maximum
possible lower displacement limit, so that it does not impact the valve rod
guide
23.
On the other hand, the longer the stroke distance (without impact), the
greater the productivity and efficiency of the pumping operation (within
practical
limits), and the greater the compression of fluid between the standing and
traveling valves 22, 24 (e.g., to avoid gas-lock). In addition, a desired
stroke of
the rod string 18 may change over time (for example, due to gradual
lengthening
of the rod string 18 as a result of lowering of a liquid level (such as at
fluid
interface 48) in the well, etc.).
In the FIG. 1 hydraulic pumping system 10 and method, the control
system 46 can automatically control operation of the hydraulic pressure source
12 to regulate the upper and lower stroke extents of the rod string 18, so
that
pump-pound is avoided, while achieving any of various desirable objectives.
Those objectives may include maximizing rod string stroke length, maximizing
production, minimizing electrical power consumption rate, minimizing peak
electrical loading, etc. However, it should be clearly understood that the
scope of
this disclosure is not limited to pursuing or achieving any particular
objective or
combination of objectives via automatic stroke extent regulation by the
control
system 46.
Referring additionally now to FIG. 2, an enlarged scale cross-sectional
view of an example of the hydraulic actuator 14 as used in the hydraulic
pumping
system 10 is representatively illustrated. Note that the hydraulic actuator 14
of
9
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FIG. 2 may be used with other systems and methods, in keeping with the
principles of this disclosure.
As depicted in FIG. 2, the hydraulic actuator 14 includes a generally
tubular cylinder 50, a piston 52 sealingly and reciprocably disposed in the
cylinder 50, and a piston rod 54 connected to the piston 52. The piston 52 and
piston rod 54 displace relative to the cylinder 50 in response to a pressure
differential applied across the piston 52.
Hydraulic fluid and pressure are communicated between the hydraulic
pressure source 12 and an annular chamber 56 in the cylinder 50 below the
piston 52 via a port 58. A vent valve 60 is connected via a tubing 62 to an
upper
chamber 64 above the piston 52. The upper chamber 64 is maintained at
substantially atmospheric pressure (zero gauge pressure), and pressure in the
annular chamber 56 is controlled by the hydraulic pressure source 12, in order
to
control displacement of the piston 52 and piston rod 54 (and the rod string 18
connected thereto).
Note that, in this example, an annular seal assembly 66 is sealingly
received in a lower flange 68 of the hydraulic actuator 14. The annular seal
assembly 66 also sealingly engages an outer surface of the piston rod 54.
Thus,
a lower end of the annular chamber 56 is sealed off by the annular seal
assembly
66.
In FIG. 2, the piston 52 is at a maximum possible upper limit of
displacement. However, during a pumping operation, the piston 52 may not be
displaced to this maximum possible upper limit of displacement. For example,
as
discussed above, an upper stroke extent of the rod string 18 may be regulated
to
achieve various objectives.
CA 02936221 2016-07-15
Similarly, during a pumping operation, the piston 52 also may not be
displaced to a maximum possible lower limit of displacement. As described more
fully below, upper and lower extents of displacement of the piston 52 and rod
54
can be varied to produce corresponding changes in the upper and lower stroke
extents of the rod string 18, in order to achieve various objectives (such as,
preventing pump-off, preventing pump-pound, optimizing pumping efficiency,
reducing peak electrical loading, etc.).
Referring additionally now to FIG. 3, a further enlarged scale cross-
sectional view of an upper portion of the hydraulic actuator 14 is
representatively
illustrated. This view is rotated somewhat about a vertical axis of the
hydraulic
actuator 14 (as compared to FIG. 2), so that a sensor 70, for example, a
magnetic field sensor, is visible in FIG. 3.
The sensor 70 is secured to an outer surface of the cylinder 50 (for
example, using a band clamp). In other examples, the sensor 70 could be
bonded, threaded or otherwise attached to the cylinder 50, or could be
incorporated into the cylinder or another component of the hydraulic actuator
14.
In some examples, a position of the sensor 70 relative to the cylinder 50
can be adjustable. The sensor 70 could be movable longitudinally along the
cylinder 50, for example, via a threaded rod or another type of linear
actuator.
A suitable magnetic field sensor is a Pepperl MB-F32-A2 magnetic flux
sensing switch marketed by Pepperl+Fuchs North America of Twinsburg, Ohio
USA. However, other magnetic field sensors may be used in keeping with the
principles of this disclosure.
The sensor 70 (when a magnetic field sensor is used) is capable of
sensing a presence of a magnet 72 through a wall 74 of the cylinder 50. The
magnet 72 is secured to, and displaces with, the piston 52. In some examples,
11
CA 02936221 2016-07-15
the sensor 70 can sense the presence of the magnet 72, even though the wall 74
comprises a ferromagnetic material (such as steel), and even though the wall
is
relatively thick (such as, approximately 1.27 cm or greater thickness).
A suitable magnet for use in the actuator 14 is a neodymium magnet (such
as, a neodymium-iron-boron magnet) in ring form. However, other types and
shapes of magnets may be used in keeping with the principles of this
disclosure.
Although only one sensor 70 is visible in FIG. 3, it is contemplated that
any number of sensors could be used with the hydraulic actuator 14. The
sensors 70 could be distributed in a variety of different manners along the
cylinder 50 (e.g., linearly, helically, evenly spaced, unevenly spaced, etc.).
In the FIG. 3 example, an output of the sensor 70 is communicated to the
control system 46, .so that a position of the piston 52 at any given point in
the
pumping operation is determinable. As the number of sensors 70 is increased,
determination of the position of the piston 52 at any given point in the
pumping
operation can become more accurate.
For example, two of the sensors 70 could be positioned on the cylinder 50,
with one sensor at a position corresponding to an upper stroke extent of the
piston 52 and magnet 72, and the other sensor at a position corresponding to a
lower stroke extent of the piston and magnet. When a sensor 70 detects that
the
piston 52 and magnet 72 have displaced to the corresponding stroke extent (by
sensing the proximate presence of the magnet 72), the control system 46
appropriately reverses the stroke direction of the piston 52 by operation of
hydraulic components to be described further below. In this example, the upper
and lower stroke extents of the piston 52 can be conveniently varied by
adjusting
the longitudinal positions of the sensors 70 on the cylinder 50.
12
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Referring additionally now to FIG. 4, a cross-sectional view of a lower
portion of the hydraulic actuator 14, the annular seal housing 44 and an upper
flange of the BOP stack 42 is representatively illustrated. In this view, a
threaded
connection 76 between the piston rod 54 and the rod string 18 can be seen in
the
annular seal housing 44 below an annular seal assembly 78.
The annular seal assembly 78 seals off an annular space between the
exterior surface of the piston rod 54 and an interior surface of the annular
seal
housing 44. The annular seal assembly 78 is similar in some respects to the
annular seal assembly 66 in the hydraulic actuator 14, but the annular seal
assembly 78 shown in FIG, 4 is exposed to pressure in the well (when the rod
BOP's are not actuated), whereas the annular seal assembly (66 in FIG. 3) is
exposed to pressure in the annular chamber (56 in FIG. 3) of the hydraulic
actuator 14.
A lubricant injector 80 slowly pumps grease or another lubricant 86 into an
annular chamber 82 formed in the lower flange 68 of the hydraulic actuator 14
and an upper flange 84 of the annular seal housing 44. The lubricant 86 flows
out
of the annular chamber 82 to a reservoir 88. In one example, the lubricant 86
could be sourced from the hydraulic fluid in the annular chamber (56 in FIG.
3) or
the hydraulic pressure source (12 in FIG. 1).
An advantage of having the lubricant 86 flow through the annular chamber
82 is that, if well fluid leaks past the annular seal assembly 78, or if
hydraulic fluid
leaks past the annular seal assembly (66 in FIG. 3), it will be apparent in
the
lubricant delivered to the reservoir 88. However, it is not necessary for the
lubricant injector 80 to deliver pressurized lubricant 86 into the annular
chamber
82 in keeping with the scope of this disclosure. For example, the lubricant 86
could instead be delivered from an unpressurized reservoir by gravity flow,
etc.
13
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An advantage of having the annular seal assemblies 66, 78 in the flanges
68, 84 is that they are both accessible by separating the flanges 68, 84 (for
example, when the, hydraulic actuator 14 is removed from the annular seal
housing 44 for periodic maintenance). However, it should be clearly understood
that the scope of this disclosure is not limited to pursuing or achieving any
particular advantage, objective or combination of objectives by the hydraulic
pumping system 10, hydraulic actuator 14, hydraulic pressure source 12 or
annular seal housing 44.
Referring additionally now to FIG. 5, a top view of an example of the
hydraulic pressure source 12 is representatively illustrated. In this view, a
top
cover of the hydraulic pressure source 12 is not illustrated, so that internal
components of the hydraulic pressure source 12 are visible.
In the FIG. 5 example, the hydraulic pressure source 12 includes a prime
mover 90, a primary hydraulic pump 92, an accessory hydraulic pump 94, a
hydraulic fluid reservoir 96, a hydraulic fluid heat radiator 98 with fan 100,
a
nitrogen concentrator assembly 102, and a gas balancing assembly 104. The
control system 46 is included with the hydraulic pressure source 12 in this
example.
The prime mover 90 can be a fixed or variable speed electric motor (or
any other suitable type of motor or engine). Preferably, the control system 46
controls operation of the prime mover 90 in an efficient manner that minimizes
a
cost of supplying electricity or fuel to the prime mover 90. This efficient
manner
may vary, depending on, for example, how a local electric utility company
charges for electrical service (e.g., by peak load or by kilowatt hours used).
Instead of an electric motor, the prime mover 90 could in other examples be an
internal combustion engine, a turbine or positive displacement motor rotated
by
14
CA 02936221 2016-07-15
flow of gas from the well, or any other type of engine or motor. The type of
prime
mover is not in any way intended to limit the scope of this disclosure.
The primary hydraulic pump 92 is driven by the prime mover 90 and
supplies hydraulic fluid 106 under pressure from the gas balancing assembly
104
to the hydraulic actuator 14, in order to raise the piston 52 (and piston rod
54 and
rod string 18). A filter 108 filters the hydraulic fluid 106 that flows from
the
hydraulic actuator 14 to the primary hydraulic pump 92 (flow from the pump to
the actuator bypasses the filter).
When the piston 52 (and piston rod 54 and rod string 18) descends, the
hydraulic fluid 106 flows back through the primary hydraulic pump 92 to the
gas
balancing assembly 104. In some examples, this "reverse" flow of the hydraulic
fluid 106 can cause a rotor in the prime mover 90 to rotate "backward" and
thereby generate electrical power. In such examples, this generated electrical
power may be used to offset a portion of the electrical-power consumed by the
prime mover 90, in order to reduce the cost of supplying electricity to the
prime
mover. However, the scope of this disclosure is not limited to generation of
electrical power by reverse flow of the hydraulic fluid 106 through the
primary
hydraulic pump 92.
The accessory hydraulic pump 94 can be used to initially charge the gas
balancing assembly 104 with the hydraulic fluid 106 and circulate the
hydraulic
fluid 106 through the radiator 98. The nitrogen concentrator assembly 102 is
used to produce pressurized and concentrated nitrogen gas by removal of
oxygen from air (that is, non-cryogenically). In other examples, cryogenic
nitrogen or another inert gas source could be used instead of, or in addition
to,
the nitrogen concentrator assembly 102.
The nitrogen concentrator assembly 102 pressurizes the gas balancing
assembly 104 and thereby causes the balance pressure discussed above to be
I 5
CA 02936221 2016-07-15
applied to the hydraulic actuator 14. The balance pressure can be varied by
control of the nitrogen concentrator assembly 102 by the control system 46. As
described more fully below, the control system 46 controls operation of the
nitrogen concentrator assembly 102 in response to various operator inputs and
sensor measurements.
Referring additionally now to FIG. 6, a schematic view of an example of
the gas balancing assembly 104 is representatively illustrated with the
nitrogen
concentrator assembly 102. In this view, it may be seen that the gas balancing
assembly 104 includes one or more gas volumes 110 that receive pressurized
nitrogen from the nitrogen concentrator assembly 102. The nitrogen
concentrator
assembly 102 includes a membrane filter 112 and a compressor 114 in this
example.
A total volume of the gas volumes 110 can be varied, depending on well
conditions, anticipated pressures, a stroke length and piston area of the
piston
(52 in FIG. 3), etc. Although three gas volumes 110 are depicted in FIG. 6,
any
number of gas volumes may be used, as desired.
The gas balancing assembly 104 also includes an accumulator 116
connected to the gas volumes 110. Thus, in this example, an upper portion of
the
accumulator 116 has the pressurized nitrogen gas 118 therein. In other
examples, the gas volumes 110 could be combined with the accumulator 116.
A lower portion of the accumulator 116 has the hydraulic fluid 106 therein.
Thus, the accumulator 116 is of the type known to those skilled in the art as
a
"gas over liquid" accumulator. However, in this example, there is no barrier
(such
as, a bladder or piston) separating the nitrogen gas 118 from the hydraulic
fluid
106 in the accumulator 116. Thus, the hydraulic fluid 106 is in direct contact
with
the nitrogen gas 118 in the accumulator 116, and maintenance requirements for
16
the accumulator 115 are reduced or eliminated (due at least to the absence of
a
barrier between the nitrogen gas 118 and the hydraulic fluid 106).
A suitable hydraulic fluid for use in the accumulator 116 in direct contact
with the nitrogen gas 118 is a polyalkylene glycol (PAG) synthetic oil, such
as
SYNLUBE P12 marketed by American Chemical Technologies, Inc. of
Fowlerville, Michigan USA. However, other enhancements thereof and other
hydraulic fluids may be used without departing from the scope of this
disclosure.
The compressor 114 pressurizes the nitrogen gas 118, and this pressure
is applied to the hydraulic fluid 106 in the accumulator 116. A valve 120
(such as,
a pilot operated control valve) selectively permits and prevents flow of the
hydraulic fluid 106 between the accumulator 116 and the primary hydraulic pump
92. The valve 120 is open while the hydraulic pressure source 12 is being used
to reciprocate the rod string 18 (thereby allowing the hydraulic fluid 106 to
flow
back and forth between the accumulator 116 and the hydraulic actuator 14), and
is otherwise normally closed. The control system 46 can control operation of
the
valve 120.
One or more liquid level sensors 122 on the accumulator 116 detect
whether a level of the hydraulic fluid 106 is at upper or lower limits. The
hydraulic
fluid 106 level typically should not (although at times it may) rise above the
upper
limit when the piston (52 in FIG. 3) displaces to its lower stroke extent in
the
cylinder (50 in FIG. 3) and triggers a sensor (70 in FIG. 3), and the
hydraulic fluid
106 level typically should not (although at times it may) fall below the lower
limit
when the piston (52 in FIG. 3) rises to its upper stroke extent and triggers a
sensor (70 in FIG. 3).
A suitable liquid level sensor for use on the accumulator 116 is an electro-
optic level switch model no. ELS-1150XP marketed by Gems Sensors & Controls
CA 2936221 2018-09-27
CA 02936221 2016-07-15
=
of Plainville, Connecticut USA. However, other types of sensors may be used in
keeping with the scope of this disclosure.
The liquid level sensors 122 are connected to the control system 46,
which can increase the hydraulic fluid 106 level by operation of the accessory
hydraulic pump 94. Typically, a decrease in hydraulic fluid 106 level is
constantly
occurring via a lubrication case drain of the primary hydraulic pump 92 and
other
seals of the hydraulic pressure source 12 and hydraulic actuator 14, with this
hydraulic fluid 106 being directed back to the radiator 98 and hydraulic fluid
reservoir 96. Although two liquid level sensors 122 are depicted in FIG. 6,
any
number of liquid level sensors (or a single continuous sensor) may be used, as
may be desired.
Referring additionally now to FIG. 7, an example process and
instrumentation diagram for the hydraulic pressure source 12 is
representatively
illustrated. Various components of the hydraulic pressure source 12 are
indicated
in the diagram using the following symbols in the table below labeled
"Equipment."
Equipment
E-1 N2 Volume Bottle (110)
E-2 N2 Volume Bottle (110)
E-3 N2 Volume Bottle (110)
E-4 Accumulator (116)
E-5 Hydraulic Fluid Vessel
E-6 Prime Mover (90)
E-7 Primary Hydraulic Pump (92)
E-8 Accessory Hydraulic Pump (94)
E-9 Radiator (98)
E-10 Hydraulic Fluid Reservoir (96)
E-11 N2 Membrane Filter (112)
E-12 Air Particle Filter (1st stage)
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E-13 Air Particle Filter (2nd stage)
E-14 Air Carbon Filter
E-15 Air Compressor
E-16 N2 Booster Compressor (15:1) (114)
E-17 Hydraulic Fluid Filter
E-18 Fan
E-19 Air Cooler
Valves
V-1 Pilot Operated Control Valve V-1 (120)
V-2 Solenoid Valve (for actuation of V-1)
V-3 Charge Shunt Valve
V-4 Safety Relief Valve
V-5 Pressure Reducing Valve
1 5 V-6 Reverse Flow Check Valve
V-7 Reverse Flow Check Valve
I nstru mentation
1-1 Fluid Level Sensor for Hydraulic Fluid Reservoir E-10 (96)
1-2 Temperature Sensor for Hydraulic Fluid Reservoir E-10 (96)
1-3 N2 Pressure Sensor
1-4 Magnetic Field Sensor(s) (70) on Cylinder (50)
1-5 Control System (46)
1-6 Accumulator E-4 (116) High Fluid Level Sensor (122)
1-7 Accumulator E-4 (116) Low Fluid Level Sensor (122)
1-8 Temperature Sensor on Primary Pump E-7 (92) Outlet
1-9 Pressure Sensor on Primary Hydraulic Pump E-7 (92) Accumulator
Side (to
prevent cavitation)
1-10 Pressure Sensor on Primary Hydraulic Pump E-7 (92) Outlet (to
Cylinder 50)
Piping
P-1 Flow to/from Primary Hydraulic Pump E-7 (92) and Cylinder 50
P-2 Flow from Control Valve V-1 (120) to Primary Pump E-7 (92)
=
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P-3 Flow from Hydraulic Fluid Vessel E-5 to Control Valve V-1 (120)
P-4 Flow from Accumulator E-4 (116) to Hydraulic Vessel E-5
= P-5 Flow to/from N2 Volume Bottle E-3 (110) and Accumulator
E-4(116)
P-6 Flow to/from N2 Volume Bottles E-2,3 (110)
P-7 Flow to/from N2 Volume Bottles E-1,2 (110)
P-8 N2 Flow from Compressor E-16 to N2 Volume Bottle E-1 (110)
P-9 Flow from Air Cooler E-19 to Air Particle Filter E-12
P-10 Flow from Air Compressor E-15 to Air Cooler E-19
P-11 Flow from Air Particle Filters E-12,13 to Air Carbon Filter E-
14
P-12 Flow from Air Carbon Filter E-14 to N2 Membrane Filter E-11 (112)
P-13 Flow from N2 Membrane Filter E-11 (112) to N2 Booster
Compressor E-16
P-14 Flow from Accessory Hydraulic Pump E-8 (94) to Valve Manifold V-
2/3/4
P-15 Flow from Valve V-2 to actuate Control Valve V-1 (120)
P-16 Flow from Primary Hydraulic Pump E-7 (92) case drain and
controls to Radiator
E-9 (98)
P-17 Flow from Valve Manifold V-2/3/4 to Radiator E-9 (98)
P-18 Flow from Cylinder Vent Valve (60) to Reservoir E-10 (96)
P-19 Flow from Air Compressor E-15 to N2 Booster Compressor E-16
P-20 Flow From Radiator E-9 (98) to Hydraulic Fluid Reservoir E-10
(96)
Note that the scope of this disclosure is not limited to any specific details
of the hydraulic pressure source 12, or any of the components thereof, as
described herein or depicted in the drawings. For example, although the
nitrogen
booster compressor E-16 is listed above as having a 15:1 ratio, other types of
compressors may be used if desired.
In a normal start-up operation, the hydraulic pressure source 12 is
powered on, and certain parameters are input to the control system 46 (for
example, via a touch screen, keypad, data port, etc.). These parameters can
include characteristics of the hydraulic actuator 14 (such as, piston 52 area
and
maximum stroke length), characteristics of the well (such as, expected minimum
CA 02936221 2016-07-15
and maximum rod string 18 loads, expected well pressure, initial fluid 26 flow
rate, etc.), or any other parameters or combination of parameters. Some
parameters may already be input to the control system 46 (such as, stored in
non-volatile memory), for example, characteristics of the hydraulic pressure
source 12 and hydraulic actuator 14 that are not expected to change, or
default
parameters.
At this point, the piston rod 54 is already connected to the rod string 18,
and the hydraulic actuator 14 is installed on the wellhead 16 above the rod
BOP
stack 42 and the annular seal housing 44. The control valve 120 is closed,
thereby preventing communication between the gas balancing assembly 104 and
the primary pump 92.
The volumes 110 and accumulator 116 may be purged with nitrogen and
optionally pre-charged with pressure prior to the start-up operation.
Similarly,
lines and volumes in the hydraulic pressure source 12 and the hydraulic
actuator
14, and lines between the hydraulic pressure source 12 and the hydraulic
actuator 14, may be purged with hydraulic fluid 106 prior to (or as part of)
the
start-up operation.
The control system 46 determines a minimum volume of the hydraulic fluid
106 that will be needed for reciprocating the piston 52 in the cylinder 50.
Alternatively, a default volume of the hydraulic fluid 106 (which volume is
appropriate for the actuator 14 characteristics) may be used.
An appropriate volume of the hydraulic fluid 106 (which volume is
preferably greater than the minimum needed) is flowed by operation of the
accessory pump 94 from the hydraulic fluid reservoir 96 to fill the hydraulic
fluid
vessel (E-5 in the Equipment Table) and a lower portion of the accumulator
116.
The level sensors 122 are used with the control system 46 to verify that an
appropriate level of the hydraulic fluid 106 is present in the accumulator
116.
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The control system 46 determines an appropriate balance pressure that
should be applied, based on, for example, the input parameters. Nominally, the
balance pressure can be equal to the expected minimum load exerted by the rod
string 18 in operation, divided by the piston area of the piston 52. However,
as
mentioned above, it may in some circumstances be advantageous to increase or
decrease the balance pressure somewhat.
The air compressor (E-15 in the Equipment Table) is activated to supply a
flow of pressurized air through the cooler (E-19 in the Equipment Table) and
the
air filters (E-12, E-13, E-14 in the Equipment Table) to the membrane filter
112.
The membrane filter 112 provides a flow of concentrated nitrogen 118 (e.g., by
removal of substantially all oxygen from the air) to the booster compressor
114.
Note that pressurized air is also supplied to the booster compressor 114 from
the
compressor E-15 for operation of the booster compressor.
The nitrogen 118 flows from the booster compressor 114 into the volumes
110 and an upper portion of the accumulator 116. The booster compressor 114
elevates a pressure of this nitrogen 118 to the desired balance pressure.
The pressure sensor 1-3 monitors the pressure in the gas balancing
assembly 104. By virtue of the hydraulic fluid 106 being in contact with the
nitrogen 118 in the accumulator 116, the nitrogen pressure is the same as the
hydraulic fluid pressure.
Note that each of the sensors (1-1, 1-2,1-3, 1-4, 1-6, 1-7, 1-8, 1-9,1-10 in
the
Equipment Table) is connected to the control system 46, so that the control
system 46 is capable of monitoring parameters sensed by the sensors.
Adjustments to the input parameters can be made by the control system 46 in
response to measurements made by the sensors if needed to maintain a desired
condition (such as, efficient and economical operation), or to mitigate an
undesired condition (such as, pump-off or pump-pound). Such adjustments may
22
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be made manually (for example, based on user input), or automatically (for
example, based on instructions or programs stored in the control system 46
memory), or a combination of manually and automatically (for example, using a
program that initiates automatic control in response to a manual input).
The piston 52, piston rod 54 and rod string 18 can now be raised by
opening the control valve 120 and operating the primary hydraulic pump 92.
When the control valve 120 is opened, the balance pressure is applied to the
annular chamber 56 below the piston 52 (see FIG. 2). Depending on the selected
level of the balance pressure, the balance pressure applied to the annular
chamber 56 will typically not cause the piston 52 and attached rod string 18
to
displace upward, but some upward displacement of the rod string 18 may be
desired in some circumstances.
The primary hydraulic pump 92 flows pressurized hydraulic fluid 106 from
the accumulator 116 and hydraulic fluid vessel E-5 to the annular chamber 56
of
the hydraulic actuator 14, and increases the hydraulic fluid pressure therein,
thereby causing the piston 52 and attached rod string 18 to rise in the
wellbore
16 and operate the downhole pump 20 (see FIG. 1). A hydraulic fluid pressure
increase (greater than the balance pressure) needed to displace the piston 52
upwardly to its upper stroke extent is dependent on various factors (such as,
rod
string 18 weight, friction in the well and in the hydraulic actuator 14,
piston 52
area, well fluid 26 density, depth to the downhole pump 20, etc.).
Nevertheless, the control system 46 can operate the primary hydraulic
pump 92, so that the hydraulic fluid 106 flows into the annular chamber 56
until
the piston 52 is displaced to its upper stroke extent. Such displacement of
the
piston 52 is indicated to the control system 46 by the sensor(s) 70 of the
hydraulic actuator 14. Note that the control system 46 can operate the primary
hydraulic pump 92 in a manner that avoids an abrupt halt of the piston 52
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displacement at the upper stroke extent (e.g., by reducing a flow rate of the
hydraulic fluid 106 as the piston 52 approaches the upper stroke extent).
The piston 52, piston rod 54 and rod string 18 can then be lowered by
ceasing operation of the primary pump 92, and allowing the hydraulic fluid 106
to
flow from the annular chamber 56 back through the primary hydraulic pump to
the hydraulic fluid vessel E-5 and the accumulator 116. Pressure in the
annular
chamber 56 below the piston 52 will, thus, return to the balance pressure and
the
load exerted by the rod string 18 will cause the piston 52 and piston rod 54
to
descend in the cylinder 50.
Depending on the level of the balance pressure at this point, the piston 52
may not return to its initial, lowermost position. Instead, the piston 52
typically will
descend to a lower stroke extent that avoids pump-pound (e.g., bottoming out
of
the valve rod bushing 25 against the valve rod guide 23), while providing for
efficient and economical operation. As the piston 52 descends in the cylinder
50
and the hydraulic fluid 106 flows from the annular chamber 56 to the hydraulic
fluid vessel E-5 and accumulator 116, the control system 46 can operate a
variable displacement swash plate (not shown separately) in the primary
hydraulic pump 92 in a manner that avoids an abrupt halt of the piston 52
displacement at the lower stroke extent (e.g., by reducing a flow rate of the
hydraulic fluid as the piston 52 approaches the lower stroke extent).
The "reverse' flow of the hydraulic fluid 106 through the primary hydraulic
pump 92 could, in some examples, cause the primary hydraulic pump 92 to
rotate backward and thereby cause the prime mover 90 (when an electric motor
is used) to generate electrical power. Thus, the prime mover 90 can serve as a
motor when the hydraulic fluid 106 is pumped to the hydraulic actuator 14, and
a
generator when the hydraulic fluid is returned to the hydraulic pressure
source
12. The generated.electrical power may be stored (for example, using
batteries,
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CA 02936221 2016-07-15
capacitors, etc.) for use by the hydraulic pressure source 12, or the
electrical
power may be supplied to the local electrical utility (for example, to offset
the cost
of electrical power supplied to the hydraulic pumping system 10, such as, in
situations where the cost is based on demand and/or total usage).
The above-described actions of raising and lowering the piston 52, piston
rod 54 and rod string 18 can be repeated indefinitely, in order to reciprocate
the
rod string 18 in the well and operate the downhole pump 20 to flow the well
fluid
26 to the surface. However, it should be understood that variations in
operation
of the hydraulic pressure source 12 and the hydraulic actuator 14 are to be
expected as the pumping operation progresses.
For example, assumptions or estimates may have been made to arrive at
certain parameters initially input to the control system 46. After an initial
stroking
of the hydraulic actuator 14, adjustments may be made automatically or
manually
(or both) via the control system 46 to account for actual conditions. Such
adjustments could include varying the balance pressure, the piston 52 upper or
lower stroke extents, the number of piston 52 strokes per minute (spm), etc.
At any point in the pumping operation, actuation of the hydraulic actuator
14 can be stopped, so that displacement of the piston 52 ceases, and a
pressure
level in the annular chamber 56 (e.g., sensed using the pressure sensor 1-10)
needed to support the load exerted by the rod string 18 can be measured. The
pressure in the accumulator 116 can then be adjusted, if needed, to provide an
appropriate balance.
The booster compressor 114 can be automatically operated by the control
system 46 to increase the balance pressure when appropriate. For example,
based on measurements of the pressure applied to the hydraulic actuator 14
over time (sensed by the pressure sensor 1-10), it may be determined that
efficiency or economy of operation (or work performed, as described more fully
CA 02936221 2016-07-15
below) would be enhanced by increasing the balance pressure. In such
circumstances, the control system 46 can operate the booster compressor 114 to
increase the pressure on the accumulator 116 until a desired, increased
hydraulic balance pressure is achieved (e.g., as sensed by the pressure sensor
l-
3).
If a pump-off condition is detected during the pumping operation, a
reciprocation speed can be adjusted to avoid this condition. For example, the
control system 46 can regulate the hydraulic fluid 106 flow rate (e.g., by
varying
an operational characteristic of the primary hydraulic pump 92 (such as, by
adjusting a swash plate of the primary hydraulic pump 92), varying a
rotational
speed of the prime mover 90, varying a restriction to flow through the control
valve 120, etc.) to decrease a speed of ascent or descent (or both) of the
piston
52 in the cylinder 50 if pump-off is detected. Alternatively (or in addition),
a stroke
length of the piston 52 could be decreased to cause a decrease in the flow
rate
of the fluid 26 from the well.
If a pump-pound condition is detected during the pumping operation, the
lower stroke extent of the piston 52 can be raised, for example, to avoid
contact
between the valve rod bushing 25 and the valve rod guide 23 in the downhole
pump 20. The lower stroke extent can be raised by decreasing the volume of
hydraulic fluid 106 returned to the hydraulic pressure source 12 from the
hydraulic actuator 14 (e.g., by the control system 46 beginning to change
displacement of a swash plate of the primary hydraulic pump 92 and thereby
terminate reverse flow when the piston 52 has descended to the raised lower
stroke extent). If the detected pump-pound is due to contacting another
component of the downhole pump 20 on an upward stroke, the upper stroke
extent of the piston 52 can be lowered by decreasing the volume of hydraulic
fluid 106 pumped into the hydraulic actuator 14 (e.g., by the control system
46
26
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ceasing operation of the primary hydraulic pump 92 when the piston 52 has
ascended to the lowered upper stroke extent).
The balance pressure can be increased at any point in the pumping
operation by the control system 46 operating the nitrogen concentrator
assembly
102 and the booster compressor 114. The balance pressure can be decreased at
any point in the operation by discharging an appropriate volume of the
nitrogen
118 in the accumulator 116 and/or the nitrogen volumes 110 to the atmosphere.
The valve manifold V-2N-3N-4 can comprise a two position manifold
(such as, a National Fluid Power Association (NFPA) D05 manifold marketed by
Daman Products Company, Inc. of Mishawaka, Indiana USA) with two position
spring return solenoid valves. In one example, a solenoid valve V-2 of the
manifold activates V-1 (control valve 120) upon V-2 being energized, and for
as
long as V-2 remains energized it holds the V-1 control valve (120) open. A
sandwich relief valve (such as, an NFPA D05 20 MPa over-pressure safety relief
valve marketed by Parker Hannifin Corporation of Cleveland, Ohio USA) can be
used with the V-2 valve. Another sandwich relief valve V-4 (such as,
adjustable 1
MPa to 7 MPa, set to 2 MPa) of the manifold can function as a charge circuit
back-pressure/relief valve placed under a solenoid valve V-3.
Energizing the V-3 solenoid valve of the manifold closes off a 2 MPa relief
flow to the radiator 98 (and back to the hydraulic fluid reservoir 96) to
cause
pressure from the accessory hydraulic pump 94 to rise to the balance pressure
and inject a volume of hydraulic fluid 106 into, P-3 (for example, to make up
losses from the pressurized gas balancing assembly 104, primary hydraulic
pump 92 and cylinder 50 circuit), until the level sensor 1-6 indicates that
sufficient
hydraulic fluid is present in the accumulator 116. When V-3 de-energizes, the
accessory hydraulic pump 94 output pressure (in P-14) returns to the 2 MPa
27
=
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=
relief valve setting. Of course, other settings and other types of valve
manifolds
may be used, without departing from the scope of this disclosure.
As mentioned above, certain adjustments may be made if a pump-pound
condition is detected. In the FIG. 7 example, a pump-pound condition can be
detected by monitoring pressure of the hydraulic fluid 106 as sensed using the
sensor 1-10.
The pump-pound condition will be apparent from fluctuations in pressure
sensed by the sensor 1-10. For example, when the valve rod bushing 25 strikes
the valve rod guide 23 of the downhole pump 20, this will cause an abrupt
change in the rod string 18 displacement and the load exerted by the rod
string,
resulting in a corresponding abrupt change in the piston rod 54 and piston 52
displacement. Such abrupt displacement and load changes will, in turn, produce
corresponding pressure changes in the hydraulic fluid 106 flowing from the
hydraulic actuator 14 to the hydraulic pressure source 12.
The control system 46 can be programmed to recognize hydraulic fluid
pressure fluctuations that are characteristic of a pump-pound condition. For
example, pressure fluctuations having a certain range of frequencies or
amplitudes (or both) could be characteristic of a pump-pound condition, and if
such frequencies or amplitudes are detected in the sensor 1-10 output, the
control
system 46 can cause certain actions to take place in response. The actions
could
include displaying an alert, sounding an alarm, recording an event record,
transmitting an indication of the pump-pound condition to a remote location,
initiating a routine to appropriately raise the lower stroke extent of the
piston 52,
etc.
An action that may be automatically implemented by the control system 46
to raise the lower stroke extent of the piston 52 can include incrementally
decreasing the volume of hydraulic fluid 106 returned to the hydraulic
pressure
28
CA 02936221 2016-07-15
source 12 from the hydraulic actuator 14 (e.g., by the control system 46
adjusting
the swash plate of the primary hydraulic pump 92 to terminate reverse flow
when
the piston 52 has descended to the raised lower stroke extent), until the pump-
pound condition is no longer detected. If pump-pound is detected on an upward
3 stroke of the piston 52, then a similar set of actions can be initiated
by the control
system 46 to appropriately lower the upper stroke extent of the piston (e.g.,
by
incrementally decreasing the volume of hydraulic fluid 106 pumped into the
hydraulic actuator 14 when the piston 52 is stroked upwardly, until the pump-
pound condition is no longer detected). As mentioned above, the upper and
.. lower stroke extents could, in some examples, be adjusted by changing
positions
of the sensors 70 on the cylinder 50.
Note that pressure fluctuations that are characteristic of a pump-pound
condition can change based on a variety of different factors, and the
characteristics of pressure fluctuations indicative of a pump-pound condition
are
not necessarily the same from one well to another. For example, a depth to the
downhole pump 20 could affect the amplitude of the pressure fluctuations, and
a
density of the fluid 26 could affect the frequency of the pressure
fluctuations.
Therefore, it may be advantageous during the start-up operation to
intentionally
produce a pump-pound condition, in order to enable detection of pressure
fluctuations that are characteristic of the pump-pound condition in that
particular
well, so that such Characteristics can be stored in the control system 46 for
use in
detecting pump-pound conditions in that particular well. Pressure fluctuations
are
considered to be a type of vibration of the hydraulic fluid 106.
However, it should be clearly understood that the scope of this disclosure
.. is not limited to use of pressure fluctuation measurements to detect a pump-
pound condition. Various other types of vibration measurements can be used to
indicate a pump-pound condition, and suitable sensors can be included in the
29
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=
system 10 to sense these other types of vibrations. For example, an acoustic
sensor, geophone or seismometer (e.g., a velocity sensor, motion sensor or
accelerometer) may be used to sense vibrations resulting from a pump-pound
condition. The sensor(s) 70 on the actuator 14 could include such sensors, or
separate sensors could be used for such purpose if desired.
As mentioned above, certain adjustments may be made if a pump-off
condition is detected. In the FIG. 7 example, a pump-pound condition can be
detected by monitoring over time the pressure of the hydraulic fluid 106 as
sensed using the sensor 1-10, and the displacement of the piston 52 as sensed
using the sensor(s) 70.
In operation, pressure of the hydraulic fluid 106 is directly related to the
load or force transmitted between the hydraulic actuator 14 and the rod string
18.
Force multiplied by displacement equals work. If a pump-off condition occurs,
the
total work performed during a reciprocation cycle will decrease due, for
example,
to gas intake to the pump 20 and/or to less fluid 26 being pumped to the
surface.
Thus, by monitoring the work performed during individual reciprocation
cycles over time, the control system 46 can detect whether a pump-off
condition
is occurring, and can make appropriate adjustments to mitigate the pump-off
condition (such as, by decreasing a reciprocation speed of the hydraulic
actuator
14, as discussed above). Such adjustments may be made automatically or
manually (or both). Other actions (for example, displaying an alert, sounding
an
alarm, recording an event record, transmitting an indication of the pump-off
condition to a remote location, etc.) may be performed by the control system
46
as an alternative to, or in addition to, the adjustments.
In FIGS. 8A & B, examples of load versus displacement graphs for the
system 10 are representatively illustrated. As mentioned above, in operation,
load or force transmitted between the hydraulic actuator 14 and the rod string
18
CA 02936221 2016-07-15
is directly related to hydraulic fluid pressure, and so the graphs could
instead be
drawn for pressure versus displacement, if desired. Thus, the scope of this
disclosure is not limited to any particular technique for determining work
performed by the hydraulic actuator 14.
A reciprocation cycle for the hydraulic actuator 14 is depicted in FIG. 8A
without a pump-off condition. In the FIG. 8A graph, it may be observed that
the
force quickly increases as the hydraulic actuator 14 begins to raise the rod
string
18, and then the force substantially levels off as the fluid 26 flows from the
well
(although in practice the force can decrease somewhat due to fluid 26 inertia
effects and as less fluid is lifted near the end of the upward stroke). The
force
then quickly decreases as the hydraulic actuator 14 allows the rod string 18
to
descend in the well, and then the force substantially levels off until an end
of the
downward stroke.
The graph of FIG. 8A has a shape (e.g., generally parallelogram) that is
indicative of a reciprocation cycle with no pump-off condition. In actual
practice,
the idealized parallelogram shape of the FIG. 8A graph will not be exactly
produced, but the control system 46 can be programmed to recognize shapes
that are indicative of reciprocation cycles with no pump-off condition.
An area A1 of the FIG. 8A graph is representative of the total work
performed during this reciprocation cycle (e.g., including a summation of the
work
performed during the upward and downward strokes). The area A1 can be readily
calculated by the control system 46 for comparison to other areas of
reciprocation cycles, either prior to or after the FIG. 8A reciprocation
cycle.
By comparing the total work performed in different reciprocation cycles,
the control system 46 can determine whether and how the work performed has
changed. If the total work performed has changed, the control system 46 can
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CA 02936221 2016-07-15
make appropriate adjustments to certain parameters, in order to mitigate any
undesired conditions, or to enhance any desired conditions.
In FIG. 8B, the force versus displacement graph for another reciprocation
cycle is depicted, in which a pump-off condition is occurring. Note that an
area A2
of the FIG. 8B graph is less than the area A1 of the FIG. 8A graph. This
indicates
that less total work is performed in the FIG. 8B reciprocation cycle, as
compared
to the FIG. 8A reciprocation cycle.
If the FIG. 8B reciprocation cycle is after the FIG. 8A reciprocation cycle,
the control system 46 can recognize that less total work is being performed
over
time, and can make appropriate adjustments (such as, by reducing the
reciprocation speed). Such adjustments can be made incrementally, with
repeated comparisons of total work performed over time, so that the control
system 46 can verify whether the adjustments are accomplishing intended
results
(e.g., increased total work performed overtime, due to reduced pump-off).
If the FIG. 8A reciprocation cycle is after the FIG. 8B reciprocation cycle,
the control system 46 can recognize that more work is being performed over
time
and that, if incremental adjustments are being made, those incremental
adjustments should continue. However, the control system 46 can discontinue
the adjustments, for example, if other objectives (such as, operational
efficiency,
economy, etc.) would be reduced if the adjustments continue.
The FIG. 8B graph has a shape that is not indicative of a reciprocation
cycle in which a pump-off condition is not occurring. Stated differently, the
shape
of the FIG. 8B graph (for example, with a rounded upward slope, reduced
maximum force on the upward stroke and one or more reductions in force during
the upward stroke) is indicative of a pump-off condition. The control system
46
can be programmed to recognize such shapes, so that adjustments can be made
to mitigate the pump-off condition.
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Similar to the procedure described above for situations (where the control
system 46 recognizes a substantial change in total work performed), the
control
system can incrementally decrease the reciprocation speed if a pump-off
condition is detected, until the shape of the force (or pressure) versus
displacement graph for a reciprocation cycle does not indicate pump-off. If
force
(or pressure) versus displacement graphs initially do not indicate a pump-off
condition, the control system 46 can incrementally increase the reciprocation
speed (to thereby increase a rate of production), until the shape of the graph
for
a reciprocation cycle does begin to indicate pump-off, at which point the
control
system can incrementally decrease the reciprocation speed until the shape of
the
graph does not indicate pump-off. In this manner, production rate can be
maximized, without any sustained pump-off condition.
It will be readily appreciated that the graphs shown in FIGS. 8A and 8B
are visual illustrations of measured force or pressure with respect to
measured
displacement of the piston 52 and rod string 18. If automatic adjustment of
any
of the hydraulic actuator 14 operating parameters, e.g., reciprocation rate,
maximum stroke extent, etc. are implemented by the control system 46, actual
graphs may not be constructed or displayed; the control system 46 may detect
the numerical or other equivalent of the "shape" of a graph by implementing
suitable detection and control processes therein in response to measurements
from any one or more of the various sensors described above.
Referring additionally now to FIG. 9, another example of the hydraulic
pumping system 10 and associated method is representatively illustrated. The
system 10 and method of FIG. 9 are substantially the same as described above
for FIGS. 1-8B, but the actuator 14 is mounted to the wellhead 16, blowout
preventer stack 42 and annular seal housing 44 at a slant (that is, inclined
relative to vertical):
33
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The wellhead 16 itself is inclined relative to vertical, and so mounting of
the blowout preventer stack 42, annular seal housing 44 and actuator 14 to the
wellhead 16 causes the blowout preventer stack 42, annular seal housing 44 and
actuator 14 to be inclined relative to vertical. Thus, the wellhead 16,
blowout
preventer stack 42, annular seal housing 44 and actuator 14 are all at a
slant,
even though they are all axially aligned with each other.
One advantage of the actuator 14 construction in the FIG. 9 example is
that the actuator 14 is mounted directly to the annular seal housing 44 and
the
actuator is sufficiently light, strong and rigid that no additional
substructure (such
as, braces, supports, etc.) or guy wires are required to support the actuator.
The
connection between the lower flange 68 of the actuator 14 and the upper flange
84 of the annular seal housing 44 is capable of supporting the actuator 14,
without any additional substructure or guy wires, although in some examples
such substructure or guy wires may be desirable.
One benefit of the actuator 14 mounting of FIG. 9 is that, even though the
actuator is mounted on a slant, it remains in a very compact configuration
(without the additional substructure or guy wires), and so multiple wellheads
16
and actuators 14, etc., can be conveniently located on a single well pad. This
reduces the number of pads needed for a field and, thus, reduces the costs of
producing the field.
It may now be fully appreciated that the above description provides
significant advancements to the art of artificial lifting for subterranean
wells. In
various examples described above, pumping of a fluid from a well can be made
more efficient, convenient, economical and productive utilizing the hydraulic
pumping system 10 and associated methods. The actuator 14 can be
conveniently mounted on a slant, without additional supporting substructure or
guy wires in some examples.
34
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The above disclosure provides to the art a hydraulic pumping method for
use with a subterranean well. In one example, the method can comprise:
mounting a hydraulic actuator 14 above a wellhead 16, the hydraulic actuator
14
and the wellhead 16 being axially aligned with each other and inclined
relative to
vertical. The hydraulic actuator 14 is unsupported by any substructure or guy
wires after the mounting step.
The mounting step can include connecting a lower flange 68 of the
hydraulic actuator 14 to an upper flange 84 of an annular seal housing 44. The
connecting step supports the hydraulic actuator 14 during operation of the
hydraulic actuator, without the substructure or the guy wires.
The method can include displacing a rod string 18 in response to pressure
applied to the hydraulic actuator 14 by a hydraulic pressure source 12
connected
to the hydraulic actuator, the hydraulic pressure source 12 including an
accumulator 116; and automatically regulating pressure in the accumulator 116
in response to measurements of the pressure applied to the hydraulic actuator
14.
The automatically regulating step can comprise maintaining a maximum
level of the pressure in the accumulator 116 at substantially a minimum level
of
the pressure applied to the hydraulic actuator 14. A hydraulic fluid 106 may
be in
contact with a pressurized gas 118 in the accumulator 116. The accumulator 116
may receive nitrogen gas 118 from a nitrogen concentrator assembly 102 while a
hydraulic fluid 106 flows between the hydraulic pressure source 12 and the
hydraulic actuator 14.
The method can include delivering a pressurized lubricant 86 to a space
between first and second seal assemblies 66, 78. The first seal assembly 66
seals about a piston rod 54 of the hydraulic actuator 14 and is exposed to
pressure in the actuator, and the second seal assembly 78 seals about the
piston
CA 02936221 2016-07-15
rod 54 and is exposed to pressure in the well. The method can also include
disconnecting the hydraulic actuator 14 from an annular seal housing 44
containing the second seal assembly 78, thereby permitting access to the
second
seal assembly in the annular seal housing 44.
The method can include automatically varying a reciprocation speed of a
rod string 18 in response to a change in work performed during reciprocation
cycles of the rod string, automatically varying the reciprocation speed of the
rod
string 18 in response to a change in detected force versus displacement in
different reciprocation cycles of the rod string, and/or varying an extent of
reciprocation displacement of the rod string 18 in response to a sensed
vibration.
The vibration may be sensed by at least one of a pressure sensor, an acoustic
sensor, a geophone and a seismometer.
Also described above is a hydraulic pumping system 10 for use with a
subterranean well. In one example, the system 10 can comprise: a hydraulic
actuator 14 including a piston 52 that displaces in response to pressure in
the
actuator, a magnet 72 that displaces with the piston 52, and at least one
magnetic field sensor 70 that detects a presence of the magnet 72. The
hydraulic
actuator 14 may be mounted above a wellhead 16, with the hydraulic actuator 14
and the wellhead 16 being axially aligned with each other and inclined
relative to
vertical.
The hydraulic actuator 14 may be unsupported by any substructure or guy
wires. A lower flange 68 of the hydraulic actuator 14 may be connected to an
upper flange 84 of an annular seal housing 44, and the connected lower and
upper flanges 68, 84 may support the hydraulic actuator 14 during operation of
the hydraulic actuator, without the substructure or the guy wires.
A ferromagnetic wall 74 of the hydraulic actuator 14 may be positioned
between the magnet 72 and the magnetic field sensor 70. The ferromagnetic wall
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CA 02936221 2016-07-15
74 of the hydraulic actuator 14 can have a thickness of at least approximately
1.25 cm.
The system 10 can include a hydraulic pump 92 connected between the
hydraulic actuator 14 and an accumulator 116. The accumulator 116 may receive
nitrogen gas 118 from a nitrogen concentrator assembly 102 while a hydraulic
fluid 106 flows between the hydraulic pump 92 and the hydraulic actuator 14.
The
hydraulic fluid 106 may be in contact with pressurized gas 118 in the
accumulator
116. Pressure in the accumulator 116 may be automatically regulated in
response to measurements of pressure applied to the hydraulic actuator 14.
A reciprocation speed of the piston 52 can be automatically varied in
response to at least one of: a) a change in work performed during
reciprocation
cycles of the system 10 and b) a change in detected force versus displacement
in different reciprocation cycles of the system 10. An extent of reciprocation
displacement of the piston 52 may be automatically varied in response to a
measured vibration.
Although various examples have been described above, with each
example having certain features, it should be understood that it is not
necessary
for a particular feature of one example to be used exclusively with that
example.
Instead, any of the features described above and/or depicted in the drawings
can
be combined with any of the examples, in addition to or in substitution for
any of
the other features of those examples. One example's features are not mutually
exclusive to another example's feature& Instead, the scope of this disclosure
encompasses any combination of any of the features.
Although each example described above includes a certain combination of
features, it should be understood that it is not necessary for all features of
an
example to be used. Instead, any of the features described above can be used,
without any other particular feature or features also being used.
3"?
CA 02936221 2016-07-15
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It should be understood that the various embodiments described herein
may be utilized in various orientations, such as inclined, inverted,
horizontal,
vertical, etc., and in various configurations, without departing from the
principles
of this disclosure. The embodiments are described merely as examples of useful
applications of the principles of the disclosure, which is not limited to any
specific
details of these embodiments.
In the above description of the representative examples, directional terms
(such as "above," "below," "upper," "lower," etc.) are used for convenience in
referring to the accompanying drawings. However, it should be clearly
.. understood that the scope of this disclosure is not limited to any
particular
directions described herein.
The terms "including," "includes," "comprising," "comprises," and similar
terms are used in a non-limiting sense in this specification. For example, if
a
system, method, apparatus, device, etc., is described as "including" a certain
feature or element, the system, method, apparatus, device, etc., can include
that
feature or element, and can also include other features or elements.
Similarly,
the term "comprises" is considered to mean "comprises, but is not limited to."
Of course, a person skilled in the art would, upon a careful consideration
of the above description of representative embodiments of the disclosure,
readily
appreciate that many modifications, additions, substitutions, deletions, and
other
changes may be made to the specific embodiments, and such changes are
contemplated by the principles of this disclosure. For example, structures
disclosed as being separately formed can, in other examples, be integrally
formed and vice versa. Accordingly, the foregoing detailed description is to
be
clearly understood as being given by way of illustration and example only, the
spirit and scope of the invention being limited solely by the appended claims
and
their equivalents.
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