Gas Lift Type Casing Pump

1. Field of the Invention:

The invention relates to a gas lift type pump for oil and gas wells which utilizes relatively low gas pressures existing in a well conduit to effect the elevation of liquids in the well conduit to the surface.

2. DESCRIPTION OF PRIOR ART:

Gas lift type pumps have long been utilized in subterranean wells where the natural pressure existing in the well is insufficient to produce a free flow of gas and liquids to the surface. Such prior art devices incorporated a plunger element which is slidably and sealably engaged with the well conduit, which may be either the well casing or a tubing string extending from the well surface to the body of liquid accumulated in the bottom of the conduit. The plunger defines a vertically extending, internal passage bypassing the external seal on the plunger element. A valve mechanism is provided within the body of the plunger and is effective to close the internal passage when the plunger has reached a preselected depth in the accumulated liquids where the hydrostatic pressure is sufficient to effect the movement of the valve to its closed position. With the valve closed, the natural gas existing in the well accumulates below the plunger and acts on the plunger as a piston to move the plunger and all liquids located above the plunger to the well surface. A typical pump of this type is shown in GRAMLING patent #4,070,134.

The prior art devices, such as the GRAMLING gas lift pump have suffered from several disadvantages. In the first place, the closing of the valve when the plunger reaches the preselected depth in the well liquids is not positively effected, so that the valve may chatter between an open and closed position and thereby substantially reduce the upwardly directed gas forces operating on the plunger to move it to the well surface. Additionally, when the valve does close, a special mechanism has to be provided at the well surface to reopen the valve to permit the plunger to again descend into the well. Lastly, since the force holding the valve in its open position is primarily derived from the weight of the valve, the valve will always close when it has reached a minimum level in the well liquids where the hydrostatic pressure on the valve slightly exceeds the weight of the valve. This is a substantial disadvantage where the gas pressure in the well is sufficient to move a greater column of liquid upwardly through the well conduit. Thus the prior art devices are not susceptible to ready adjustment to accommodate the specific pressures and liquid depths found in various wells.

The method and apparatus of this invention contemplates the utilization of a plunger which is slidably and sealably mounted in a well conduit, such as the well casing, extending from the surface of the well to a preselected depth within the pool of liquid accumulating in the bottom of the well. A tubular body is slidably and sealably mounted in the well conduit by an external sealing element and defines a vertically extending internal fluid passage which bypasses the external sealing element engagable with the well conduit. Thus, the tubular body functions as a plunger which readily moves downwardly into the well until it reaches a stop previously mounted in the well which is at a predetermined depth relative to the accumulating liquids in the bottom of the well.

An annular valve seat surrounds the vertically extending internal passage in the tubular body and cooperates with an axially shiftable valve head to close the fluid passage when the plunger reaches a depth in the well fluids corresponding to a preselected hydrostatic pressure.

The valve head is biased to its open position by a bellows mechanism which is subjected at the surface to a preselected trapped fluid pressure which approximates the hydrostatic fluid pressure level at which it is desired that the valve close. In addition, the valve head is detachably secured in its open position by a latching mechanism such as a collet, so that the hydrostatic pressure force exerted on the valve head to move it to its closed position must be sufficient to not only overcome the downward bias of the trapped fluid pressure acting on the bellows but also to overcome the retention capability of the collet latching mechanism. When the well hydrostatic pressure reaches such a level, the valve head will shift to its closed position with a positive snap action and will be positively retained in its closed position by virtue of the fact that the effective area upon which the well hydrostatic pressure operates on the valve head exceeds the effective area of the bellows.

With the valve head in its closed position, the pressure forces of the well gases trapped beneath the plunger build up to a level sufficient to move the plunger, and all liquids trapped in the well conduit above the plunger, upwardly to the surface.

At the surface, a lubricator pipe is provided having two vertically spaced radial discharge ports. Chokes are provided in each of the two ports to provide a predetermined resistance to flow of fluids through such ports. As the plunger rises in the well, the trapped liquids above the plunger are discharged through both ports. As the plunger approaches the ports, the chokes maintain the hydrostatic pressure on the valve actuating mechanism so as to prevent its early opening. When the plunger moves upwardly into the lubricator pipe so that the external seal element on the plunger is disposed between two vertically spaced ports, the remaining liquid above the plunger is discharged through the upper port and the actuating gases bleed off through the lower port. The two radial discharge ports are interconnected by a pipe to equalize pressure between the two ports, thus equalizing pressures above and below the plunger and permitting the trapped fluid pressure operating on the bellows to return the valve head to its original, collet secured, open position and the plunger will immediately start on the next downward stroke in the well conduit.

The objects and further advantages of the method and apparatus embodying this invention will be readily apparent to those skilled in the art from the following detailed description, taken in conjunction with the annexed sheets of drawings, on which is shown a preferred embodiment of the invention.

FIG. 1 is a schematic vertical sectional view of a complete well having a gas lift pump embodying this invention positioned in such well.

FIGS. 2A and 2B collectively constitute a vertical quarter sectional view of a plunger for a gas lift type pump embodying this invention with the internal valve mechanism shown in elevation.

FIG. 3 is a view similar to FIG. 2B but with the internal valve mechanism shown in section and in its open position.

Referring to FIG. 1, there is schematically shown a complete subterranean well incorporating a gas operated plunger lift pump embodying this invention. The well comprises a casing 1 extending from the surface to a pool of liquid in the well with which the bottom end of the casing is in fluid communication by conventional screens or perforated pipe sections (not shown). In the bottom of the well casing 1, a stop mechanism 2 is mounted in conventional fashion by slips 2a and incorporates a spring 2b for arresting the downward movement of a plunger type pump unit 10 embodying this invention. The detailed construction of pump unit 10 will be hereinafter set forth.

At the top of the well, a knife valve 3 of the type having a smooth bore and sold by L & M VALVE COMPANY of Cleveland, Ohio is suitably secured to the casing 1 to effect the cut-off of fluids in the event that the retrieval of the pump 10 for inspection or repair is desired. Above the knife valve 3, a lubricator pipe 4 is provided having vertically spaced, radial discharge ports 5a and 5b communicating with pipes 6a and 6b. Choke elements 6c are placed in each of the pipes 6a and 6b to restrict flow through such ports and produce a back pressure approximating the well hydrostatic pressure at the lowest level reached by the pump 10.

A spring biased stop 7 is conventionally mounted in the top end of the lubricator pipe 4 and a conventional end cap 4a is detachably secured to the top end of the lubricator pipe 4. Additionally, the discharge ports 5a and 5b are pressure equalized by a connecting pipe 6d, and a shut-off valve 8 is incorporated in the pipe 6a leading from the lower discharge port 5a. The combined fluid flow through the ports 5a and 5b is then directed by piping 9 to a suitable storage tank or a separator unit (not shown).

A plunger type pump 10 is provided with one or more annular elastomeric sealing elements 15a and 15b slidably and sealably engaging the walls of the casing 1. The plunger type pump 10 reciprocates from a lower position determined by the spring stop 2 to an upper position abutting the upper spring stop 7 and effects the pumping of liquids from the liquid pool by utilization of the gas pressure commonly found in subterranean wells to elevate the plunger type pump 10 from the extreme lower position to its extreme upper position through the operation of a valving mechanism 30 incorporated within the plunger type pump 10, which is illustrated in the remaining figures of the drawings and will be described in detail.

The plunger type pump 10 has a tubular body assemblage 12. A pair of elastomeric seal cups 15a and 15b are conventionally mounted on the exterior of the pump body 12 in vertically spaced relationship. While both elastomeric seal elements 15a and 15b may be designed to effect a slidable sealing relationship with the bore of the well casing 1, preferably the upper elastomeric seal element 15a contacts the bore of casing 1 in sealing relationship while the lower elastomeric sealing element is of more rugged construction and is dimensioned to be spaced from contact with the bore of the casing 1. This construction provides for a faster rate of descent of the plunger type pump 10 in the casing 1. Additionally, the more rugged lower elastomeric seal element 15b functions as a centering device and protects the upper elastomeric sealing element 15a from excessive wear incurred in traversing the pipe joints commonly found in the casing 1 and passing through portions of the well casing 1 which are not exactly vertically aligned. Each of the annular elastomeric elements 15a and 15b are secured to the exterior of the tubular body assemblage 12 by mounting rings 15c to which the top end of the particular annular elastomeric element is bonded. Such rings abut respectively against upwardly facing shoulders 12a and 12b provided on the exterior of the tubular body assemblage 12 and are secured in abutting position by downwardly facing shoulders 12c and 12 d respectively provided on structural elements of the tubular body assemblage 12. Additionally, O-rings 15e effect the sealing of the annular elastomeric elements 15a and 15b relative to the exterior of the tubular body assemblage 12.

The tubular body assemblage 12 of the plunger type pump unit 10 comprises, from the top down, a wireline engagable sub 12e having a fishing neck 12f traversed by ports 12y. The sub 12e is threadably secured to the top end of an upper body sleeve 12g by threads 12h and sealed by seal ring 12t.

The lower end of upper body sleeve 12g is provided with internal threads 12j by which it is secured to the top end of a intermediate body sleeve 12k. The lower end of the intermediate body sleeve 12k is provided with external threads 12m which threadably engage a lowermost body sleeve 12n and are sealed by O-ring 12x. The bottom end of the lowermost body sleeve 12n is provided with internal threads 12p which threadably engage a cup-shaped closure element 12q. The lowermost body sleeve 12n is further provided with peripherally spaced slots 12r providing communication between the bore of the casing 1 and the interior of the tubular body assemblage 12.

Additionally, the lowermost body sleeve 12n is provided with an internally projecting shoulder 12s and such shoulder functions to secure an annular valve seat ring 14 in position. Above shoulder 12s, a space out sleeve 16 is provided which abuts a peripheral notch 32a formed on a flanged tubular bottom element 32 forming the bottom end of a valve actuator housing 30. The peripheral flange 32b has its upwardly facing surface 32c in abutment with the lower end of the intermediate body sleeve 12k. Thus, both the valve seat ring 14 and the entire valve actuating housing 30 are clamped in position by tightening of the threads 12m between the intermediate body sleeve 12k and the lowermost body sleeve 12n.

The bottom flanged element 32 is further provided with a plurality of peripherally spaced ports 32d through which fluid can flow axially through the tubular body assemblage 10 in the annulus 20 defined between the bore of tubular body assemblage 10 and the exterior of the valve actuator assembly 30.

The upper end of the tubular bottom element 32 is provided with external threads 32e which engage the lower end of a housing sleeve 34. This threaded connection is sealed by a pair of O-rings 32f. The upper end of the housing sleeve 34 is of reduced diameter an is provided with external threads 34a and internal threads 34b. The external threads are secured to the bottom end of a top sub 36 and this threaded connection is sealed by O-rings 34c. Top sub 36 defines a fluid pressure chamber or dome 36a in its medial portions and has a reduced diameter upper end portion 36b defining a constricted bore 36c extending into the chamber 36a. A check valve 37 similar to those employed in automobile tires is mounted in the constricted portion of the bore 36c and a plug 36d is threadably secured in internal threads 36e of a counterbore 36f and sealed thereto by O-ring 36g.

The bottom tubular flanged element 32 is further provided with a upwardly facing slot 32g within which the end of a bellows 40 is sealably secured in a suitable manner, as by welding. The upper end of bellows 40 is similarly secured to an enlarged shoulder 42a provided on an actuator stem 42. The upper portion 42b of actuator stem 42 has a collet engaging sleeve 44 secured thereto by one or more radial pins 44a which project beyond the external periphery of the sleeve 44. A valve head retaining collet 46 has a ring portion 46a externally threaded to engage in the internal threads 34b of the valve sleeve 34 and the radial pins 44a project between the arms 46b of the collet 46 to prevent the collet from unscrewing from the valve sleeve 34. The enlarged collet heads 46c overlie the end of collet engaging sleeve 44 in the run-in or open position of the valve assemblage 30, as shown in FIG. 3.

The actuator stem 42 is provided with external threads 42c on its lower end which threadably engage internal threads provided on a valve mandrel 48 which extends downwardly through the valve sleeve 34, the tubular flanged bottom element 32 and at least into the valve seat ring 14. Mandrel 48 is provided with one or more axially extending slots 48b which respectively receive radially disposed pins 32h which are pressed into appropriate radial bores provided in the flanged lower element 32. This pin and slot connection prevents relative rotation between the connected elements.

A stop for the downward movement of the valve actuator mandrel 48 to prevent excessive compression of the bellows 40 is provided by a guide bushing 47 threadably secured in the bottom end of the bore of the flanged lower element 32 by threads 32j. The guide sleeve 47 cooperates with the external surface of the actuator mandrel 48 in a non-sealed, bearing relationship. Thus, fluid entering the interior of the tubular body 10 through the axial slots 12r or the upwardly open annulus 20 can pass freely to surround the internal surfaces of the annular bellows 40 and thereby exert well hydrostatic pressure on such internal surfaces to axially expand the bellows 40 and thus move the valve actuator mandrel 48 upwardly.

A valve head assemblage 50 is secured to the bottom end 49a of a support sleeve 49 which is threadably secured to the bottom end of actuator mandrel 48 by threads 48d and the threaded connection is secured by a pin 48e. The bottom 49a of the support sleeve 49 has an external convex configuration which cooperates with a concave surface 52a provided on the upper end of a seal body sleeve 52. Thus, the seal body sleeve 52 may freely swivel relative to the valve actuator mandrel 48. Seal mounting sleeve 52 is provided with a downwardly facing shoulder 52b against which an annular seal holder 54 is compressed by a pair of nuts 59 engaging external threads 52c formed on the lower portions of the seal mounting sleeve 52. The threaded connection is sealed by an O-ring 52d. The seal holder 54 mounts an annular elastomeric ring 56 which is engagable with the depending seal rib 14a provided on the rigidly mounted seal ring 14. It necessarily follows that upward movement of the actuator mandrel 48 will bring the annular elastomeric seal mass 56 into intimate sealing engagement with a depending sealing rib 14a formed on valve seat ring 14.

The operation of the foredescribed plunger type pump will be readily apparent to those skilled in the art. The pump is, of course, only utilized in wells where a significant amount of gas is produced in the formation to which the casing 1 extends. The gas pressure is, however, not sufficient to force any liquids existing in the well up to the surface. Thus, in the event that such liquids are hydrocarbons, they cannot be recovered except through the installation of a conventional sucker rod or submersible pump with the attendant large capital expense and the requirement for daily inspection and maintenance of the pumping unit. In wells primarily producing gas, the production may be substantially impaired by liquids accumulating in the bottom of the well, whether such liquids are hydrocarbons or saltwater. In either event, it is highly desirable to effect the removal of liquids from the bottom of the well without the necessity of installing conventional pumping units.

Prior to installing the pump unit 10 in the well, a trapped gas pressure is applied to the exterior surfaces of the bellows 40 by removing the plug 36d and effecting a conventional hose connection to the threads 36e with a source of pressured gas which may be air, nitrogen or other inert gas. Such gas not only fills the chamber surrounding the bellows 40 but also fills the dome chamber 36a and is brought to a pressure approximating the anticipated well hydrostatic pressure when the pump unit 10 is positioned on the lower spring stop 2, which is positioned below the liquid level in the well. The gas supplied is trapped by check valve 37. The plug 36d is replaced and pump unit 10 is then inserted through the top end of the lubricator pipe by the removal of the end cap 4a and the upper spring stop 7. The pump unit 10 will proceed to slide downwardly through the well casing 1 with the valve head 52 biased by bellows 40 to its open position, in which it is retained by collet 46, thus maintaining an open passage for well fluids through the body assemblage 12 of the pump unit 10.

Pump unit 10 thus proceeds downwardly in the well casing until it either encounters the bottom well stop 2 or reaches a sufficient depth in any fluids existing in the well casing to produce a hydrostatic pressure substantially in excess of the trapped fluid pressure operating on the bellows 40. Such hydrostatic pressure must be greater than the trapped bellows pressure due to the fact that the valve actuating mechanism is also restrained against upward movement by the collet 46. When such level of hydrostatic pressure is achieved, the collet 46 will release and the valve head assembly 50 will move to a closed position with a snap action. It should be noted that in its closed position, the effective area of the valve head 50 upon which the hydrostatic pressure is acting is substantially greater than the effective area of the trapped fluid pressure existing in the bellows unit 40, thus assuring that once closed, the valve would remain closed until a substantial reduction in well hydrostatic fluid pressure is produced.

The pump 10 will then be moved upwardly by the pressure of the gases generated in the well acting on the entire cross-sectional area of the pump unit 10 as defined by the maximum diameter of the upper annular elastomeric seal unit 15a. If this gas pressure is not sufficient to initiate the movement of the pump 10, it will remain in its lower position while the gas pressure gradually builds up to a level sufficient to elevate the pump unit 10. When the pump unit 10 moves upwardly, all of the well fluid trapped above the pump unit 10 will be moved with it, thus maintaining the same hydrostatic pressure on the interior of the bellows 40 so that there is no effective force generated sufficient to shift the valve head 50 from its closed position.

As the plunger unit approaches the top of the well, it will be observed that the trapped fluids carried upwardly by the pump 10 will be discharged through the vertically spaced discharge ports 5a and 5b. The chokes 6 provided in such discharge ports create an effective back pressure so that the hydrostatic pressure exerted on the pump unit 10 from above is not substantially reduced until the upper annular elastomeric seal unit 15a passes over the lower discharge port 6b and engages the upper stop 7. In this position, the gas pressure which has been urging the pump unit 10 upwardly is dissipated through the lower discharge port 5b and supplied to a separator tank through the pipe 9. Since the pressures at the two discharge ports are substantially equalized by the connecting conduit 6d, a point will be reached wherein the hydrostatic pressure exerted on one side of the bellows 40 will decrease below the trapped fluid pressure acting on the other side of the bellows 40, hence the bellows will expand and shift the valve actuator 48 and the valve head 50 to its open position. This permits the pump unit to again pass downwardly through the well casing to begin another cycle of pumping action.

While this invention has been described in connection with its application as a casing pump, a pump 10 embodying the method and apparatus of this invention could obviously be utilized in any conduit, such as a tubing string, which extends from a pool of liquids in the bottom of a well to the well surface. Utilizing the casing as the fluid conduit provides a maximum effective piston area upon which the well gases can operate, hence requires less effective well gas pressure to produce the pumping action than would be the case with a smaller diameter conduit.

The foredescribed plunger type pump construction has the further advantage that the valving mechanism 30 may be removed as a unit from the interior of the valve body assemblage 12 and replaced in another unit. Furthermore, the same size valve mechanism may be utilized in different sizes of pump body assemblies, thus reducing the need for maintaining an inventory of different sizes of valve mechanisms in order to provide a pump for each of a plurality of different sized casings.

Removal of the pump unit 10 from the well may be conveniently accomplished by closing th knife valve 3 when the pump unit 10 is in its upper position. The end cap 4a on the lubricator pipe 4 may then be removed, together with the spring stop 7, and the entire valve pump unit 10 pulled out of the lubricator pipe.

Although the invention has been described in terms of specified embodiments which are set forth in detail, it should be understood that this is by illustration only and that the invention is not necessarily limited thereto, since alternative embodiments and operating techniques will become apparent to those skilled in the art in view of the disclosure. Accordingly, modifications are contemplated which can be made without departing from the spirit of the described invention.