Apparatus and system control for the removal of fluids and gas from a well

[0002] This application is a continuation-in-part of related U.S. patent application Ser. No. 09/827,446 filed Apr. 6, 2001, now U.S. Pat. No. 6,460,622

[0003] 1. Field of the Invention

[0004] The invention relates to an oil bailer apparatus for use in bailing oil from an oil well as well as removing natural gas, wherein a bailer tube is lowered to collect the fluid and raised above ground for the depositing of the fluids into a reservoir.

[0005] 2. Description of Related Art

[0006] Oil bailers are known in the art. However, previous methods of extracting oil, in particular, the bailers and controls used with such bailers fail to differentiate between oil and water in a given well. The problem of non-differentiating between water and oil is especially experienced in low producing wells.

[0007] Known related art includes the solid state control system for the oil bailer depicted in U.S. Pat. No. 4,516,911 to Senghaas et al., the oil bailer depicted in U.S. Pat. No. 4,368,909 to Alexander, Jr., and the automated bailer depicted in U.S. Pat. No. 4,037,662 to Bowling.

[0008] None of the devices in the above references solve the problem of differentiating between water and oil, especially in low producing wells, and at the same time, address the recovery of natural gas from the oil pumping operation.

[0009] It is therefore the intention of this invention to provide an improved oil bailing system, which differentiates between oil and water in a given well, removes only oil, capable of operating on 5,000 foot wells and operates at the removal rate of 25-35 barrels per day. The invention can differentiate between water and oil by the incorporation in the system design of a water and oil and water sensor that provides feedback to a programmable logic controller (PLC) to operate the mechanical system portion of the apparatus, and to provide means for accessing and collecting data of the operation of the equipment including system errors. This will be used to gather and record daily gas and oil production and then transfer all data to a central terminal PC by way of the internet.

[0010] The invention which is an apparatus and system control for the removal of fluids and gas from a well includes means for removing fluids from a well casing, and the fluids being substantially oil and water.

[0011] The means for removing fluids from the well casing is coupled directly to an upper end of the well casing and further includes a bailer tube sized to allow an up and down travel of the bailer tube inside the well casing and inside a bailer tube housing assembly vertically aligned with the well casing. The direct coupling may be made by a number of ways known in the art such as a flanged pipe connection or preferably a union connection. The bailer tube housing assembly has an actuated 3-ported valve means proximate a lower end of the bailer tube housing assembly for selectively opening the bailer tube housing assembly when allowing the bailer tube to travel into the well casing and for closing the bailer tube housing assembly after the bailer tube has traveled up into the bailer tube housing assembly and for directing a captured column of oil to a temporary storage tank.

[0012] Also included is pulley means proximate an upper end of and above the bailer tube housing assembly over which a cable wire attached to an upper end of the bailer tube is run. An opposite end of the cable wire is attached to driven winch means for pulling the bailer tube out of the well casing and for lowering the bailer tube into the well casing. A lower end of the bailer tube has an electrically operated 120 v (AC) or 24 v (DC) bailer valve for selectively capturing the column of oil inside the well casing when said bailer tube is lowered therein, and for discharging said captured column of oil into the temporary storage tank when the bailer tube is raised out of the well casing. The bailer valve is typically a two-way direct current (DC) or 120 v (AC) valve.

[0013] The bailer valve is in electrical operative communication with a programmable logic controller (PLC) means for monitoring, operating and controlling the apparatus and for translating readable information to obtain and record operational parameters. The PLC means is typically an electrical enclosure housing with various processing capabilities which includes a micro-processing unit typical of computers, gauges for monitoring various desired operating parameters such as flow rates of oil and gases, oil level in the temporary storage tank, pressures, bailer tube travel speeds, etc., actuator switches for activating and controlling the winch and pumping means to empty the temporary storage tank, among several other necessary or desired functions.

[0014] The lower end of the bailer tube further includes oil and water sensing means for differentiating between the water and oil inside the well casing as the bailer tube descends therein, the oil and water sensing means facilitating the defining of a top of the water and a bottom of a well casing column of oil. The cable wire is typically a multiple conductor cable wire, which is in electrical communication between the bailer valve and the driven winch means.

[0015] The cable wire is also electrically and operatively connected to the programmable logic controller means. The programmable logic controller means calculates an optimum depth required for removal of oil without water from the well casing and once correctly positioned, the bailer valve is closed thereby capturing oil inside said bailer tube and the bailer tube is elevated above ground so that the bailer valve is inside the bailer housing assembly and above the actuated 3-ported valve means at which location, the actuated 3-ported valve means is closed after which the bailer valve is opened and the captured oil in the bailer tube is discharged into the temporary storage tank. The actuated 3-ported valve means, the driven winch means, the oil and water sensor means are each in electrical and operative communication with the programmable logic controller means. The programmable logic controller means controls and monitors a speed of the bailer tube at each location of the bailer tube inside the well casing as the bailer tube is being lowered into and elevated out of the well casing.

[0016] The invention further includes natural gas recovery means for recovering a natural gas exhausting from the well casing. The natural gas recovery means comprises a gas and oil separator means, which directs the natural gas exiting the well casing from a location below the actuated 3-ported valve means, and means for draining a condensate and means for directing a separated gas to gas distribution means.

[0017] The oil and water sensor means is typically a proximity switch which is activated by the dielectric sensing capability. The sensor provides a 0-20 mA signal back to the PLC, thereby defining the top of the water and the bottom of the well casing column of oil, including defining any trapped gas pockets.

[0018] The driven winch means preferably further comprises encoder means mounted to a measuring head in electrical communication with the programmable logic controller means for converting a rotation of the winch means into a linear motion to determine a speed of the bailer tube traveling inside the well casing and a location within said well casing.

[0019] The temporary storage means comprises means for monitoring the level of captured oil in the temporary storage tank, and actuation means operatively connected to pumping means for pumping the captured oil from the temporary storage tank to a predetermined storage location.

[0020] The actuated 3-ported valve means is preferably one of a slide gate valve and a ball valve.

[0021] The natural gas recovery means further comprises means for monitoring one of a flow rate of natural gas exhausting from the well casing, a volumetric quantity of natural gas exhausting from the well casing, and a combination thereof. A corresponding natural gas recovery means data from the means for monitoring one of the flow rate of natural gas exhausting from the well casing, the volumetric quantity of natural gas exhausting from the well casing, and the combination thereof is transmitted to the programmable logic controller means.

[0022] Support and guide means at the upper end of the bailer housing assembly for supporting and guiding the wire cable are also included. The support and guide means comprises a line wiper/pack-off sheave assembly (also called a line wiper and sheave assembly) including at least one wire cable line wiper and at least one hydraulic greasing port for greasing and sealing said wire cable. Typically, the line wiper/pack-off sheave assembly includes a first hydraulic greasing port in overlying relationship to a first line wiper, a second hydraulic greasing port in underlying relationship to the first line wiper and a second line wiper in underlying relationship to the second hydraulic greasing port.

[0023] The invention further comprises a proximity sensor switch located proximate the upper end of the bailer housing assembly. The proximity sensor switch is in electrical communication with the programmable logic controller means and being means for stopping the bailer tube being raised from the well casing. A back up proximity sensor switch located in a predetermined spaced apart relationship with the proximity sensor switch, typically about 4-8 inches above the proximity sensor switch, is included and acts as means for stopping the bailer tube should the proximity sensor switch fail. This switch is also in electrical communication with the programmable logic controller means.

[0024] The programmable logic controller means further monitors a top of the oil column location within the well casing as well as a bottom location of the oil column within the well casing, the bottom location corresponding to a location of the top of the water column within the well casing. The optimum depth in the well casing of the lower end of the bailer tube for capturing the column of oil without water is an intermediate location between the location of the top of the oil column and above the location of the bottom of the oil column.

[0025] The programmable logic controller means performs an operational logging sequence during which the programmable logic controller means operationally opens the bailer valve and the actuated 3-ported valve means, starts the lowering of the bailer tube into the well casing accelerating to a predetermine adjustable travel speed, allows the bailer tube to descend to a pre-set logging depth above the location of the top of the oil column within the well casing, decreases the adjustable travel speed so that the lower end of the bailer tube enters into the oil column at which point the oil and water sensor means identifies a depth of the top of the oil column, the lower end of the bailer tube continues to descend until the oil and water sensor means identifies a depth of the top of the water in the well casing, transmits data reflective of the identification of the depth of the top of the oil and water to the programmable logic controller means which recalculates desired operational parameters including a new logging depth, optimum depth and bailer tube travel speed, closes the bailer valve, starts elevating the bailer tube through the well casing until the bailer tube enters the bailer tube housing assembly, stops the bailer tube when the lower end of the bailer tube is above the actuated 3-ported valve means, closes the actuated 3-ported valve means, opens the bailer valve for a predetermined top dwell time and redirects/discharges the captured oil in the bailer tube into the temporary storage tank, closes the bailer valve after the captured oil has been discharged into the temporary storage tank, and repeats the above operational logging sequence as desired.

[0026] The programmable logic controller means also performs a balanced oil production operational sequence during which the programmable logic controller means operationally opens the bailer valve and the actuated 3-ported valve means, starts the lowering of the bailer tube into the well casing accelerating to a predetermine adjustable travel speed, allows the bailer tube to descend to a pre-set logging depth above the location of the top of the oil column within the well casing, decreases the adjustable travel speed so that the second end of the bailer tube enters into the oil column at which point the oil and water sensor means identifies a depth of the top of the oil column, the lower end of the bailer tube continues to descend into the oil column and stops at the optimum depth at which point the bailer valve is closed after a predetermined preset dwell time to capture oil, transmits data reflective of the identification of the new depth of the top of the oil and optimum depth to the programmable logic controller means which continually calculates and monitors desired operational parameters including the logging depth, optimum depth and bailer tube travel speed, starts elevating the bailer tube through the well casing until the upper end of the bailer tube enters the bailer tube housing assembly, stops the bailer tube when the lower end of the bailer tube is above the actuated 3-ported valve means, closes the actuated 3-ported valve means, opens the bailer valve for a predetermined top dwell time and redirects the captured oil-in the bailer tube into the temporary storage tank, closes the bailer valve after the captured oil has been discharged into the temporary storage tank, and repeats the above balanced oil production operational sequence as desired.

[0027] The programmable logic controller means further monitors an accumulated level of oil in the temporary storage tank, monitors gaseous pressure, monitors well pressure in the well casing and temporary storage tank using corresponding pressure sensor means, and monitors a tension in the cable wire.

[0028] The invention further comprises a field communicator, which is operatively in communication with the programmable logic controller means. The field communicator is operatively in communication with a data base server, the data base server for storing, organizing and polling data outputted from the programmable logic controller means, for users to change operating parameters of the programmable logic controller means, for providing historical data and performing diagnostics, and for providing data collection, reporting, analysis and visualization displays. The data base server is accessible by a user through a website. Another embodiment is the inclusion of a paging system in operative communication with the programmable logic controller means, the paging system for communicating pre-set alarms and messages between a field service department and the programmable logic controller means.

[0029] The inventive method comprises the steps of providing an apparatus and system control for the removal of oil and gas from a well as described above; conducting a first sequence logging process during which the programmable logic controller means operationally opens the bailer valve and the actuated 3-ported valve means, starts the lowering of the bailer tube into the well casing accelerating to a predetermine adjustable travel speed, allows the bailer tube to descend to a pre-set logging depth above the location of the top of the oil column within the well casing, decreases the adjustable travel speed so that the lower end of the bailer tube enters into the oil column at which point the oil and water sensor means identifies a depth of the top of the oil column, the second end of the bailer tube continues to descend until the oil and water sensor means identifies a depth of the top of the water in the well casing, transmits data reflective of the identification of the depth of the top of the oil and water to the programmable logic controller means which recalculates desired operational parameters including a new logging depth, optimum depth and bailer tube travel speed, closes the bailer valve, starts elevating the bailer tube through the well casing until the bailer tube enters the bailer tube housing assembly, stops the bailer tube when the lower end of the bailer tube is above the actuated 3-ported valve means, closes the actuated 3-ported valve means, opens the bailer valve for a predetermined top dwell time and redirects the captured oil in the bailer tube into the temporary storage tank, closes the bailer valve after the captured oil has been discharged into the temporary storage tank, and repeats the above operational logging sequence as desired; and performing a balanced oil production operational sequence during which the programmable logic controller means operationally opens the bailer valve and the actuated 3-ported valve means, starts the lowering of the bailer tube into the well casing accelerating to the predetermine adjustable travel speed, allows the bailer tube to descend to the pre-set logging depth above the location of the top of the oil column within the well casing, decreases the adjustable travel speed so that the lower end of the bailer tube enters into the oil column at which point the oil and water sensor means identifies the depth of the top of the oil column, the lower end of the bailer tube continues to descend into the oil column and stops at the optimum depth at which point the bailer valve is closed after the predetermined preset dwell time to capture oil, transmits the data reflective of the identification of the depth of the top of the oil and optimum depth to the programmable logic controller means which continually calculates and monitors desired operational parameters including the logging depth, optimum depth and bailer tube travel speed, starts elevating the bailer tube through the well casing until the first end of the bailer tube enters the well casing, stops the bailer tube when the lower end of the bailer tube is above the actuated 3-ported valve means, closes the actuated 3-ported valve means, opens the bailer valve for a predetermined top dwell time and redirects the captured oil in the bailer tube into the temporary storage tank, closes the bailer valve after the captured oil has been discharged into the temporary storage tank, and repeats the above balanced oil production operational sequence until a change in depth is noted such as to require re-initiation of the logging process.

[0030] The programmable logic controller means can be programmed to cycle through the first sequence logging process at predetermined time intervals. The programmable logic controller means monitors the rate that the oil column is decreasing or increasing and makes necessary adjustments to slow down or speed up a normal running sequence. The normal running sequence starts out with the travel speed at an optimum operating speed and as a rate of the oil column is decreasing, the programmable logic controller means compares this rate with a current rate of speed of the bailer tube and slows the travel speed of the bailer tube slightly with every cycle, and while monitoring the rate of decrease of the oil column, the programmable logic controller means continuously makes small adjustments until the oil column stops decreasing in size and maintains a steady constant oil column height. The programmable logic controller means continues to run at the travel speed of the bailer tube while continuing to monitor the size of the oil column, and continues to make adjustments in order to maintain a balanced sized oil column.

[0031] In another embodiment of the invention, the PLC means for one or more field sites is operatively connected with one or more Field Communicator PCs, each including a dial up modem, ISDN connector and an FTP router, which in turn communicates with a data base server PC. This server is accessible through a website in which data collection, reporting, analysis and visualization displays can be viewed by a customer base. In addition, each PLC means is operatively in communication with a paging system, which outputs data to a field service department.

[0032] For a fuller understanding of the nature and objects of the invention, reference should be made to the following detailed description, taken in connection with the accompanying drawings, in which:

[0033] FIG. 1ais a schematic partial view of a lower portion of the invention;

[0034] FIG. 1bis a schematic partial view of an upper portion of the invention looking from an edge view;

[0035] FIG. 1cis a schematic partial view of the upper portion of FIG. 1blooking from a side view;

[0036] FIG. 1dis a schematic partial view from the side of the lower portion of the invention;

[0037] FIG. 2 is a schematic view of the bailer tube assembly;

[0038] FIG. 3 is a conceptual depiction of the end of the bailer tube inside the well casing at an optimum depth;

[0039] FIG. 4 is a schematic view depicting a captured oil column ascending out of the well casing;

[0040] FIG. 5ais a diagrammatic flow chart depicting logging process controlled by the PLC means;

[0041] FIG. 5bis a diagrammatic flow chart depicting a portion of the normal operational mode of the invention;

[0042] FIG. 5cis a diagrammatic flow chart depicting the remaining portion of the normal operational mode started in FIG. 5b;

[0043] FIG. 5dis a diagrammatic flow chart depicting various operational parameters and characteristics monitored and controlled by the PLC; and

[0044] FIG. 5eis a diagrammatic chart depicting an embodiment of the invention in which several individual field site PLCs, which are connected through a paging system to a Field Service Department, are also in modem communication with one or more Field Communicator PCs, which in turn route data to a server which can be accessed from a website.

[0045] Before referring to the drawings, the following is a general and simplified description of a typical application of the structure and its operation.

[0046] The mechanical structure is typically directly attached to the oil casing by means of a union, which supports the bailer housing assembly. The lower bailer housing is equipped with a pressure sensor, which monitors the gas pressure through the PLC and a gas flow meter, which monitors gas flow output in cubic feet per minute (CFM) through the PLC. The remainder of the bailer housing includes a 3-ported 4″ hydraulic actuated ball valve, a 4″ flanged pipe and a line wiper with grease injection/sheave assembly or line wiper/pack-off sheave assembly.

[0047] The ball valve is used to close off the entry to the oil casing during the depositing operation thus allowing transfer of the oil to the holding tank and prevention of gas back flow to the holding tank. The flanged bailer housing is designed long enough to house the lift long bailer assembly. The line wiper and sheave assembly system is used to prevent escapement of gases and oil from the topside of the bailer housing whereas the sheave or pulley means is used to support and guide the wire line or cable. The greasing unit is driven and operated by a hydraulic drum pump motor and interfaced with the PLC to operate on an hourly or as needed schedule.

[0048] The wire lines typically are of a {fraction (5/16)}″ (0.331) diameter, 7 conductor-jacketed cables with seven conductive wires weaved under the wire and jacket. Four of the conductive wires are used to activate (open and close) the electrical bailer solenoid valve upon the sequence of operation. Two wires are used to gather the signal(s) from the proximity sensor.

[0049] The topside end of the cable is attached to a hydraulic driven winch, which is used to rise and lower the wire line attached to the bailer in and out of the casing. All incoming signals and outgoing 24 VDC power is transmitted through the winch and wire and tied back to the PLC for operational and informational data.

[0050] The bailer tube is typically a 3″ pipe capable of holding 4 gallons of oil which will encase a 2 way 24 v DC or 120 v AC valve at the bottom of the bailer to allow the capture and discharge of the oil. Part of the valve assembly consists of an oil and water sensor to differentiate between water and oil level.

[0051] A proximity switch is mounted in a location where the bailer tube is stopped once it is fully extended out of the oil casing and above the ball valve where oil can be discharge without reentering the oil casing.

[0052] An approximate 60 gallon oil reservoir tank or temporary storage tank is typically mounted to the mainframe structure or on its own independent frame and capable of holding up to 40 gallons of oil. Level switches monitor the oil level in the tank where the oil is removed with the use of a pump to a larger storage tank. A pressure switch is used monitor the pressure in the tank.

[0053] An optional fluid injection pump is linked to the PLC to supply a fluid as required to break down heavy paraffin wells as required per well.

[0054] The electrical enclosure consist of a PLC which operates and controls the mechanical functions of the mechanical system and translates readable information to obtain operating data such as, but not limited to, the following:

[0055] Travel Speeds of the bailer

[0056] Depth location of bailer

[0057] Linear Travel (Encoder)

[0058] Speed of Bailer

[0059] Location of the Bailer

[0060] Oil vs. Water sensing from Bailer ball valve assembly

[0061] Flow meter and volume of Gas intake per day

[0062] Flow meter and volume of Oil intake per day

[0063] Level sensor of oil in the tank reservoir

[0064] Encoder to monitor linear travel

[0065] Turning on/off the pump delivering oil to the holding tank

[0066] Cycles per minute

[0067] Pressure sensing of gas

[0068] Pressure sensing of oil

[0069] Pressure of reservoir

[0070] Translate information to a remote location

[0071] Balance oil production

[0072] Tension sensing or slack detection in the wire line

[0073] In a typical sequence of operation, with the bailer tube ball valve in the open position, the wire line winch releases the bailer tube slowly into the hole of the casing at an adjustable slow speed. The speed gradually increases at a given parameter and begins downward travel at an adjustable higher rate called “travel speed”. An encoder mounted to a measuring head converts RPM to linear motion through the PLC therefore, always knowing the location of the bailer. As the bailer tube reaches the oil column the speed is slowed down for easier entry. The oil and water liquid sensor identifies the exact location liquid level begins, differentiates between oil and water and communicates the information back to the PLC. The tube continues to travel downward until the oil and water sensor is activated upon making contact with a second source fluid (water). Gas pockets are also identified by the oil and water sensor. The PLC stores this information for future use. This second liquid level is known as the top of the water and bottom of the oil column. The PLC automatically calculates the optimum depth required for removing the oil without removing water. Once correctly positioned, the bailer tube valve is closed and the bailer begins its travel upward to the surface. The return speed is gradual and increases to the “travel speed” at a given parameter. As the bailer tube reaches the surface and before entering the bailer housing, its speed is decreased before being stopped by a primary sensor mounted at the top of the bailer housing, which stops the travel of the bailer tube. A second sensor is located 6 inches above the first sensor to act as a safety or over ride to stop travel if first sensor fails. The 3-ported 4″ ball valve is then closed and the bailer valve containing the oil is then opened thus allowing the oil to be diverted and transferred to the holding tank. Once fully drained, the 3-ported 4″ ball valve is actuated to the bailer pass through position and prepared to repeat the process.

[0074] The above first sequence is referred to as the “Logging Process”. The logging process provides the necessary data required for the PLC to pre-determine target settings.

[0075] As the oil extraction process begins, the weight of the oil column decreases due to the decreasing size of the oil column, the water under the oil column may drive the oil column higher resulting in a change in the location of the top of the oil column.

[0076] The PLC continuously monitors the location of the top of the oil column and the depth in order to “balance” the oil column, resulting in a faster or slower cycle rate. For this reason the logging process must repeat approximately every five cycles.

[0077] The second part of the operation sequence is the balancing process. The normal operating target or depth setting would be the center of the oil column but could be changed if necessary depending on the location oil vs. water. The PLC then would automatically calculate this distance and under normal operation, travel down to this point and stop and dwell for a period of time before starting back up the hole.

[0078] Gas removal is typically accomplished according to the following description. A 2″ National Pipe Thread (NPT) coupling located above the union, which is connected to the well casing, may be used as the means for gas removal. As the gases rise to the surface, they are allowed to free flow outwards through the gas flow meter thus allowing data to be collected through the PLC. A pressure sensor located and mounted above the union is used to monitor high-pressure situations and shutdown the system if extreme high pressures are present.

[0079] The balancing operation sequence begins with the PLC opening the well casing 3-ported 4″ ball valve. The bailer tube begins its decent into the hole at a slow (adjustable) speed with an adjustable parameter to determine when it picks up speed to “the travel speed.” The travel speed is adjustable. The PLC, already knowing the location of the top of the oil column, travels down the hole at “travel speed”. As it arrives, an adjustable parameter begins to slow the tube within several feet or inches from the top of the oil column. This allows the tube to lower down into the oil at a safe rate of speed. This slow down parameter is important because the top of the oil column will be changing constantly. The PLC then closes the retrieval (bailer) tube valve after a predetermined amount of time called the dwell time.

[0080] The tube begins to travel back up the hole at an adjustable speed until it arrives at the parameter that tells the tube to speed up to a predetermined rate of speed.

[0081] The tube travels up to the parameter that tells the tube to slow down to a predetermined rate of speed as it enters in to the bailer housing and arrives at the proximity sensor and stops.

[0082] The 3-ported 4″ ball valve closes and the retrieval tube opens and stays open for a predetermined amount of time before closing. This span of time is called the top dwell time.

[0083] The PLC can be programmed to cycle through a logging sequence every so often. Therefore it will monitor the rate that the oil column is decreasing or increasing and make necessary adjustments to slow down or speed up the normal running sequence. The normal running sequence starts out with the travel speed at optimum operating speed and as the rate the oil column is decreasing the PLC compares this rate with the current rate of speed and slows or increases the travel speed slightly with every cycle. While monitoring the rate of decrease, the PLC is continuously making small adjustments until the oil column stops decreasing in size maintaining a steady constant level. The PLC continues to run at this travel speed while continuing to monitor the size of the oil column continuing to make adjustments in order to maintain a balanced size oil column.

[0084] The communication and data collection aspects of the invention include the following. The PLC, primarily used to operate the system most efficiently is also used to continuously monitor and collect data. Data collection includes desired parameters such as, but not limited to, the following:

[0085] Oil production per hour

[0086] Gas production per hour

[0087] Level of oil in holding tank

[0088] Positioning of bailer in casing

[0089] Pressure of Oil holding tank

[0090] Gas pressure in casing

[0091] Winch wire tension

[0092] 3-ported 4″ ball valve position

[0093] Travel Speed

[0094] Cycles per hour

[0095] Fluid injection cycles/Hr

[0096] Drum Pump cycles/Hr

[0097] The system faults typically include:

[0098] Oil Pump out motor failure

[0099] Oil tank level sensor failure

[0100] System shut-down

[0101] Bailer stop switch failure

[0102] Winch tension switch failure

[0103] Bailer valve failure

[0104] Bailer sensor failure

[0105] 3-ported ball valve position failure

[0106] Fluid injection pump failure (Optional)

[0107] Drum Pump failure

[0108] Tank Pressure switch

[0109] Bailer housing pressure switch

[0110] Field communicator(s) (PC's), strategically placed, are typically located locally around the service area and continuously makes call ups to the individual units collecting the following data:

[0111] Cycle speed

[0112] Cycle rate

[0113] Barrels/hr

[0114] CFM of gas

[0115] The #1 PC server located in a central operating location such as a company office which may even be in a city or town thousands of miles away from the field site, does daily polling to each field communicator to gather production data and is capable of linking up to any specific unit to make program changes to the PLC program, which include the following:

[0116] Cycle time

[0117] Dwell time

[0118] Depth of bailer

[0119] Cycle speed

[0120] Cycle rate

[0121] Fluid injection rate (Optional)

[0122] Grease injection rate

[0123] Each unit typically has a call in/out modem capable of linking up the main server or field communicator for data collection, program changes and “dial out” to a paging service to report a unit out of service.

[0124] Given the parameters, software, referred to as RS View software, is provided and designed to show pictorial, graphical and numerical displays such as:

[0125] Tank level

[0126] Bailer location and depth

[0127] Barrels/Hr (Oil)

[0128] CFM of Gas

[0129] Cycle rate

[0130] Bailer Speed

[0131] Dwell time

[0132] Fluid injection rate (Optional)

[0133] Grease injection rate

[0134] Tank Pressure

[0135] Bailer housing pressure

[0136] Referring now to the drawings, in particular FIGS. 1a-1d, 2-4 and 5a-5e, the invention which is an apparatus and system control for the removal of fluids and gas from a well and is depicted generally as 10, includes means 12 for removing fluids from a well casing 16, the fluids being substantially oil 18 and water 20.

[0137] The means 12 for removing fluids from the well casing is coupled directly to an upper end of the well casing 16 and further includes a bailer tube 90 sized to allow an up and down travel of the bailer tube 90 inside the well casing 16 and inside a bailer tube housing assembly 28 vertically aligned with the well casing 16. The direct coupling may be made by a number of ways known in the art such as a flanged pipe connection or preferably a union connection 30. The bailer tube housing assembly 28 has an actuated 3-ported valve means 34 proximate a lower end of the bailer tube housing assembly 28 for selectively opening the bailer tube housing assembly 28 when allowing the bailer tube 90 to travel into the well casing 16 and for closing the bailer tube housing assembly 28 after the bailer tube 90 has traveled up into the bailer tube housing assembly 28 and for directing a captured column of oil 18 to a temporary storage tank 22.

[0138] Also included is pulley means or a sheave 64 proximate an upper end of and above the bailer tube housing assembly 28 over which a cable wire 68 attached to an upper end of the bailer tube 90 is run. An opposite end of the cable wire 68 is attached to driven winch means 56 for pulling the bailer tube 90 out of the well casing 16 and for lowering the bailer tube 90 into the well casing 16. A lower end of the bailer tube 90 has a bailer valve 90afor selectively capturing the column of oil 18 inside the well casing 16 when said bailer tube 90 is lowered therein, and for discharging said captured column of oil 18 into the temporary storage tank 22 when the bailer tube 90 is raised out of the well casing 16. The bailer valve 90ais typically a two-way direct current (DC) or alternating current (AC) actuated valve.

[0139] The bailer valve 90ais in electrical operative communication with a programmable logic controller (PLC) means 100 for monitoring, operating and controlling the apparatus and for translating readable information to obtain and record operational parameters. The PLC means 100 is typically an electrical enclosure housing with various processing capabilities which includes a micro-processing unit typical of computers, gauges for monitoring various desired operating parameters such as flow rates of oil and gases 112,114, oil level 116 in the temporary storage tank 22, pressures 124,128, bailer tube travel speeds 102,146 etc., actuator switches for activating and controlling the winch and pumping means 22a,120 to empty the temporary storage tank 22 and transfer its contents to another storage tank 14, among several other necessary or desired functions.

[0140] The lower end of the bailer tube 90 further includes oil and water sensing means 70 for differentiating between the water 20 and oil 18 inside the well casing 16 as the bailer tube 90 descends therein, the oil and water sensing means 70 facilitating the defining of a top of the water 98aand a bottom of a well casing column of oil 98b. The cable wire 68 is typically a multiple conductor cable wire which is in electrical communication between the bailer valve 90aand the driven winch means 56.

[0141] The cable wire 68 is also electrically and operatively connected to the programmable logic controller means 100. The programmable logic controller means 100 calculates an optimum depth 98drequired for removal of oil 18 without water 20 from the well casing 16 and once correctly positioned, the bailer valve 90ais closed thereby capturing oil 18 inside said bailer tube 90 and the bailer tube 90 is elevated so that the bailer valve 90ais inside the bailer housing assembly 28 and above the actuated 3-ported valve means 34 (the hydraulic actuator is designated as 32) at which location, the actuated 3-ported valve means 34 is closed after which the bailer valve 90ais opened and the captured oil 18 in the bailer tube 90 is discharged into the temporary storage tank 22. The actuated 3-ported valve means 34, the driven winch means 56, the oil and water sensor means 70 are each in electrical and operative communication with the programmable logic controller means 100. The programmable logic controller means 100 controls and monitors a speed 102 of the bailer tube 90 at each location or bailer depth 104 of the bailer tube 90 inside the well casing 16 as the bailer tube 90 is being lowered into and elevated out of the well casing 16.

[0142] The invention further includes natural gas recovery means for recovering a natural gas exhausting from the well casing 16. The natural gas recovery means comprises a gas and oil separator means 48, which directs the natural gas exiting the well casing 16 from a location below the actuated 3-ported valve means 34, and means for draining a condensate 46 and means for directing a separated gas to gas distribution means 42. Also shown in FIG. 1ais a pressure regulator 38 for safety reasons, an auxiliary gas distribution port 40 should one be needed, a hammer union trunnion 44 and a gas flow meter 50.

[0143] The oil and water sensor means 70 is typically a proximity switch or sensor which is activated by its dielectric sensing capability as it contacts the fluid and gas pockets in the well casing including the water 20 under the oil 18 in the well casing 16, thereby defining the top of the water 98aand the bottom 98bof the well casing column of oil 18.

[0144] The driven winch means 56 preferably further comprises encoder means in electrical communication with the programmable logic controller means 100 for converting a rotation of the winch means 56 into a linear motion to determine a speed 102 of the bailer tube 90 traveling inside the well casing 16 and a location 104 within said well casing 16. As shown in FIGS. 1aand 1c, typical components include a chain 92awith a drive sprocket 92b. Winch means 56 may typically be a sprocket for mating with chain 92a. Other typical components include a hydraulic power supply 94 for the hydraulic driven components and a hydraulic hand pump 72awhich may be connected to grease fitting ports 72.

[0145] Included is temporary storage means which comprises means for monitoring the level 116 of captured oil 18 in the temporary storage tank 22, and actuation means operatively connected to pumping means 22afor pumping the captured oil 18 from the temporary storage tank 22 to a predetermined storage location 14.

[0146] The actuated 3-ported valve means 34 is typically a ball valve; however, a slide gate valve may be adapted as necessary.

[0147] The natural gas recovery means further comprises means for monitoring one of a flow rate 50 of natural gas exhausting from the well casing 16, a volumetric quantity of natural gas 112 exhausting from the well casing 16, and a combination thereof. A corresponding natural gas recovery means data from the means for monitoring one of the flow rate 50 of natural gas exhausting from the well casing 16, the volumetric quantity of natural gas 112 exhausting from the well casing 16, and the combination thereof is transmitted to the programmable logic controller means 100.

[0148] Support and guide means at the upper end of the bailer housing assembly 28 for supporting and guiding the wire cable 68 are also included. The support and guide means comprises a line wiper/pack-off sheave assembly 62 including at least one wire cable line wiper 76 and at least one hydraulic greasing port 72 for greasing and sealing said wire cable 68. Typically, the line wiper/pack-off sheave assembly 62 includes a first hydraulic greasing port 72 in overlying relationship to a first line wiper 76, a second hydraulic greasing port 72 in underlying relationship to the first line wiper 76 and a second line wiper 76 in underlying relationship to the second hydraulic greasing port 72. Typically, assembly 62 includes a pulley or sheave 64 and a sheave support arm 66.

[0149] The invention further comprises a proximity sensor switch 88alocated proximate the upper end of the bailer housing assembly 28. The proximity sensor switch 88ais in electrical communication with the programmable logic controller means 100 and being means for stopping the bailer tube 90 being raised from the well casing 16. A back up proximity sensor switch 88blocated in a predetermined spaced apart relationship with the proximity sensor switch 88a, typically about 4-8 inches above the proximity sensor switch 88a, is included and acts as means for stopping the bailer tube 90 should the proximity sensor switch 88bfail. This switch 88bis also in electrical communication with the programmable logic controller means 100.

[0150] The programmable logic controller means 100 further monitors a top 98cof the oil column location within the well casing 16 as well as a bottom 98blocation of the oil column within the well casing 16, the bottom location 98bcorresponding to a location of the top 98aof the water column within the well casing 16. The optimum depth 98din the well casing 16 of the lower end of the bailer tube 90 for capturing the column of oil 18 without water 20 is an intermediate location between the location of the top 98cof the oil column and above the location of the bottom 98bof the oil column.

[0151] The programmable logic controller means 100 performs an operational logging sequence during which the programmable logic controller means 100 operationally opens the bailer valve 90aand the actuated 3-ported valve means 34, starts the lowering of the bailer tube 90 into the well casing 16 accelerating to a predetermine adjustable travel speed 102, allows the bailer tube 90 to descend to a pre-set logging depth above the location of the top 98cof the oil column within the well casing 16, decreases the adjustable travel speed 102 so that the lower end of the bailer tube 90 enters into the oil column at which point the oil and water sensor means 70 identifies a depth of the top 98cof the oil column, the lower end of the bailer tube 90 continues to descend until the oil and water sensor means 70 identifies a depth of the top 98aof the water in the well casing 18, transmits data reflective of the identification of the depth of the top 98c, 98aof the oil and water to the programmable logic controller means 100 which recalculates desired operational parameters including a new logging depth, optimum depth and bailer tube travel speed, closes the bailer valve 90a, starts elevating the bailer tube 90 through the well casing 16 until the bailer tube 90 enters the bailer tube housing assembly 28, stops the bailer tube 90 when the lower end of the bailer tube 90 is above the actuated 3-ported valve means 34, closes the actuated 3-ported valve means 34, opens the bailer valve 90afor a predetermined top dwell time thereby redirecting the captured oil 18 in the bailer tube 90 into the temporary storage tank 22, closes the bailer valve 90aafter the captured oil 18 has been discharged into the temporary storage tank 22, and repeats the above operational logging sequence as desired. The presence of a gas pocket is also identified by the oil and water sensor means 70 and this data is also transmitted to the PLC 100.

[0152] The programmable logic controller means 100 also performs a balanced oil production operational sequence during which the programmable logic controller means 100 operationally opens the bailer valve 90aand the actuated 3-ported valve means 34, starts the lowering of the bailer tube 90 into the well casing 18 accelerating to a predetermine adjustable travel speed 102, allows the bailer tube 90 to descend to a pre-set logging depth above the location of the top 98cof the oil column within the well casing 16, decreases the adjustable travel speed 102 so that the lower end of the bailer tube 90 enters into the oil column 18 at which point the oil and water sensor means 70 identifies a depth of the top 98cof the oil column, the lower end of the bailer tube 90 continues to descend into the oil column and stops at the optimum depth 98dat which point the bailer valve 90ais closed after a predetermined preset dwell time to capture oil 18, transmits data reflective of the identification of the depth of the top 98cof the oil and optimum depth 98dto the programmable logic controller means 100 which continually calculates and monitors desired operational parameters including the logging depth, optimum depth 98dand bailer tube travel speed 102, starts elevating the bailer tube 90 through the well casing 16 until the upper end of the bailer tube 90 enters the bailer tube housing assembly 28, stops the bailer tube 90 when the lower end of the bailer tube 90 is above the actuated 3-ported valve means 34, closes the actuated 3-ported valve means 34, opens the bailer valve 90afor a predetermined top dwell time thereby discharging the captured oil 18 in the bailer tube 90 into the temporary storage tank 22, closes the bailer valve 90aafter the captured oil 18 has been discharged into the temporary storage tank 22, and repeats the above balanced oil production operational sequence as desired.

[0153] Other typical operating structural features shown in the drawings include a basket strainer 36 in the line between the 3-ported valve means 34 and the storage tank 22; an electric motor 54 and hydraulic pump 52 for operating the winch means 56; an oil flow meter 58; a coupling 74, typically 4½ inch, at the upper end of the bailer housing assembly 28; a fluid fill port 78 and associated vent port 82; a quick disconnect bailer connector 84; and a bailer coil 80.

[0154] The programmable logic controller means 100 further monitors an accumulated level 116 of oil 18 in the temporary storage tank 22, monitors gaseous pressure and oil pressure 124, 128 in the well casing 16 and temporary storage tank 22 using corresponding pressure sensor means, and monitors a tension 134 in the cable wire 68.

[0155] The invention further comprises a field communicator 160, which is operatively in communication with the programmable logic controller means 100. The field communicator 160 is operatively in communication with a data base server 162, the data base server for storing, organizing and polling data outputted 138 from the programmable logic controller means 100, for users to change operating parameters of the programmable logic controller means 100, for providing historical data and performing diagnostics, and for providing data collection, reporting, analysis and visualization displays. The data base server 162 is accessible by a user or customer base 166 through a website 164. Another embodiment is the inclusion of a paging system 170 in operative communication with the programmable logic controller means 100, the paging system 170 for communicating pre-set alarms and messages between a field service department 168 and the programmable logic controller means 100.

[0156] Referring back to the structure as shown conceptually in the drawings, the contents of the temporary storage tank 22 can optionally be gravity drained to another location such as a transport truck or other storage location (generically shown in FIG. 1aas 14), the contents may be pumped to a transport tank or other storage location, or the system may have the capability of gravity draining and pumping the contents whichever suits the needs of the field operator.

[0157] Typically, bailer tube housing assembly 28 is made from a 4 inch pipe while the bailer tube 90 is generally a 3 inch pipe of sufficient length and capable of holding in its interior space approximately 4 gallons of oil.

[0158] Examples of such other parameters and components monitored by the PLC means 100 may include an oil pump on/off switch 120 for emptying the storage tank 22, a data translator 130, a winch speed indicator 146, bailer location 108, bailer valve open position indicator 148aand closed position indicator 148b, a data output 138, a cycle per minute indicator 122, a cable wire tension sensor indicator 134, a hydraulic winch level sensor 152, a bailer stop switch sensor indicator 88a, 88b, and a dial up module 136. The data output 138 may be transmitted using a modem 150. That is, the PLC means 100 is a means for monitoring, operating and controlling the apparatus 10 and for translating readable information or output data 138 to obtain and record operational parameters such as the depth of the bailer tube 104, the location of the bailer tube 108, the flow/volume of gas intake 112, the flow/volume of oil intake 114, the bailer tube cycles per minute 122 and the tension in the cable wire 134, among other operational parameters desired in the field.

[0159] As mentioned above, the PLC means 100 can be programmed to cycle through the logging sequence mode every so often as well as at the start of operations. Therefore, it will monitor the rate that the oil column 18 is decreasing or increasing and make necessary adjustments to slow down or speed up the normal running sequence. The normal running sequence starts out with the travel speed 102 at optimum operating speed and as the rate the oil column is decreasing, the PLC means 100 compares this rate with the current rate of speed and adjusts the travel speed slightly as needed during the operating cycles. While monitoring the rate of decrease, the PLC means 100 is continuously making small adjustments until the oil column stops decreasing in size (height) maintaining a steady constant height. The PLC means 100 continues to run at this travel speed 102 while continuing to monitor the size of the oil column 18, continuing to make adjustments in order to maintain a balanced sized oil column 18.

[0160] The PLC means 100 also activates the actuation means or pump on/off switch 120 which is operatively connected to the pumping means 22afor pumping the captured oil 18 from the temporary storage tank 22 when said temporary storage tank 22 accumulates a predetermined level of captured oil 18. Production for a given well is monitored in the PLC means 100 at 112 and 114.

[0161] Well operations will typically start with a logging process mode. Based on experience and geological surveys, the field operators generally have an educated feeling as to the depth at which a top 98cof an oil column so the logging process can be initiated such that the bailer tube 90 is made to accelerate to a pre-set depth above the expected top 98cof the oil column. Of course, if the field operators desire that pre-set depth may be a couple of hundred feet or more to as little as a few inches below the top of the well casing 16.

[0162] In another embodiment of the invention, multiple apparatus and control systems 10 may be located at various field sites and centrally monitored and controlled. For example, FIG. 5edepicts one or more apparatus and control systems at one site or multiple sites, in this case, three oil recovery/PLC units denoted as #1, #2 and #3 respectively, which are in communication with a paging system 170 for communication with a Field Service Department 168 which may be located at or near the sites or remotely some distance away. Field service operators may use this communication means to operationally monitor and control each field installation. Similarly, each apparatus and control systems 10 is in communication a field communicator PC 160 using a dial up modem, an ISDN connector and a FTP router. The field communicator PC transfers data 138 to a data base server PC 162, which may be located at a central data processing site. This server PC 162 typically may utilize an AB RS View software, an Microsoft sequel server data base software and a historian software to analyze, manipulate, store, display data and graphics, among many other functions.

[0163] For aid in understanding the interrelationship and capabilities of the invention, the following definitions are provided. The dial up modem is used to go online with a CPU from a remote location to report for down time faults, among other parameters. It typically can provide for up to 244 different paging alarms of pre-set messages. An ISDN connection or Integrated Services Digital Network is set of international communication standards, which are accepted worldwide by communication carriers using a router, that plugs into a phone line jack. ISDN connections can be up to 5 times faster than analog dial up. An FTP (File Transfer Protocol) Router is a device, which allows a specific file or files in a defined location on a hard drive, to be accessed for downloading across the internet. An ALLEN-BRADLEY® ROCKWELL SOFTWARE® View software (AB RS) is an example of a custom graphic interface software package, which can directly communicate with a known process, thereby allowing users to change operating parameters. Changes can include feed rate, operating speeds and flow rates, among other parameters. This type of software can also provide machine or equipment history, alarm history, and performs diagnostics. A MICROSOFT® sequel server (PC) is a data base system written by Microsoft Corporation for storing, organizing and polling large amounts of data. Other similar systems are known in the art. The historian software is a software package for data collection, reporting, analysis and visualization, including graphics, display. With the integration of these described features, a website 164 may be used to access data from the server 162 by the customer base 166.

[0164] For example, apparatus 10 may be installed in one field site location, or multiple apparatus 10 may be installed at or near the same location, or one or more apparatus 10 may be installed at multiple field site locations. Each of these installations, no matter where located, whether it be in a particular state, country or continent, may be connected to a regional field communicator 160 supporting the installations. The server 162 may however be located in a different state, country or continent and accessible from anywhere in the world using the website 164.

[0165] The apparatus 10 is generally arranged as diagrammatically depicted in FIGS. 1a-1dand structurally supported by a support frame 60 which is built to suit the configuration and may include a ladder to reach the pulley means 64, a base platform, necessary braces, etc.

[0166] As seen from the foregoing description, the present invention satisfies a long felt need to provide a device in generally low producing wells which can account for the rate of replenishment of oil in the well bore such that only oil is removed as opposed to the removal of combined oil and water, the latter requiring a much higher production cost to separate the water and to re-inject the water back into the well bore.

[0167] The invention is clearly new and useful. Moreover, it was not obvious to those of ordinary skill in this art at the time it was made, in view of the prior art considered as a whole as required by law.

[0168] It will thus be seen that the objects set forth above, and those made apparent from the foregoing description, are efficiently attained and since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing construction or shown in the accompanying drawings shall be interpreted as illustrative and not in the limiting sense.

[0169] It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.

[0170] Now that the invention has been described,