US20220235636A1 - Rod rotator assembly for an artificial lift system - Google Patents
Rod rotator assembly for an artificial lift system Download PDFInfo
- Publication number
- US20220235636A1 US20220235636A1 US17/580,795 US202217580795A US2022235636A1 US 20220235636 A1 US20220235636 A1 US 20220235636A1 US 202217580795 A US202217580795 A US 202217580795A US 2022235636 A1 US2022235636 A1 US 2022235636A1
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- United States
- Prior art keywords
- housing
- load cell
- rod
- rotator assembly
- top cap
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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- 238000012544 monitoring process Methods 0.000 description 5
- 238000005086 pumping Methods 0.000 description 4
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- 238000013461 design Methods 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
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- 238000004891 communication Methods 0.000 description 1
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- 238000012545 processing Methods 0.000 description 1
Images
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B47/00—Pumps or pumping installations specially adapted for raising fluids from great depths, e.g. well pumps
- F04B47/02—Pumps or pumping installations specially adapted for raising fluids from great depths, e.g. well pumps the driving mechanisms being situated at ground level
- F04B47/022—Pumps or pumping installations specially adapted for raising fluids from great depths, e.g. well pumps the driving mechanisms being situated at ground level driving of the walking beam
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/12—Methods or apparatus for controlling the flow of the obtained fluid to or in wells
- E21B43/121—Lifting well fluids
- E21B43/126—Adaptations of down-hole pump systems powered by drives outside the borehole, e.g. by a rotary or oscillating drive
- E21B43/127—Adaptations of walking-beam pump systems
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B47/00—Survey of boreholes or wells
- E21B47/008—Monitoring of down-hole pump systems, e.g. for the detection of "pumped-off" conditions
- E21B47/009—Monitoring of walking-beam pump systems
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B47/00—Pumps or pumping installations specially adapted for raising fluids from great depths, e.g. well pumps
- F04B47/02—Pumps or pumping installations specially adapted for raising fluids from great depths, e.g. well pumps the driving mechanisms being situated at ground level
- F04B47/026—Pull rods, full rod component parts
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B9/00—Piston machines or pumps characterised by the driving or driven means to or from their working members
- F04B9/02—Piston machines or pumps characterised by the driving or driven means to or from their working members the means being mechanical
Definitions
- the present disclosure relates generally to a rod rotator assembly for an artificial lift system.
- the oil within the reservoirs may be under sufficient pressure to drive the oil through the well to the surface. However, over time, the natural pressure of the oil may decline, and an artificial lift system may be used to extract the oil from the reservoir.
- the artificial lift system may include a pump disposed within the reservoir and a wellhead at the surface.
- a tubing string may be supported by the wellhead and may extend to the reservoir, and the pump may drive the oil from the reservoir to the wellhead via the tubing string.
- the pump is driven by a series of polish rods that extend through the tubing string to the pump.
- the polish rods are lifted and lowered by a pump jack, which supports the polish rods.
- the repeated lifting and lowering movement of the polish rods causes the polish rods to wear at the point(s) of contact with the tubing string.
- certain artificial lift systems include a rod rotator to drive the polish rods to rotate within the tubing string, thereby distributing the wear around the circumference of the polish rods. As a result, the longevity of the polish rods may be increased.
- Certain artificial lift systems include a load cell configured to monitor the load on the polish rods. If the load on the polish rods is outside of a target range (e.g., above a maximum threshold load or below a minimum threshold load), an operator may adjust or terminate operation of the artificial lift system.
- the load cell is disposed about a top polish rod and positioned between the rod rotator and a carrier, which is coupled to the pump jack by cables and supports the rod rotator.
- a first set of alignment plates may be disposed between the rod rotator and the load cell.
- a second set of alignment plates may be disposed between the load cell and the carrier.
- the load cell and the two sets of alignment plates increases the height of the stack of equipment supported by the pump jack, which increases the stroke length of the pump jack.
- a rod rotator assembly for an artificial lift system includes a housing configured to be supported by a carrier of the artificial lift system.
- the rod rotator assembly also includes a top cap configured to rotate relative to the housing, in which the top cap is configured to support a polish rod of the artificial lift system.
- the rod rotator assembly includes a load cell disposed within the housing. The load cell is configured to support the top cap, and the load cell is configured to output a sensor signal indicative of a load applied by the polish rod to the housing.
- FIG. 1 is a schematic side view of an embodiment of an artificial lift system having an embodiment of a rod rotator assembly
- FIG. 2 is a schematic side view of a portion of the artificial lift system of FIG. 1 , including a wellhead and a polish rod connection assembly;
- FIG. 3 is a schematic side view of the polish rod connection assembly of FIG. 2 , in which the polish rod connection assembly includes the rod rotator assembly;
- FIG. 4 is a schematic cross-sectional view of the rod rotator assembly of FIG. 3 ;
- FIG. 5 is a cross-sectional perspective view of the rod rotator assembly of FIG. 3 .
- FIG. 1 is a schematic side view of an embodiment of an artificial lift system 10 having an embodiment of a rod rotator assembly 12 .
- the artificial lift system 10 includes a pump 14 disposed within a reservoir 16 .
- the artificial lift system 10 also includes a wellhead 18 at the surface 20 .
- a tubing string 22 which is supported by the wellhead 18 , extends from the surface 20 to the reservoir 16 .
- the pump 14 is configured to drive oil from the reservoir 16 to the surface 20 via the tubing string 22 and the wellhead 18 .
- the pump 14 is driven by a series of polish rods that extend through the tubing string 22 to the pump 14 .
- a polish rod 24 at the end of the series of polish rods is coupled to a pump jack 26 of the artificial lift system 10 .
- the pump jack 26 is configured to lift and lower the polish rods, thereby driving the pump 14 .
- One or more polish rods may contact the tubing string 22 at one or more points along a circumference of the polish rod(s). Accordingly, as the polish rods are driven to move within the tubing string 22 , certain point(s) on the polish rod(s) may wear.
- the rod rotator assembly 12 is configured to drive the polish rods to rotate within the tubing string 22 , thereby distributing the wear around the circumference of the polish rod(s). As a result, the longevity of the polish rods may be increased.
- the rod rotator assembly 12 is supported by a carrier (e.g., carrier bar) that is supported by the pump jack 26 via one or more cables.
- the rod rotator assembly 12 includes a housing configured to be supported by the carrier of the artificial lift system 10 .
- the rod rotator assembly 12 includes a top cap configured to rotate relative to the housing, in which the top cap is configured to support the polish rod 24 (e.g., via a polish rod clamp).
- the rod rotator assembly 12 also includes a load cell disposed within the housing (e.g., between the top cap and a base of the housing). The load cell is configured to support the top cap, and the load cell is configured to output a sensor signal indicative of a load applied by the polish rod to the housing. Accordingly, load on the polish rods may be monitored (e.g., continuously, periodically, on demand, etc.) to facilitate operation of the artificial lift system 10 .
- operation of the pump jack 26 may be adjusted or terminated (e.g., automatically or manually) in response to the load on the polish rods being outside of a target range (e.g., above a maximum threshold load or below a minimum threshold load).
- a target range e.g., above a maximum threshold load or below a minimum threshold load.
- the load cell is disposed within the rod rotator assembly housing, the height of the stack supported by the carrier may be reduced (e.g., as compared to a configuration in which a load cell is positioned between the rod rotator and the carrier, a first set of alignment plates is positioned between the rod rotator and the load cell, and a second set of alignment plates is positioned between the load cell and the carrier), thereby reducing the stroke length of the pump jack.
- the number of component interfaces along the polish rod may be reduced (e.g., as compared to a configuration in which a load cell is positioned between the rod rotator and the carrier, a first set of alignment plates is positioned between the rod rotator and the load cell, and a second set of alignment plates is positioned between the load cell and the carrier), thereby reducing the possibility of misalignment of components at the interfaces.
- FIG. 2 is a schematic side view of a portion of the artificial lift system 10 of FIG. 1 , including the wellhead 18 and a polish rod connection assembly 28 .
- the wellhead 18 includes a tubing spool 30 that supports the tubing string (e.g., via a tubing hanger coupled to an end of the tubing string and engaged with the tubing spool).
- the wellhead 18 also includes a pumping tee 32 coupled to the tubing spool 30 and to a flowline 34 .
- the pumping tee 32 is configured to receive oil from the tubing spool 30 and to control the flow of the oil through the flow line 34 .
- the flow line 34 may extend to a storage or processing facility.
- the wellhead 18 includes a stuffing box 36 coupled to the pumping tee 32 .
- the stuffing box is configured to establish a seal around the polish rod 24 that substantially blocks flow of oil through the polish rod/stuffing box interface while enabling the upward/downward movement of the polish rod.
- the wellhead 18 includes the tubing spool 30 , the pumping tee 32 , and the stuffing box 36 in the illustrated embodiment, the wellhead may include other and/or additional components in other embodiments.
- the polish rod connection assembly 28 includes the rod rotator assembly 12 , which is configured to drive the polish rod 24 to rotate relative to the wellhead 18 and the tubing string.
- the polish rod connection assembly 28 also includes a carrier 38 (e.g., carrier bar) configured to support the rod rotator assembly 12 .
- the carrier 38 may be coupled to the pump jack by one or more cables.
- the polish rod connection assembly 28 includes one or more polish rod clamps 40 configured to non-movably couple to the polish rod 24 .
- the polish rod clamps 40 transfer the load (e.g., substantially vertical load) of the polish rods to the rod rotator assembly 12 , the load flows through the rod rotator assembly 12 to the carrier 38 , and the load applied to the carrier is transferred to the pump jack via the cable(s). Accordingly, during an upward movement of the pump jack, the pump jack lifts the carrier 38 via the cable(s), the carrier 38 drives the rod rotator assembly 12 to move upwardly, and the rod rotator assembly 12 drives the polish rods to move upwardly via engagement of the rod rotator assembly 12 with the polish rod clamp(s). During a downward movement of the pump jack, the pump jack drives the polish rod 24 downwardly. Because the polish rod clamp(s) 40 are non-movably coupled to the polish rod 24 , the polish rod clamp(s) 40 drive the rod rotator assembly 12 to move downwardly, thereby driving the carrier 38 to move downwardly.
- the polish rod clamp(s) 40 are non-movably coupled to the polish rod 24 , the polish rod
- FIG. 3 is a schematic side view of the polish rod connection assembly 28 of FIG. 2 .
- the polish rod connection assembly 28 includes the rod rotator assembly 12 , the carrier 38 , and the polish rod clamps 40 .
- the rod rotator assembly 12 includes a housing 42 , which is supported by the carrier 38 .
- the rod rotator assembly 12 also includes a top cap 44 configured to rotate relative to the housing 42 .
- the top cap 44 is engaged with the polish rod clamp(s) 40 , thereby supporting the polish rods.
- rotation of the top cap 44 relative to the housing 42 drives the polish rods to rotate, thereby increasing the longevity of the polish rods.
- the polish rod connection assembly 28 includes two polish rod clamps 40 in the illustrated embodiment, in other embodiments, the polish rod connection assembly may include more or fewer polish rod clamps (e.g., 1, 3, 4, or more).
- the rod rotator assembly 12 includes a lever 46 configured to drive the top cap to rotate.
- the lever 46 is coupled to a worm gear of the rod rotator assembly 12 , and movement of the lever drives the worm gear to rotate.
- the worm gear is engaged with a main gear of the rod rotator assembly 12 and configured to drive the main gear to rotate.
- the main gear is non-rotatably coupled to the top cap 44 . Accordingly, movement of the lever 46 drives the top cap 44 to rotate, thereby driving the polish rods to rotate via contact between the top cap 44 and the polish rod clamps 40 .
- the lever 46 may be driven to move via a cable extending between the lever 46 and a base of the pump jack.
- the cable may cyclically drive the lever 46 to move in response to the rod rotator assembly 12 moving to a distance away from the pump jack cable anchor point that is greater than the length of the cable.
- the top plate 44 is driven to rotate by the lever 46 , the worm gear, and the main gear in the embodiment disclosed herein, the top plate may be driven to rotate relative to the rod rotator assembly housing via any other suitable device/assembly (e.g., electric motor, pneumatic actuator, another suitable mechanical drive assembly, etc.).
- a set of alignment plates 48 is positioned between the housing 42 of the rod rotator assembly 12 and the carrier 38 (e.g., carrier bar).
- the set of alignment plates 48 may include a first alignment plate having a hemispherical recess and a second alignment plate having a hemispherical protrusion.
- the hemispherical protrusion of the second alignment plate is engaged with the hemispherical recess of the first alignment plate, thereby enabling the alignment plates to slide relative to one another.
- One alignment plate of the set may be engaged with the rod rotator assembly housing 42 , and the other alignment plate of the set may be engaged with the carrier 38 .
- the set of alignment plates 48 facilitates a transfer of load (e.g., substantially vertical load) from the rod rotator assembly housing 42 to the carrier 38 even while the housing 42 and the carrier 38 are not aligned with one another (e.g., the bottom surface of the housing 42 is not parallel to the top surface of the carrier 38 ). Accordingly, the non-vertical load (e.g., load that is not along the direction of extension/movement of the polish rod 24 ) applied to the polish rod 24 at the interface between the housing 42 and the carrier 38 may be substantially reduced, thereby increasing the longevity of the polish rod 24 .
- load e.g., substantially vertical load
- the set of alignment plates may have another suitable arrangement that facilitates transfer of load (e.g., substantially vertical load) from the rod rotator housing to the carrier while substantially reducing the non-vertical load applied to the polish rod due to misalignment of the housing/carrier.
- load e.g., substantially vertical load
- the set of alignment plates may be omitted.
- FIG. 4 is a schematic cross-sectional view of the rod rotator assembly 12 of FIG. 3 .
- the rod rotator assembly 12 includes the housing 42 and the top cap 44 .
- the housing 42 is configured to be supported by the carrier, and the top cap 44 is configured to rotate relative to the housing 42 .
- the top cap 44 is also configured to support the polish rod via the polish rod clamp(s).
- the rod rotator assembly 12 also includes a load cell 50 , a bearing 52 , and the main gear 54 disposed within the housing 42 .
- the main gear 54 is non-rotatably coupled to the top cap 44 and configured to be driven to rotate by a worm gear or an electrical rotary motor.
- the load cell 50 is disposed within the housing 42 (e.g., between the top cap 44 and a base 56 of the housing 42 ).
- the load cell 50 is configured to support the top cap 44
- the load cell 50 is configured to output a sensor signal indicative of a load applied by the polish rod to the housing 42 .
- the bearing 52 is disposed between the load cell 50 and the main gear 54 , thereby enabling the main gear 54 to rotate relative to the load cell 50 , which may be non-rotatably coupled to the housing 42 .
- the load cell may be non-rotatably coupled to the main gear.
- the bearing may be disposed between the load cell and the base of the housing.
- “disposed between” refers to an arrangement in which one component is positioned between at least a portion of another component and at least a portion of a further component.
- the rod rotator assembly 12 includes a single bearing 52 in the illustrated embodiment, in other embodiments, the rod rotator assembly may include more or fewer bearings (e.g., 0, 2, 3, or more).
- one or more bushings may be disposed between components within the rod rotator assembly housing (e.g., alone or in combination with the bearing(s)).
- the bearing may be omitted, and a bushing may be disposed between the main gear and the load cell.
- top cap 44 is driven to rotate by the main gear 54 in the illustrated embodiment
- the top cap may be driven to rotate by any other suitable device/assembly (e.g., in which at least a portion of the device/assembly is disposed within the housing between the top cap and the load cell).
- an electrical rotary motor e.g., gimbaled or non-gimbaled
- gimbaled or non-gimbaled may be disposed between the load cell and the top cap.
- a first portion (e.g., body) of the motor may be non-rotatably and translatably coupled to the housing, and a second portion (e.g., rotary shaft) may be non-rotatably coupled to the top cap to drive the top cap to rotate.
- a second portion e.g., rotary shaft
- the main gear, the worm gear, the lever, and the bearing may be omitted.
- the load cell 50 is positioned between the top cap 44 and a portion (e.g., base 56 ) of the housing 42 , the load applied by the polish rods to the top cap 44 is transferred through the load cell 50 to the housing 42 , which is supported by the carrier. Accordingly, the load on the polish rods may be monitored by the load cell (e.g., continuously, periodically, on demand, etc.) to facilitate operation of the artificial lift system 10 . For example, operation of the pump jack may be adjusted or terminated (e.g., automatically or manually) in response to the load on the polish rods being outside of a target range (e.g., above a maximum threshold load or below a minimum threshold load).
- a target range e.g., above a maximum threshold load or below a minimum threshold load.
- the load cell may output the sensor signal indicative of the load applied by the polish rods to the housing 42 via a wired or wireless connection.
- a load cell cable 58 extends between the load cell and a monitoring/control system, and the sensor signal may be output via the load cell cable 58 .
- the load cell may be communicatively coupled to the monitoring/control system via a wireless connection.
- the wireless connection may utilize any suitable wireless communication protocol, such as Bluetooth, WiFi, radio frequency identification (RFID), a proprietary protocol, or a combination thereof.
- the load cell 50 may include any suitable sensor(s) configured to monitor the load on the polish rods, such as piezoelectric sensor(s), strain gauge(s), other suitable type(s) of sensor(s), or a combination thereof.
- the height of the stack supported by the carrier may be reduced (e.g., as compared to a configuration in which a load cell is positioned between the rod rotator and the carrier, a first set of alignment plates is positioned between the rod rotator and the load cell, and a second set of alignment plates is positioned between the load cell and the carrier). Accordingly, the stroke length of the pump jack may be reduced.
- the number of component interfaces along the polish rod may be reduced (e.g., as compared to a configuration in which a load cell is positioned between the rod rotator and the carrier, a first set of alignment plates is positioned between the rod rotator and the load cell, and a second set of alignment plates is positioned between the load cell and the carrier).
- a set of alignment plates is not disposed within the housing in the illustrated embodiment, in other embodiments, at least one set of alignment plates may be disposed within the housing (e.g., between the main gear and the load cell).
- FIG. 5 is a cross-sectional perspective view of the rod rotator assembly 12 of FIG. 3 .
- the rod rotator assembly 12 includes a housing 42 , which is supported by the carrier.
- the housing 42 includes the base 56 and a body 60 extending upwardly from the base 56 along a longitudinal axis 62 of the rod rotator assembly 12 .
- the body 60 forms a first opening 64 on an opposite longitudinal side of the housing 42 from the base 56 , and the first opening 64 provides access to an interior 66 of the housing 42 .
- the base 56 of the housing 42 forms a second opening 68 .
- the openings in the housing 42 facilitate passage of the polish rod through the housing 42 .
- annular bushing 70 is disposed within the second opening 68 .
- the annular bushing 70 is configured to contact the polish rod, thereby substantially blocking dirt and/or debris from entering the housing interior 66 via the second opening 68 .
- the housing 42 includes the annular bushing 70 in the illustrated embodiment, in other embodiments, the annular bushing may be omitted.
- the housing 42 has an annular shape in the illustrated embodiment, in other embodiments, the housing may have any other suitable shape (e.g., polygonal, elliptical, irregular, etc.).
- the rod rotator assembly 12 includes a top cap 44 configured to rotate relative to the housing 42 .
- the top cap 44 is configured to rotate along a circumferential axis 72 of the rod rotator assembly 12 .
- the top cap 44 is configured to support the polish rods via the polish rod clamp(s).
- the top cap 44 includes a body 74 and a platform 76 .
- the body 74 extends through the first opening 64 in the housing 42 into the interior 66 of the housing 42
- the platform 76 has an engagement surface 78 configured to engage the polish rod clamp(s), thereby supporting the polish rods.
- the platform 76 of the top cap 44 has an opening 80 configured to facilitate passage of the polish rod (e.g., top polish rod) through the platform 76 .
- the body 74 of the top cap 44 is configured to be disposed outwardly from the polish rod along a radial axis 82 of the rod rotator assembly 12 , thereby facilitating passage of the polish rod through the body 74 .
- the body 74 of the top cap 44 extends through the first opening 64 of the housing 42 into the interior 66 of the housing 42 in the illustrated embodiment, in other embodiments, the body may not extend into the housing interior (e.g., the body may be non-rotatably coupled to a component of the rod rotator assembly positioned at least partially outside of the housing, such as the main gear). Furthermore, in certain embodiments, the body of the top cap may be omitted (e.g., the platform of the top cap may be non-rotatably coupled to a component of the rod rotator assembly, such as the main gear).
- the rod rotator assembly 12 includes a main gear 54 non-rotatably coupled to the body 74 of the top cap 44 .
- the main gear 54 may be non-rotatably coupled to the body 74 of the top cap 44 via any suitable type(s) of connection(s), such as welded connection(s), a press-fit connection, fastener connection(s), adhesive connection(s), other suitable type(s) of connection(s), or a combination thereof.
- the main gear 54 is configured to be driven to rotate by a worm gear. In the illustrated embodiment, movement of the lever 46 drives the worm gear to rotate, thereby driving the main gear 54 to rotate.
- the main gear 54 Due to the non-rotatable coupling between the main gear 54 and the body 74 of the top cap 44 , rotation of the main gear 54 drives the top cap 44 to rotate, thereby driving the polish rods to rotate via the contact between the engagement surface 78 of the top cap 44 and the polish rod clamp(s).
- the main gear 54 is driven to rotate by a worm gear coupled to the lever 46 in the illustrated embodiment, in other embodiments, the main gear may be driven to rotate by a motor (e.g., electric motor, hydraulic motor, pneumatic motor, etc.).
- the main gear may be omitted, and a motor (e.g., electric motor, hydraulic motor, pneumatic motor, etc.) may drive the top cap to rotate, as discussed above with reference to FIG. 4 .
- the rod rotator assembly 12 includes a load cell 50 , which is disposed within the interior 66 of the housing 42 .
- the load cell 50 is configured to support the top cap 44
- the load cell 50 is configured to output a sensor signal indicative of a load applied by the polish rods to the housing 42 . Because the load cell 50 is positioned between the top cap 44 and a portion (e.g., base 56 ) of the housing 42 , the load applied by the polish rods to the top cap 44 is transferred through the load cell 50 to the housing 42 , which is supported by the carrier. Accordingly, the load on the polish rods may be monitored by the load cell (e.g., continuously, periodically, on demand, etc.) to facilitate operation of the artificial lift system 10 .
- the load cell 50 may include any suitable sensor(s) configured to monitor the load on the polish rod, such as piezoelectric sensor(s), strain gauge(s), other suitable type(s) of sensor(s), or a combination thereof.
- the rod rotator assembly 12 includes a bearing 52 disposed between the load cell 50 and the main gear 54 along the longitudinal axis 62 of the rod rotator assembly 12 .
- the bearing 52 enables the main gear 54 to rotate relative to the load cell 50 , which may be non-rotatably coupled to the housing 42 .
- the bearing 52 includes a ball bearing (e.g., including multiple bearing balls between two races).
- the bearing may include other suitable type(s) of bearing(s) (e.g., alone or in combination with one or more ball bearings), such as roller bearing(s), fluid bearing(s), other suitable type(s) of bearing(s), or a combination thereof.
- the rod rotator assembly 12 includes a single bearing 52 in the illustrated embodiment, in other embodiments, the rod rotator assembly may include more or fewer bearings (e.g., 0, 2, 3, 4, or more).
- the body 74 of the top cap 44 overlaps the main gear 54 , the bearing 52 , and a portion of the load cell 50 along the longitudinal axis 62 .
- the body 74 of the top cap 44 includes a ledge 84 (e.g., annular ledge) engaged with the main gear 54 .
- the main gear 54 is disposed between the ledge 84 of the body 74 of the top cap 44 and the bearing 52 along the longitudinal axis 62 of the rod rotator assembly 12 .
- the load applied by the polish rods to the top cap 44 is transferred to the main gear 54 via the ledge 84 , to the bearing 52 via the main gear 54 , to the load cell 50 via the bearing 52 , and to the housing 42 via the load cell 50 . Accordingly, the load applied by the polish rods is transferred through the load cell 50 , thereby enabling the load cell to monitor the load applied by the polish rods to the housing 42 .
- the load may be transferred from the ledge to the load cell via another suitable path (e.g., through the main gear alone, through a bushing, through a motor, etc.).
- the body of the top cap engages a corresponding component of the rod rotator assembly (e.g., the main gear, a motor, etc.) via the ledge in the embodiments disclosed above
- the body of the top cap may engage the corresponding component via another suitable surface of the body (e.g., a bottom surface of the body, etc.).
- the ledge may be omitted.
- the body of the top cap may be omitted, and the platform of the top cap may engage the corresponding component of the rod rotator assembly.
- the load cell 50 is disposed between the body 74 of the top cap 44 (e.g., the ledge 84 of the body 74 of the top cap 44 ) and the base 56 of the housing 42 . Accordingly, the load applied by the polish rods to the top cap 44 is transferred through the load cell 50 to the base 56 of the housing 42 . While the load cell 50 is supported by the base 56 of the housing 42 in the illustrated embodiment, in other embodiments, the load cell may be supported by another suitable portion of the housing.
- the body of the housing may include a ledge, and the load cell may be supported by the ledge. In such embodiments, the load applied by the polish rods to the top cap may be transferred through the load cell to the housing via the ledge.
- the load cell may be coupled to the body of the housing by any suitable type(s) of connection(s), such as fastener connection(s), adhesive connection(s), a press fit connection, other suitable type(s) of connection(s), or a combination thereof. Additionally or alternatively, the load cell may be coupled to the body of the housing via one or more protrusion/recess interfaces. In embodiments in which the load cell is coupled to the body of the housing, the body supports the load cell, and the load applied by the polish rods to the top cap may be transferred through the load cell to the body of the housing.
- the rod rotator assembly 12 includes an adapter ring 86 disposed between the body 74 of the top cap 44 and the load cell 50 along the radial axis 82 of the rod rotator assembly 12 .
- the adapter ring 86 is configured to substantially block radial movement of the top cap body 74 relative to the load cell 50 and to facilitate establishment of a seal between the top cap body 74 and the load cell 50 (e.g., to substantially block dirt and/or debris from entering a cavity between the top cap body and the housing body).
- a first seal 88 (e.g., o-ring, etc.) is disposed between the adapter ring 86 and the top cap body 74
- a second seal 90 (e.g., o-ring, etc.) is disposed between the adapter ring 86 and the load cell 50 , thereby establishing the seal between the top cap body 74 and the load cell 50
- the rod rotator assembly includes two seals at the adapter ring in the illustrated embodiment, in other embodiments, the rod rotator assembly may include more or fewer seals at the adapter ring (e.g., 0, 1, 3, 4, or more). For example, in certain embodiments, at least one of the first and second seals may be omitted.
- the rod rotator assembly 12 includes a third seal 92 (e.g., o-ring, etc.) disposed between the platform 76 of the top cap 44 and the body 60 of the housing 42 along the radial axis 82 .
- the third seal 92 is configured to substantially block dirt and/or debris from entering the cavity between the top cap body and the housing body. While a single seal is disposed between the platform and the housing body along the radial axis in the illustrated embodiment, in other embodiments, more or fewer seals (e.g., 0, 2, 3, 4, or more) may be disposed between the platform and the housing body along the radial axis.
- the load cell 50 may output a sensor signal indicative of the load applied by the polish rods to the housing 42 via a wired or wireless connection.
- the load cell 50 is configured to output the sensor signal via a wired connection
- the wired connection includes a load cell cable 58 , which may extend between the load cell 50 and a monitoring/control system.
- the rod rotator assembly 12 includes a connector 94 coupled to the body 60 of the housing 42 .
- the connector 94 is configured to establish a wired connection to the load cell 50 .
- the connector may include one or more conductors electrically coupled to the load cell, and the connector may be configured to selectively establish an electrical connection between the conductor(s) and the load cell cable 58 .
- the connector 94 is coupled to the body 60 of the housing 42 via a threaded connection.
- the connector may be coupled to the housing body via other suitable type(s) of connection(s) (e.g., alone or in combination with the threaded connection), such as adhesive connection(s), fastener connection(s), other suitable type(s) of connection(s), or a combination thereof.
- the connector is coupled to the body of the housing in the illustrated embodiment, in other embodiments, the connector may be coupled to another suitable portion of the housing, such as the base.
- the load cell cable may be configured to establish an optical connection between the load cell and the monitoring/control system.
- the connector may be configured to establish an optical connection between the load cell and the load cell cable.
- the connector may be omitted.
- the load cell cable may extend through an opening in the housing to the load cell.
- the load cell may be communicatively coupled to the monitoring/control system via a wireless connection.
- the height of the stack supported by the carrier may be reduced (e.g., as compared to a configuration in which a load cell is positioned between the rod rotator and the carrier, a first set of alignment plates is positioned between the rod rotator and the load cell, and a second set of alignment plates is positioned between the load cell and the carrier). Accordingly, the stroke length of the pump jack may be reduced.
- the number of component interfaces along the polish rod may be reduced (e.g., as compared to a configuration in which a load cell is positioned between the rod rotator and the carrier, a first set of alignment plates is positioned between the rod rotator and the load cell, and a second set of alignment plates is positioned between the load cell and the carrier).
- a set of alignment plates is not disposed within the interior of the housing in the illustrated embodiment, in other embodiments, at least one set of alignment plates may be disposed within the interior of the housing (e.g., between the main gear and the load cell).
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Abstract
A rod rotator assembly for an artificial lift system includes a housing configured to be supported by a carrier of the artificial lift system. The rod rotator assembly also includes a top cap configured to rotate relative to the housing, in which the top cap is configured to support a polish rod of the artificial lift system. In addition, the rod rotator assembly includes a load cell disposed within the housing. The load cell is configured to support the top cap, and the load cell is configured to output a sensor signal indicative of a load applied by the polish rod to the housing.
Description
- This application claims priority from and the benefit of U.S. Provisional Application Ser. No. 63/140,672, entitled “ROD ROTATOR ASSEMBLY FOR AN ARTIFICIAL LIFT SYSTEM”, filed Jan. 22, 2021, which is hereby incorporated by reference in its entirety.
- The present disclosure relates generally to a rod rotator assembly for an artificial lift system.
- Wells are drilled into reservoirs to discover and produce oil. The oil within the reservoirs may be under sufficient pressure to drive the oil through the well to the surface. However, over time, the natural pressure of the oil may decline, and an artificial lift system may be used to extract the oil from the reservoir. The artificial lift system may include a pump disposed within the reservoir and a wellhead at the surface. A tubing string may be supported by the wellhead and may extend to the reservoir, and the pump may drive the oil from the reservoir to the wellhead via the tubing string.
- The pump is driven by a series of polish rods that extend through the tubing string to the pump. The polish rods are lifted and lowered by a pump jack, which supports the polish rods. The repeated lifting and lowering movement of the polish rods causes the polish rods to wear at the point(s) of contact with the tubing string. Accordingly, certain artificial lift systems include a rod rotator to drive the polish rods to rotate within the tubing string, thereby distributing the wear around the circumference of the polish rods. As a result, the longevity of the polish rods may be increased.
- Certain artificial lift systems include a load cell configured to monitor the load on the polish rods. If the load on the polish rods is outside of a target range (e.g., above a maximum threshold load or below a minimum threshold load), an operator may adjust or terminate operation of the artificial lift system. In certain artificial lift systems, the load cell is disposed about a top polish rod and positioned between the rod rotator and a carrier, which is coupled to the pump jack by cables and supports the rod rotator. To substantially reduce the non-vertical load applied to the top polish rod due to misalignment of the rod rotator and the load cell, a first set of alignment plates may be disposed between the rod rotator and the load cell. In addition, to substantially reduce the non-vertical load applied to the top polish rod due to misalignment of the load cell and the carrier, a second set of alignment plates may be disposed between the load cell and the carrier. Unfortunately, the load cell and the two sets of alignment plates increases the height of the stack of equipment supported by the pump jack, which increases the stroke length of the pump jack.
- In certain embodiments, a rod rotator assembly for an artificial lift system includes a housing configured to be supported by a carrier of the artificial lift system. The rod rotator assembly also includes a top cap configured to rotate relative to the housing, in which the top cap is configured to support a polish rod of the artificial lift system. In addition, the rod rotator assembly includes a load cell disposed within the housing. The load cell is configured to support the top cap, and the load cell is configured to output a sensor signal indicative of a load applied by the polish rod to the housing.
- These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
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FIG. 1 is a schematic side view of an embodiment of an artificial lift system having an embodiment of a rod rotator assembly; -
FIG. 2 is a schematic side view of a portion of the artificial lift system ofFIG. 1 , including a wellhead and a polish rod connection assembly; -
FIG. 3 is a schematic side view of the polish rod connection assembly ofFIG. 2 , in which the polish rod connection assembly includes the rod rotator assembly; -
FIG. 4 is a schematic cross-sectional view of the rod rotator assembly ofFIG. 3 ; and -
FIG. 5 is a cross-sectional perspective view of the rod rotator assembly ofFIG. 3 . - One or more specific embodiments of the present disclosure will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
- When introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Any examples of operating parameters and/or environmental conditions are not exclusive of other parameters/conditions of the disclosed embodiments.
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FIG. 1 is a schematic side view of an embodiment of anartificial lift system 10 having an embodiment of arod rotator assembly 12. As illustrated, theartificial lift system 10 includes apump 14 disposed within areservoir 16. Theartificial lift system 10 also includes awellhead 18 at thesurface 20. Atubing string 22, which is supported by thewellhead 18, extends from thesurface 20 to thereservoir 16. Thepump 14 is configured to drive oil from thereservoir 16 to thesurface 20 via thetubing string 22 and thewellhead 18. - The
pump 14 is driven by a series of polish rods that extend through thetubing string 22 to thepump 14. As illustrated, apolish rod 24 at the end of the series of polish rods is coupled to apump jack 26 of theartificial lift system 10. Thepump jack 26 is configured to lift and lower the polish rods, thereby driving thepump 14. One or more polish rods may contact thetubing string 22 at one or more points along a circumference of the polish rod(s). Accordingly, as the polish rods are driven to move within thetubing string 22, certain point(s) on the polish rod(s) may wear. Therod rotator assembly 12 is configured to drive the polish rods to rotate within thetubing string 22, thereby distributing the wear around the circumference of the polish rod(s). As a result, the longevity of the polish rods may be increased. As discussed in detail below, therod rotator assembly 12 is supported by a carrier (e.g., carrier bar) that is supported by thepump jack 26 via one or more cables. - In certain embodiments, the
rod rotator assembly 12 includes a housing configured to be supported by the carrier of theartificial lift system 10. In addition, therod rotator assembly 12 includes a top cap configured to rotate relative to the housing, in which the top cap is configured to support the polish rod 24 (e.g., via a polish rod clamp). Therod rotator assembly 12 also includes a load cell disposed within the housing (e.g., between the top cap and a base of the housing). The load cell is configured to support the top cap, and the load cell is configured to output a sensor signal indicative of a load applied by the polish rod to the housing. Accordingly, load on the polish rods may be monitored (e.g., continuously, periodically, on demand, etc.) to facilitate operation of theartificial lift system 10. For example, operation of thepump jack 26 may be adjusted or terminated (e.g., automatically or manually) in response to the load on the polish rods being outside of a target range (e.g., above a maximum threshold load or below a minimum threshold load). Because the load cell is disposed within the rod rotator assembly housing, the height of the stack supported by the carrier may be reduced (e.g., as compared to a configuration in which a load cell is positioned between the rod rotator and the carrier, a first set of alignment plates is positioned between the rod rotator and the load cell, and a second set of alignment plates is positioned between the load cell and the carrier), thereby reducing the stroke length of the pump jack. In addition, the number of component interfaces along the polish rod may be reduced (e.g., as compared to a configuration in which a load cell is positioned between the rod rotator and the carrier, a first set of alignment plates is positioned between the rod rotator and the load cell, and a second set of alignment plates is positioned between the load cell and the carrier), thereby reducing the possibility of misalignment of components at the interfaces. -
FIG. 2 is a schematic side view of a portion of theartificial lift system 10 ofFIG. 1 , including thewellhead 18 and a polishrod connection assembly 28. In the illustrated embodiment, thewellhead 18 includes atubing spool 30 that supports the tubing string (e.g., via a tubing hanger coupled to an end of the tubing string and engaged with the tubing spool). Thewellhead 18 also includes apumping tee 32 coupled to thetubing spool 30 and to aflowline 34. Thepumping tee 32 is configured to receive oil from thetubing spool 30 and to control the flow of the oil through theflow line 34. Theflow line 34 may extend to a storage or processing facility. Furthermore, thewellhead 18 includes astuffing box 36 coupled to thepumping tee 32. The stuffing box is configured to establish a seal around thepolish rod 24 that substantially blocks flow of oil through the polish rod/stuffing box interface while enabling the upward/downward movement of the polish rod. While thewellhead 18 includes thetubing spool 30, thepumping tee 32, and thestuffing box 36 in the illustrated embodiment, the wellhead may include other and/or additional components in other embodiments. - As discussed in detail below, the polish
rod connection assembly 28 includes therod rotator assembly 12, which is configured to drive thepolish rod 24 to rotate relative to thewellhead 18 and the tubing string. The polishrod connection assembly 28 also includes a carrier 38 (e.g., carrier bar) configured to support therod rotator assembly 12. Thecarrier 38 may be coupled to the pump jack by one or more cables. In addition, the polishrod connection assembly 28 includes one or more polish rod clamps 40 configured to non-movably couple to thepolish rod 24. The polish rod clamps 40 transfer the load (e.g., substantially vertical load) of the polish rods to therod rotator assembly 12, the load flows through therod rotator assembly 12 to thecarrier 38, and the load applied to the carrier is transferred to the pump jack via the cable(s). Accordingly, during an upward movement of the pump jack, the pump jack lifts thecarrier 38 via the cable(s), thecarrier 38 drives therod rotator assembly 12 to move upwardly, and therod rotator assembly 12 drives the polish rods to move upwardly via engagement of therod rotator assembly 12 with the polish rod clamp(s). During a downward movement of the pump jack, the pump jack drives thepolish rod 24 downwardly. Because the polish rod clamp(s) 40 are non-movably coupled to thepolish rod 24, the polish rod clamp(s) 40 drive therod rotator assembly 12 to move downwardly, thereby driving thecarrier 38 to move downwardly. -
FIG. 3 is a schematic side view of the polishrod connection assembly 28 ofFIG. 2 . As previously discussed, the polishrod connection assembly 28 includes therod rotator assembly 12, thecarrier 38, and the polish rod clamps 40. In the illustrated embodiment, therod rotator assembly 12 includes ahousing 42, which is supported by thecarrier 38. Therod rotator assembly 12 also includes atop cap 44 configured to rotate relative to thehousing 42. As illustrated, thetop cap 44 is engaged with the polish rod clamp(s) 40, thereby supporting the polish rods. In addition, due to the engagement of thetop cap 44 with the polish rod clamp(s) 40, rotation of thetop cap 44 relative to thehousing 42 drives the polish rods to rotate, thereby increasing the longevity of the polish rods. While the polishrod connection assembly 28 includes two polish rod clamps 40 in the illustrated embodiment, in other embodiments, the polish rod connection assembly may include more or fewer polish rod clamps (e.g., 1, 3, 4, or more). - In the illustrated embodiment, the
rod rotator assembly 12 includes alever 46 configured to drive the top cap to rotate. In certain embodiments, thelever 46 is coupled to a worm gear of therod rotator assembly 12, and movement of the lever drives the worm gear to rotate. As discussed in detail below, the worm gear is engaged with a main gear of therod rotator assembly 12 and configured to drive the main gear to rotate. The main gear, in turn, is non-rotatably coupled to thetop cap 44. Accordingly, movement of thelever 46 drives thetop cap 44 to rotate, thereby driving the polish rods to rotate via contact between thetop cap 44 and the polish rod clamps 40. Thelever 46 may be driven to move via a cable extending between thelever 46 and a base of the pump jack. As therod rotator assembly 12 moves upwardly and downwardly with the polish rod during operation of the pump jack, the cable may cyclically drive thelever 46 to move in response to therod rotator assembly 12 moving to a distance away from the pump jack cable anchor point that is greater than the length of the cable. While thetop plate 44 is driven to rotate by thelever 46, the worm gear, and the main gear in the embodiment disclosed herein, the top plate may be driven to rotate relative to the rod rotator assembly housing via any other suitable device/assembly (e.g., electric motor, pneumatic actuator, another suitable mechanical drive assembly, etc.). - In the illustrated embodiment, a set of
alignment plates 48 is positioned between thehousing 42 of therod rotator assembly 12 and the carrier 38 (e.g., carrier bar). The set ofalignment plates 48 may include a first alignment plate having a hemispherical recess and a second alignment plate having a hemispherical protrusion. The hemispherical protrusion of the second alignment plate is engaged with the hemispherical recess of the first alignment plate, thereby enabling the alignment plates to slide relative to one another. One alignment plate of the set may be engaged with the rodrotator assembly housing 42, and the other alignment plate of the set may be engaged with thecarrier 38. The set ofalignment plates 48 facilitates a transfer of load (e.g., substantially vertical load) from the rodrotator assembly housing 42 to thecarrier 38 even while thehousing 42 and thecarrier 38 are not aligned with one another (e.g., the bottom surface of thehousing 42 is not parallel to the top surface of the carrier 38). Accordingly, the non-vertical load (e.g., load that is not along the direction of extension/movement of the polish rod 24) applied to thepolish rod 24 at the interface between thehousing 42 and thecarrier 38 may be substantially reduced, thereby increasing the longevity of thepolish rod 24. While a set of alignment plates having a hemispherical protrusion/hemispherical recess is disclosed above, the set of alignment plates may have another suitable arrangement that facilitates transfer of load (e.g., substantially vertical load) from the rod rotator housing to the carrier while substantially reducing the non-vertical load applied to the polish rod due to misalignment of the housing/carrier. Furthermore, in certain embodiments, the set of alignment plates may be omitted. -
FIG. 4 is a schematic cross-sectional view of therod rotator assembly 12 ofFIG. 3 . As previously discussed, therod rotator assembly 12 includes thehousing 42 and thetop cap 44. Thehousing 42 is configured to be supported by the carrier, and thetop cap 44 is configured to rotate relative to thehousing 42. Thetop cap 44 is also configured to support the polish rod via the polish rod clamp(s). In the illustrated embodiment, therod rotator assembly 12 also includes aload cell 50, abearing 52, and themain gear 54 disposed within thehousing 42. Themain gear 54 is non-rotatably coupled to thetop cap 44 and configured to be driven to rotate by a worm gear or an electrical rotary motor. In addition, theload cell 50 is disposed within the housing 42 (e.g., between thetop cap 44 and abase 56 of the housing 42). Theload cell 50 is configured to support thetop cap 44, and theload cell 50 is configured to output a sensor signal indicative of a load applied by the polish rod to thehousing 42. As illustrated, thebearing 52 is disposed between theload cell 50 and themain gear 54, thereby enabling themain gear 54 to rotate relative to theload cell 50, which may be non-rotatably coupled to thehousing 42. However, in other embodiments, the load cell may be non-rotatably coupled to the main gear. In such embodiments, the bearing may be disposed between the load cell and the base of the housing. As used herein, “disposed between” refers to an arrangement in which one component is positioned between at least a portion of another component and at least a portion of a further component. - While the
rod rotator assembly 12 includes asingle bearing 52 in the illustrated embodiment, in other embodiments, the rod rotator assembly may include more or fewer bearings (e.g., 0, 2, 3, or more). In addition, in certain embodiments, one or more bushings may be disposed between components within the rod rotator assembly housing (e.g., alone or in combination with the bearing(s)). For example, the bearing may be omitted, and a bushing may be disposed between the main gear and the load cell. Furthermore, while thetop cap 44 is driven to rotate by themain gear 54 in the illustrated embodiment, in other embodiments, the top cap may be driven to rotate by any other suitable device/assembly (e.g., in which at least a portion of the device/assembly is disposed within the housing between the top cap and the load cell). For example, in certain embodiments, an electrical rotary motor (e.g., gimbaled or non-gimbaled) may be disposed between the load cell and the top cap. In such embodiments, a first portion (e.g., body) of the motor may be non-rotatably and translatably coupled to the housing, and a second portion (e.g., rotary shaft) may be non-rotatably coupled to the top cap to drive the top cap to rotate. Furthermore, in such embodiments, the main gear, the worm gear, the lever, and the bearing may be omitted. - Because the
load cell 50 is positioned between thetop cap 44 and a portion (e.g., base 56) of thehousing 42, the load applied by the polish rods to thetop cap 44 is transferred through theload cell 50 to thehousing 42, which is supported by the carrier. Accordingly, the load on the polish rods may be monitored by the load cell (e.g., continuously, periodically, on demand, etc.) to facilitate operation of theartificial lift system 10. For example, operation of the pump jack may be adjusted or terminated (e.g., automatically or manually) in response to the load on the polish rods being outside of a target range (e.g., above a maximum threshold load or below a minimum threshold load). The load cell may output the sensor signal indicative of the load applied by the polish rods to thehousing 42 via a wired or wireless connection. In the illustrated embodiment, aload cell cable 58 extends between the load cell and a monitoring/control system, and the sensor signal may be output via theload cell cable 58. However, in other embodiments, the load cell may be communicatively coupled to the monitoring/control system via a wireless connection. The wireless connection may utilize any suitable wireless communication protocol, such as Bluetooth, WiFi, radio frequency identification (RFID), a proprietary protocol, or a combination thereof. Furthermore, theload cell 50 may include any suitable sensor(s) configured to monitor the load on the polish rods, such as piezoelectric sensor(s), strain gauge(s), other suitable type(s) of sensor(s), or a combination thereof. - Because the load cell is disposed within the rod rotator assembly housing, the height of the stack supported by the carrier may be reduced (e.g., as compared to a configuration in which a load cell is positioned between the rod rotator and the carrier, a first set of alignment plates is positioned between the rod rotator and the load cell, and a second set of alignment plates is positioned between the load cell and the carrier). Accordingly, the stroke length of the pump jack may be reduced. In addition, the number of component interfaces along the polish rod may be reduced (e.g., as compared to a configuration in which a load cell is positioned between the rod rotator and the carrier, a first set of alignment plates is positioned between the rod rotator and the load cell, and a second set of alignment plates is positioned between the load cell and the carrier). As a result, the possibility of misalignment of components at the interfaces may be reduced. While a set of alignment plates is not disposed within the housing in the illustrated embodiment, in other embodiments, at least one set of alignment plates may be disposed within the housing (e.g., between the main gear and the load cell).
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FIG. 5 is a cross-sectional perspective view of therod rotator assembly 12 ofFIG. 3 . As previously discussed, therod rotator assembly 12 includes ahousing 42, which is supported by the carrier. In the illustrated embodiment, thehousing 42 includes thebase 56 and abody 60 extending upwardly from thebase 56 along alongitudinal axis 62 of therod rotator assembly 12. Thebody 60 forms afirst opening 64 on an opposite longitudinal side of thehousing 42 from thebase 56, and thefirst opening 64 provides access to an interior 66 of thehousing 42. Furthermore, in the illustrated embodiment, thebase 56 of thehousing 42 forms asecond opening 68. The openings in thehousing 42 facilitate passage of the polish rod through thehousing 42. In the illustrated embodiment, anannular bushing 70 is disposed within thesecond opening 68. Theannular bushing 70 is configured to contact the polish rod, thereby substantially blocking dirt and/or debris from entering thehousing interior 66 via thesecond opening 68. While thehousing 42 includes theannular bushing 70 in the illustrated embodiment, in other embodiments, the annular bushing may be omitted. Furthermore, while thehousing 42 has an annular shape in the illustrated embodiment, in other embodiments, the housing may have any other suitable shape (e.g., polygonal, elliptical, irregular, etc.). - Furthermore, as previously discussed, the
rod rotator assembly 12 includes atop cap 44 configured to rotate relative to thehousing 42. Thetop cap 44 is configured to rotate along acircumferential axis 72 of therod rotator assembly 12. Furthermore, as previously discussed, thetop cap 44 is configured to support the polish rods via the polish rod clamp(s). In the illustrated embodiment, thetop cap 44 includes abody 74 and aplatform 76. Thebody 74 extends through thefirst opening 64 in thehousing 42 into the interior 66 of thehousing 42, and theplatform 76 has anengagement surface 78 configured to engage the polish rod clamp(s), thereby supporting the polish rods. In the illustrated embodiment, theplatform 76 of thetop cap 44 has anopening 80 configured to facilitate passage of the polish rod (e.g., top polish rod) through theplatform 76. In addition, thebody 74 of thetop cap 44 is configured to be disposed outwardly from the polish rod along aradial axis 82 of therod rotator assembly 12, thereby facilitating passage of the polish rod through thebody 74. While thebody 74 of thetop cap 44 extends through thefirst opening 64 of thehousing 42 into the interior 66 of thehousing 42 in the illustrated embodiment, in other embodiments, the body may not extend into the housing interior (e.g., the body may be non-rotatably coupled to a component of the rod rotator assembly positioned at least partially outside of the housing, such as the main gear). Furthermore, in certain embodiments, the body of the top cap may be omitted (e.g., the platform of the top cap may be non-rotatably coupled to a component of the rod rotator assembly, such as the main gear). - In the illustrated embodiment, the
rod rotator assembly 12 includes amain gear 54 non-rotatably coupled to thebody 74 of thetop cap 44. Themain gear 54 may be non-rotatably coupled to thebody 74 of thetop cap 44 via any suitable type(s) of connection(s), such as welded connection(s), a press-fit connection, fastener connection(s), adhesive connection(s), other suitable type(s) of connection(s), or a combination thereof. As previously discussed, themain gear 54 is configured to be driven to rotate by a worm gear. In the illustrated embodiment, movement of thelever 46 drives the worm gear to rotate, thereby driving themain gear 54 to rotate. Due to the non-rotatable coupling between themain gear 54 and thebody 74 of thetop cap 44, rotation of themain gear 54 drives thetop cap 44 to rotate, thereby driving the polish rods to rotate via the contact between theengagement surface 78 of thetop cap 44 and the polish rod clamp(s). While themain gear 54 is driven to rotate by a worm gear coupled to thelever 46 in the illustrated embodiment, in other embodiments, the main gear may be driven to rotate by a motor (e.g., electric motor, hydraulic motor, pneumatic motor, etc.). Furthermore, in certain embodiments, the main gear may be omitted, and a motor (e.g., electric motor, hydraulic motor, pneumatic motor, etc.) may drive the top cap to rotate, as discussed above with reference toFIG. 4 . - In addition, as previously discussed, the
rod rotator assembly 12 includes aload cell 50, which is disposed within theinterior 66 of thehousing 42. Theload cell 50 is configured to support thetop cap 44, and theload cell 50 is configured to output a sensor signal indicative of a load applied by the polish rods to thehousing 42. Because theload cell 50 is positioned between thetop cap 44 and a portion (e.g., base 56) of thehousing 42, the load applied by the polish rods to thetop cap 44 is transferred through theload cell 50 to thehousing 42, which is supported by the carrier. Accordingly, the load on the polish rods may be monitored by the load cell (e.g., continuously, periodically, on demand, etc.) to facilitate operation of theartificial lift system 10. Furthermore, as previously discussed, theload cell 50 may include any suitable sensor(s) configured to monitor the load on the polish rod, such as piezoelectric sensor(s), strain gauge(s), other suitable type(s) of sensor(s), or a combination thereof. - In the illustrated embodiment, the
rod rotator assembly 12 includes abearing 52 disposed between theload cell 50 and themain gear 54 along thelongitudinal axis 62 of therod rotator assembly 12. Thebearing 52 enables themain gear 54 to rotate relative to theload cell 50, which may be non-rotatably coupled to thehousing 42. In the illustrated embodiment, thebearing 52 includes a ball bearing (e.g., including multiple bearing balls between two races). However, in other embodiments, the bearing may include other suitable type(s) of bearing(s) (e.g., alone or in combination with one or more ball bearings), such as roller bearing(s), fluid bearing(s), other suitable type(s) of bearing(s), or a combination thereof. Furthermore, while therod rotator assembly 12 includes asingle bearing 52 in the illustrated embodiment, in other embodiments, the rod rotator assembly may include more or fewer bearings (e.g., 0, 2, 3, 4, or more). - In the illustrated embodiment, the
body 74 of thetop cap 44 overlaps themain gear 54, thebearing 52, and a portion of theload cell 50 along thelongitudinal axis 62. In addition, thebody 74 of thetop cap 44 includes a ledge 84 (e.g., annular ledge) engaged with themain gear 54. As illustrated, themain gear 54 is disposed between theledge 84 of thebody 74 of thetop cap 44 and thebearing 52 along thelongitudinal axis 62 of therod rotator assembly 12. Accordingly, the load applied by the polish rods to thetop cap 44 is transferred to themain gear 54 via theledge 84, to thebearing 52 via themain gear 54, to theload cell 50 via thebearing 52, and to thehousing 42 via theload cell 50. Accordingly, the load applied by the polish rods is transferred through theload cell 50, thereby enabling the load cell to monitor the load applied by the polish rods to thehousing 42. In embodiments in which the main gear and/or the bearing is omitted, the load may be transferred from the ledge to the load cell via another suitable path (e.g., through the main gear alone, through a bushing, through a motor, etc.). Furthermore, while the body of the top cap engages a corresponding component of the rod rotator assembly (e.g., the main gear, a motor, etc.) via the ledge in the embodiments disclosed above, in certain embodiments, the body of the top cap may engage the corresponding component via another suitable surface of the body (e.g., a bottom surface of the body, etc.). In such embodiments, the ledge may be omitted. In addition, in certain embodiments, the body of the top cap may be omitted, and the platform of the top cap may engage the corresponding component of the rod rotator assembly. - In the illustrated embodiment, the
load cell 50 is disposed between thebody 74 of the top cap 44 (e.g., theledge 84 of thebody 74 of the top cap 44) and thebase 56 of thehousing 42. Accordingly, the load applied by the polish rods to thetop cap 44 is transferred through theload cell 50 to thebase 56 of thehousing 42. While theload cell 50 is supported by thebase 56 of thehousing 42 in the illustrated embodiment, in other embodiments, the load cell may be supported by another suitable portion of the housing. For example, in certain embodiments, the body of the housing may include a ledge, and the load cell may be supported by the ledge. In such embodiments, the load applied by the polish rods to the top cap may be transferred through the load cell to the housing via the ledge. Furthermore, in certain embodiments, the load cell may be coupled to the body of the housing by any suitable type(s) of connection(s), such as fastener connection(s), adhesive connection(s), a press fit connection, other suitable type(s) of connection(s), or a combination thereof. Additionally or alternatively, the load cell may be coupled to the body of the housing via one or more protrusion/recess interfaces. In embodiments in which the load cell is coupled to the body of the housing, the body supports the load cell, and the load applied by the polish rods to the top cap may be transferred through the load cell to the body of the housing. - In the illustrated embodiment, the
rod rotator assembly 12 includes anadapter ring 86 disposed between thebody 74 of thetop cap 44 and theload cell 50 along theradial axis 82 of therod rotator assembly 12. Theadapter ring 86 is configured to substantially block radial movement of thetop cap body 74 relative to theload cell 50 and to facilitate establishment of a seal between thetop cap body 74 and the load cell 50 (e.g., to substantially block dirt and/or debris from entering a cavity between the top cap body and the housing body). In the illustrated embodiment, a first seal 88 (e.g., o-ring, etc.) is disposed between theadapter ring 86 and thetop cap body 74, and a second seal 90 (e.g., o-ring, etc.) is disposed between theadapter ring 86 and theload cell 50, thereby establishing the seal between thetop cap body 74 and theload cell 50. While the rod rotator assembly includes two seals at the adapter ring in the illustrated embodiment, in other embodiments, the rod rotator assembly may include more or fewer seals at the adapter ring (e.g., 0, 1, 3, 4, or more). For example, in certain embodiments, at least one of the first and second seals may be omitted. Furthermore, in the illustrated embodiment, therod rotator assembly 12 includes a third seal 92 (e.g., o-ring, etc.) disposed between theplatform 76 of thetop cap 44 and thebody 60 of thehousing 42 along theradial axis 82. Thethird seal 92 is configured to substantially block dirt and/or debris from entering the cavity between the top cap body and the housing body. While a single seal is disposed between the platform and the housing body along the radial axis in the illustrated embodiment, in other embodiments, more or fewer seals (e.g., 0, 2, 3, 4, or more) may be disposed between the platform and the housing body along the radial axis. - As previously discussed, the
load cell 50 may output a sensor signal indicative of the load applied by the polish rods to thehousing 42 via a wired or wireless connection. In the illustrated embodiment, theload cell 50 is configured to output the sensor signal via a wired connection, and the wired connection includes aload cell cable 58, which may extend between theload cell 50 and a monitoring/control system. Furthermore, in the illustrated embodiment, therod rotator assembly 12 includes aconnector 94 coupled to thebody 60 of thehousing 42. Theconnector 94 is configured to establish a wired connection to theload cell 50. For example, the connector may include one or more conductors electrically coupled to the load cell, and the connector may be configured to selectively establish an electrical connection between the conductor(s) and theload cell cable 58. In the illustrated embodiment, theconnector 94 is coupled to thebody 60 of thehousing 42 via a threaded connection. However, in other embodiments, the connector may be coupled to the housing body via other suitable type(s) of connection(s) (e.g., alone or in combination with the threaded connection), such as adhesive connection(s), fastener connection(s), other suitable type(s) of connection(s), or a combination thereof. Furthermore, while the connector is coupled to the body of the housing in the illustrated embodiment, in other embodiments, the connector may be coupled to another suitable portion of the housing, such as the base. In addition, while electrical connections are disclosed above, in certain embodiments, the load cell cable may be configured to establish an optical connection between the load cell and the monitoring/control system. In such embodiments, the connector may be configured to establish an optical connection between the load cell and the load cell cable. Furthermore, in certain embodiments, the connector may be omitted. In such embodiments, the load cell cable may extend through an opening in the housing to the load cell. In addition, as previously discussed, the load cell may be communicatively coupled to the monitoring/control system via a wireless connection. - Because the load cell is disposed within the interior of the rod rotator assembly housing, the height of the stack supported by the carrier may be reduced (e.g., as compared to a configuration in which a load cell is positioned between the rod rotator and the carrier, a first set of alignment plates is positioned between the rod rotator and the load cell, and a second set of alignment plates is positioned between the load cell and the carrier). Accordingly, the stroke length of the pump jack may be reduced. In addition, the number of component interfaces along the polish rod may be reduced (e.g., as compared to a configuration in which a load cell is positioned between the rod rotator and the carrier, a first set of alignment plates is positioned between the rod rotator and the load cell, and a second set of alignment plates is positioned between the load cell and the carrier). As a result, the possibility of misalignment of components at the interfaces may be reduced. While a set of alignment plates is not disposed within the interior of the housing in the illustrated embodiment, in other embodiments, at least one set of alignment plates may be disposed within the interior of the housing (e.g., between the main gear and the load cell).
- While only certain features have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the disclosure.
- The techniques presented and claimed herein are referenced and applied to material objects and concrete examples of a practical nature that demonstrably improve the present technical field and, as such, are not abstract, intangible or purely theoretical. Further, if any claims appended to the end of this specification contain one or more elements designated as “means for [perform]ing [a function] . . . ” or “step for [perform]ing [a function] . . . ”, it is intended that such elements are to be interpreted under 35 U.S.C. 112(f). However, for any claims containing elements designated in any other manner, it is intended that such elements are not to be interpreted under 35 U.S.C. 112(f).
Claims (20)
1. A rod rotator assembly for an artificial lift system, comprising:
a housing configured to be supported by a carrier of the artificial lift system;
a top cap configured to rotate relative to the housing, wherein the top cap is configured to support a polish rod of the artificial lift system; and
a load cell disposed within the housing, wherein the load cell is configured to support the top cap, and the load cell is configured to output a sensor signal indicative of a load applied by the polish rod to the housing.
2. The rod rotator assembly of claim 1 , wherein the load cell is configured to output the sensor signal via a wired connection.
3. The rod rotator assembly of claim 1 , comprising a main gear non-rotatably coupled to the top cap, wherein the main gear is configured to be driven to rotate by a worm gear.
4. The rod rotator assembly of claim 3 , comprising a bearing disposed between the load cell and the main gear.
5. The rod rotator assembly of claim 1 , wherein the load cell is disposed between the top plate and a base of the housing.
6. The rod rotator assembly of claim 1 , wherein a set of alignment plates is not disposed within the housing.
7. A rod rotator assembly for an artificial lift system, comprising:
a housing configured to be supported by a carrier of the artificial lift system, wherein the housing has a base and a body extending upwardly from the base along a longitudinal axis of the rod rotator assembly, the body forms an opening on an opposite longitudinal side of the housing from the base, and the opening provides access to an interior of the housing;
a top cap configured to rotate relative to the housing, wherein the top cap is configured to support a polish rod of the artificial lift system, the top cap has an engagement surface configured to engage a polish rod clamp to support the polish rod, and the top cap has a body extending through the opening in the housing; and
a load cell disposed within the interior of the housing between the body of the top cap and the base of the housing along the longitudinal axis of the rod rotator assembly, wherein the load cell is configured to support the top cap, and the load cell is configured to output a sensor signal indicative of a load applied by the polish rod to the housing.
8. The rod rotator assembly of claim 7 , wherein the load cell is configured to output the sensor signal via a wired connection.
9. The rod rotator assembly of claim 8 , comprising a connector coupled to the body of the housing and configured to establish the wired connection to the load cell.
10. The rod rotator assembly of claim 7 , comprising a main gear non-rotatably coupled to the body of the top cap, wherein the main gear is configured to be driven to rotate by a worm gear.
11. The rod rotator assembly of claim 10 , wherein the body of the top cap has a ledge engaged with the main gear, and the main gear is disposed between the ledge of the body of the top cap and the load cell along the longitudinal axis of the rod rotator assembly.
12. The rod rotator assembly of claim 10 , comprising a bearing disposed between the load cell and the main gear along the longitudinal axis of the rod rotator assembly.
13. The rod rotator assembly of claim 12 , wherein the bearing comprises a ball bearing.
14. The rod rotator assembly of claim 7 , wherein a set of alignment plates is not disposed within the interior of the housing.
15. The rod rotator assembly of claim 7 , comprising an adapter ring disposed between the body of the top cap and the load cell along a radial axis of the rod rotator assembly.
16. An artificial lift system, comprising:
a polish rod configured to drive a pump disposed within a reservoir;
a carrier configured to be coupled to a pump jack of the artificial lift system; and
a rod rotator assembly, comprising:
a housing supported by the carrier;
a top cap configured to rotate relative to the housing, wherein the top cap is configured to support the polish rod; and
a load cell disposed within the housing, wherein the load cell is configured to support the top cap, and the load cell is configured to output a sensor signal indicative of a load applied by the polish rod to the housing.
17. The artificial lift system of claim 16 , wherein the rod rotator assembly comprises a main gear non-rotatably coupled to the top cap, and the main gear is configured to be driven to rotate by a worm gear.
18. The artificial lift system of claim 17 , wherein the rod rotator assembly comprises a bearing disposed between the load cell and the main gear.
19. The artificial lift system of claim 16 , wherein the load cell is disposed between the top plate and a base of the housing.
20. The artificial lift system of claim 16 , wherein a set of alignment plates is not disposed within the housing.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US17/580,795 US20220235636A1 (en) | 2021-01-22 | 2022-01-21 | Rod rotator assembly for an artificial lift system |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US202163140672P | 2021-01-22 | 2021-01-22 | |
US17/580,795 US20220235636A1 (en) | 2021-01-22 | 2022-01-21 | Rod rotator assembly for an artificial lift system |
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US20220235636A1 true US20220235636A1 (en) | 2022-07-28 |
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Application Number | Title | Priority Date | Filing Date |
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US17/580,795 Abandoned US20220235636A1 (en) | 2021-01-22 | 2022-01-21 | Rod rotator assembly for an artificial lift system |
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Cited By (2)
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US20220412339A1 (en) * | 2021-06-24 | 2022-12-29 | Daltec Oil Tools Srl | Rod rotator assembly for well pumping rod strings |
USD1011381S1 (en) * | 2021-05-13 | 2024-01-16 | Tom C. Whilden, Jr. | Sucker rod string rotator with position indicator |
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US20190203579A1 (en) * | 2017-12-31 | 2019-07-04 | Walter Phillips | Apparatus and Method for Detecting the Rotation of a Rod-String in a Wellbore |
US20200018127A1 (en) * | 2018-07-13 | 2020-01-16 | Norris Rods, Inc. | Gear rod rotator systems |
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US20210355769A1 (en) * | 2020-05-18 | 2021-11-18 | Redhead Services, L.L.C. | Polish rod leveling assembly |
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US20080035325A1 (en) * | 2006-08-09 | 2008-02-14 | Ali-Zada Vagif | Polished rod rotator |
US20120085552A1 (en) * | 2010-10-12 | 2012-04-12 | Weatherford/Lamb, Inc. | Wellhead Rotating Breech Lock |
US20180112475A1 (en) * | 2015-04-08 | 2018-04-26 | 1914415 Alberta Ltd | Polished rod rotator with height adjuster |
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USD1011381S1 (en) * | 2021-05-13 | 2024-01-16 | Tom C. Whilden, Jr. | Sucker rod string rotator with position indicator |
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