TUBING-PULLING SYSTEMS

Abstract

It is an object of the invention to provide tubing-pulling system including: a hydraulic power unit including a power source and a hydraulic pump; a tubing-pulling unit; and a hydraulic hose adapted and configured to circulate hydraulic fluid pressurized by the hydraulic pump through the tubing-pulling unit. This object of the invention can have a variety of embodiments.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Patent Application Ser. No. 62/048,355, filed Sep. 10, 2014. The entire content of this application is hereby incorporated by reference herein.

BACKGROUND OF THE INVENTION

Water wells typically include a drilled and lined well casing extending to reach an underground aquifer. A submersible, electric pump sits at the bottom of the well casing and pumps water through a length of tubing to the top of the well casing, where the tubing connects to water distribution pipes.

Depending on the hydrology and geology of a particular location, well casings (and the associated tubing within the well casing) can extend between about 10 feet to over 3,000 feet. Accordingly, tools are required to pull the considerable length of tubing and the pump from the well casing whenever maintenance must be performed (e.g., to replace the pump).

SUMMARY OF THE INVENTION

It is an object of the invention to provide tubing-pulling system including: a hydraulic power unit including a power source and a hydraulic pump; a tubing-pulling unit; and a hydraulic hose adapted and configured to circulate hydraulic fluid pressurized by the hydraulic pump through the tubing-pulling unit.

This object of the invention can have a variety of embodiments. The power source can be an internal combustion engine. The power source can be an electric motor. The power source can be mounted on a wheeled cart.

The tubing-pulling unit can be removably couplable to the power source. Upon removable coupling of the tubing-pulling unit to the power source, a handle of the tubing-pulling unit can be at least about 30″ from a base of a wheel of the wheeled cart.

The hydraulic power unit can further include: one or more foot pedals adapted and configured to control flow of hydraulic fluid to the tubing-pulling unit.

The tubing-pulling unit can further include at least one casing clamp adapted and configured press against a surface of a well casing. The at least one casing clamp can be adapted to press against an interior surface of the well casing.

The at least one casing clamp can include a light source. The light source can be adapted and configured to illuminate a pitless adapter within the well casing. The light source can be adapted and configured to illuminate at least four feet of the well casing. The light source can be a plurality of light-emitting diodes.

The at least one casing clamp can have a curved outer surface.

The tubing-pulling unit can further include a plurality of wheels adapted and configured to grip a length of tubing and rotate to pull the length of tubing. The plurality of wheels can be airless wheels. The plurality of wheels can each define a single circumferential groove. The plurality of wheels can each define two circumferential grooves. The tubing-pulling unit can further include one or more pistons adapted and configured to press the plurality of wheels against the length of tubing. The tubing-pulling unit can further include one or more accumulators in communication with the pistons and adapted and configured to temporarily relieve excess pressure when a well component having a larger diameter than the length of tubing passes between the plurality of wheels. The system can further include a controller adapted and configured to control a rotational speed of the plurality of wheels. The controller can be adapted and configured to control the rotational speed of the plurality of the wheels to be between about 1 RPM and 72 RPM.

The system can be capable of generating at least 675 pounds of lifting force.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the nature and desired objects of the present invention, reference is made to the following detailed description taken in conjunction with the accompanying drawing figures wherein like reference characters denote corresponding parts throughout the several views.

FIG. 1 depicts a tubing-pulling system according to an embodiment of the invention.

FIG. 2 depicts a hydraulic power unit according to an embodiment of the invention.

FIG. 3 depicts a valving arrangement according to an embodiment of the invention.

FIG. 4 depicts the separation of a tubing-pulling system into a hydraulic power unit and a tubing-pulling unit coupled via one or more hydraulic hoses.

FIG. 5A depicts a side view of a tubing-pulling unit according to an embodiment of the invention.

FIG. 5B depicts a bottom view of a tubing-pulling unit according to an embodiment of the invention.

FIG. 5C depicts a perspective view of a wheel assembly according to an embodiment of the invention.

FIG. 6 depicts the attachment of the tubing-pulling unit to the top of a well casing.

FIG. 7 depicts the illumination of a well casing in order to visualize a pitless adapter according to an embodiment of the invention.

FIGS. 8A and 8B depict a tubing-pulling unit including a plurality of adjustable legs.

FIG. 9 depicts a perspective view of a tubing-pulling unit including a plurality of circumferential, concave grooves according to an embodiment of the invention.

FIGS. 10A-10C depict various components of wheels according to an embodiment of the invention.

DEFINITIONS

The instant invention is most clearly understood with reference to the following definitions:

As used herein, the singular form “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.

Unless specifically stated or obvious from context, as used herein, the term “about” is understood as within a range of normal tolerance in the art, for example within 2 standard deviations of the mean. “About” can be understood as within 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0,5%, 0.1%, 0.05%, or 0.01% of the stated value. Unless otherwise clear from context, all numerical values provided herein are modified by the term about.

As used in the specification and claims, the terms “comprises,” “comprising,” “containing,” “having,” and the like can have the meaning ascribed to them in U.S. patent law and can mean “includes,” “including,” and the like.

Unless specifically stated or obvious from context, the term “or,” as used herein, is understood to be inclusive.

Ranges provided herein are understood to be shorthand for all of the values within the range. For example, a range of 1 to 50 is understood to include any number, combination of numbers, or sub-range from the group consisting 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, or 50 (as well as fractions thereof unless the context clearly dictates otherwise).

As used in the specification and claims, the term “tubing” includes hollow cylinders that can be flexible or rigid (e.g., pipes). Tubing can be polymeric, metallic, or a combination thereof.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, one aspect of the invention provides a tubing-pulling system 100 including a hydraulic power unit 102 and a tubing-pulling unit 104. Aspects of the invention are capable of generating at least 675 pounds of lifting force.

Unlike conventional well pump pullers that are single-piece units weighing over 155 pounds, embodiments of the invention can separate into at least two pieces that collectively weigh less than conventional well pump pullers and individually each weigh less than half of conventional well pump pullers.

Hydraulic Power Unit

Referring to FIG. 2, the hydraulic power unit 102 can include a power source 206 and a hydraulic pump 208. Power source 206 and hydraulic pump 208 can be coupled together so that power generated by the power source 206 actuates hydraulic pump 208 through a variety of arrangements such as in-line or offset mountings (e.g., using belts, chains, gears, couplings, and the like).

Power source 206 can include an internal combustion engine, an electric motor, and the like. In one embodiment, power source 206 is an internal combustion engine, such as a so-called “small engine” (typically a two- or four-stroke engine powered by a hydrocarbon fuels such as gasoline or ethanol, having one or two cylinders, and producing between less than 1 to about 15 horsepower). Suitable small engines are available from a variety manufacturers such as Briggs & Stratton of Wauwatosa, Wis. and American Honda Motor Company, Inc of Torrance, Calif.

Power source 206 can also include an electric motor adapted and configured to utilized alternating current (e.g., from 120 V line voltage in the United States) or direct current (e.g., from a 12 V battery) to generate torque.

In some embodiments, power sources 206 are interchangeable so that a desired power source 206 can be selected for a particular application (e.g., based on a distance from an electrical outlet) and coupled to tubing-pulling unit 104.

Hydraulic power unit 102 can also include one or more tires 210 that allow movement of hydraulic power unit 102 (and the entire tubing-pulling system 100 when the tubing-pulling unit 104 is coupled to the hydraulic power unit 102). Tires 210 can be pneumatic or solid.

Hydraulic power unit 102 can also include one or more marriage members 212 adapted and configured to facilitate removable coupling of the tubing-pulling unit 104 to the hydraulic power unit 102. For example, the marriage members 212 can be male posts upon which corresponding female members on the tubing-pulling unit 104 sit. One or more fasteners such as pins, bolts, screws, tabs, and the like can prevent or inhibit decoupling of the hydraulic power unit 102 and tubing-pulling unit 104 until desired.

Hydraulic power unit 102 can also include a hydraulic fluid storage tank 214 and hydraulic fluid cap 216 permitting monitoring of hydraulic fluid levels and addition of additional hydraulic fluid when appropriate.

Hydraulic power unit 102 can also include one or more pedals 218 that allow a user to control the flow of hydraulic fluid to and from the tubing-pulling unit 104 in order to control the direction and speed of a length of tubing being moved by the tubing-pulling unit 104.

As seen most clearly in FIG. 3, hydraulic power unit 102 can include a valving arrangement 300 adapted and configured to control fluid of hydraulic fluid during various situations. When valve 320 is turned so that the word “DONE” is horizontal, the hydraulic load is removed from the power source 106, which aids in starting the power source 106. When valve 320 is turned so that the word “GO” is horizontal, power source 106 and hydraulic pump 108 is engaged so that hydraulic fluid is pressurized and flows to tubing-pulling unit 104. When valve 320 is turned so that the word “GO” is horizontal and valve 322 is turned so that the word “CLAMP” is horizontal, pistons 542 on the tubing-pulling unit 104 are extended or retracted in order to push wheels 538 towards each other in order to clamp down and grip the length of tubing. When valve 320 is turned so that the word “GO” is horizontal and valve 322 is turned so that the word “PULL” is horizontal, hydraulic fluid is blocked from entering pistons 542 on the tubing-pulling unit 104 and locks in the clamping pressure and, instead, can flow to hydraulic motors 546 to rotate wheels and pull the length of tubing. When valve 320 is turned so that the word “DONE” is horizontal, the hydraulic load is removed from the power source 106 and from pistons 542 so that wheels 538 can be spread apart.

Hydraulic Hoses

Referring now to FIG. 4, one or more hydraulic hoses 424 can be adapted and configured to circulate hydraulic fluid between the hydraulic power unit 102 and the tubing-pulling unit 104

Hydraulic hoses 424 can be commercially-available hoses designed to withstand hydraulic fluids (e.g., hydraulic oils) and elevated pressures (e.g., up to 160 PSI). In some embodiments, two, three, four, or more hydraulic hoses 424 are utilized so that a recirculating fluid flow is achieved between the hydraulic power unit 102 and the tubing-pulling unit 104 and so that components of tubing-pulling unit 104 can be selectively controlled based on actuation of valving arrangement 300. A plurality of hydraulic hoses 424 can be surrounded by a sheath (e.g. a textile sheath) in order to prevent tangling or kinking of hydraulic hoses 106 and to protect hydraulic hoses 106 from damage from abrasion, UV light, and the like.

Hydraulic hoses 424 can be coupled to hydraulic power source 102 and tubing-pulling unit 424 through one or more commercially-available connectors 426, such as so-called “quick connect” connectors that permit coupling and decoupling without the need for tools.

Tubing-Pulling Unit

Referring now to FIGS. 5A and 5B, tubing pulling unit 104 can include a deck 528 adapted and configured to sit on top of a well casing. Deck 528 can define a substantially flat surface. One or more casing clamps 530 can extend below the deck 528 and can be substantially perpendicular to the deck 528. Casing clamps 530 can be translated laterally relative to the deck 528 and to each other in order to press against a surface of the well casing in order to restrain hold the tubing pulling unit 104 in place relative to the well casing while a pitless adapter is visualized and engaged, a length of tubing is pulled from the well casing, a length of tubing is reinstalled into the well casing, and/or a pitless adapter is repositioned. Mounting the tubing pulling unit 104 on the well casing (as depicted in FIG. 6) advantageously allows for rapid deployment of tubing pulling unit 104 and accommodates well casings that are taller than conventional well pullers as well as casings that extend above highly sloped surfaces. Mounting of the tubing-pulling unit 104 on a well casing is facilitated, in part, by the loose coupling of tubing-pulling unit 104 to hydraulic power source 102. By separating tubing-pulling unit 104 from hydraulic power source 102, tubing-pulling unit 104 can more easily be lifted, positioned, and balanced on the well casing and is isolated from vibrations generated during operation of hydraulic power source 102.

Casing clamps 530 can be adapted and configured to press against an interior or exterior surface of a well casing. In order to promote better contact and maximize the cross-sectional area of a working channel within the well casing, the outer and/or inner surfaces of casing clamps can have a curved surface adapted and configured to approximate an interior or exterior surface of a well casing. For example, the outer surface of casing clamps 530 can be arcs having a diameter of about 5 inches, about 6 inches, about 8 inches, about 10 inches, and the like, Smaller external diameters may be preferred because casing clamps 530 that fit in a 5″ well casing will also fit within a 10″ well casing.

Deck 528 and casing clamps 530 can be fabricated from and/or coated with a wear-resistant material such as steel, “high speed steel,” carbon steel, brass, copper, iron, polycrystalline diamond compact (PDC), hardface, ceramics, carbides, ceramic carbides, cermets, enamels, and the like, Suitable coatings are described, for example, in U.S. Patent Application Publication No, 2007/0202350. In other embodiments, deck 528 and casing clamps 530 can be fabricated from and/or coated with an elastomer or other compliant material in order to grip a surface of a well casing.

Casing clamps 530 can be advanced or retracted through a variety of mechanisms. In one embodiment, threaded rods 532 can be rotated by turning handles 534.

Casing clamps 530 can include a light source 536 such as a bank of light emitting diodes in order to illuminate a portion of the well casing. Such illumination is particularly valuable when locating and engaging a pitless adapter, which is typically located below the frost line (e.g., about 4 feet below the top of the well casing) in cold environments. The illumination of the well casing including the pitless adapter can be seen in the bottom panel of FIG. 7 and can be compared to the unilluminated well casing in the top panel of FIG. 7.

Tubing-pulling unit 104 can also include one or more wheels 538 or other gripping members (e.g., tracks or belts) adapted and configured to grip a length of tubing and pull the length of tubing from the well casing. Wheels 538 can be airless or pneumatic wheels and can define one or more circumferential, concave grooves 540 adapted and configured to form increased surface contact with the length of tubing. Wheels 538 and/or circumferential, concave grooves 540 can be sized to accommodate particular tubing sizes or can flex to accommodate any tubing size within a range (e.g. between about ¾″ to 2″ Iron Pipe Size).

Wheels 538 can be engaged and disengaged from the length of tubing through a variety of mechanisms. In one embodiment, one or more pistons 542 press or retract wheels 538 against the length of tubing. Pistons 542 can be powered by hydraulic fluid pressurized by the hydraulic power unit 102. Wheel assemblies (including wheels 538 and associated hydraulic motors 546) can travel laterally along tubular members 543 based on forces generated by pistons 542. Wheel assemblies can be retracted to allow an unobstructed view of the pitless adapter within the well casing with a pitless wrench. Additionally, wheel assemblies can be removed from tubing pulling unit 104 to further reduce the weight of the tubing-pulling unit 104 until casing claims 530 are engaged with the well casing.

Tubing-pulling unit 104 can also include one or more accumulators or shocks 544 in communication with the pistons 542 and adapted and configured to temporarily relieve excess pressure when a well component (e.g., a pitless adapter, a torque stop, a cable guard, and the like) having a larger diameter than the length of tubing passes through between wheels 538. Accumulator 544 can include a nitrogen-filled bladder that can be compressed in order to accommodate hydraulic fluid as pistons 542 are compressed to accommodate larger well components.

Tubing-pulling unit 104 can also include one or more hydraulic motors 546 coupled to wheels 538 and hydraulic power unit 102 via hydraulic hoses 424 and adapted and configured to rotate wheels 538 in a desired direction and rotational speed.

Tubing-pulling unit 104 can also include a handle 546 that can be used to either lift the tubing-pulling unit 104 or to push the assembled tubing-pulling unit 100 in a similar manner to hand truck. Handle 546 can be mounted at variety of heights to balance the user's ability to fit the tubing-pulling system 100 in a vehicle with the user's ability to push or pull the tubing pulling unit system without bending over to an uncomfortable degree. For example, handle 546 can be about 30″ above the base of the assembled tubing-pulling system 100. Handle 546 can be removable or can be permanently mounted. Depending on the user's needs, the tubing-pulling system 100 can be stored loaded, stored, and/or unloaded from a vehicle as separate components.

Tubing-pulling system 100 can also include a controller or governor programmed to control the operation of one or more components of the tubing-pulling system 100. The controller can regulate the operation of one or more components to maintain safe or optimal operating conditions. For example, the controller can restrict the hydraulic pressure generated by the hydraulic power unit 102 unit to less than or equal to 160 PSI, The controller can also control the rotational speed of the plurality of wheels (e.g., by controlling the flow rate of hydraulic fluid from hydraulic power unit 102) to between about 1 RPM and about 72 RPM.

Controller can be programmed to implement an “Auto Feed” or “Auto Stop” feature that allows the users to step away from the system 100 during pulling operations (e.g., to walk the length of tubing out away from the well casing). Controller can suspend pulling when specified level of resistance (e.g., measured via a proxy such as a hydraulic pressure) is detected.

Referring now FIGS. 8A and 8B, tubing-pulling unit 104 can also include one or more adjustable legs 848 that allow the tubing-pulling unit 104 to be positioned over well casing without attachment to the well casing. Such a stand is particularly advantageous well pulling tubing from small diameter well casings or well casings having well-seal plates over a top orifice.

Referring now to FIG. 9, wheels 938 can include a plurality (e.g. two) of circumferential, concave grooves 940a, 940b. Such a structure can be particularly advantageous for use in geothermal heating wells that pump fluid through loops of PVC tubing within well casings to utilize the earth as a heat source or heat sink.

Referring now to FIGS. 10A-10C, wheels 538, 938 can include an inner elastomeric ring 1050 surrounding a rim 1052 (e.g., a rim made of a metal such as aluminum, iron, alloys thereof, and the like). Inner elastomeric ring 1050 can be rotationally coupled to the rim 1052 by a interference fit (also known as a press fit or friction fit) produced, for example, by stretching inner elastomeric ring 1050 over rim 1052 or by a shrink-fitting technique in which the inner elastomeric ring 1050 is heated to cause thermal expansion and/or the rim 1052 is cooled (e.g., through an ice bath or liquefied gas) to cause thermal shrinkage, thereby allowing assembly before the components return to ambient temperature. Alternatively, inner elastomeric ring 1050 can be coupled to rim 1052 through an adhesive such an epoxy resins. The assembled inner elastomeric ring 1050 and rim 1052 assembly can transmit and withstand significant strength without incurring the significant costs of casting or machining a solid metal rim having cogs.

Inner elastomeric ring 1050 can include a plurality of outer cogs 1054 designed to engage complementary inner cavities 1056 on an outer elastomeric ring 1058. Outer elastomeric ring 1058 can be an airless or non-pneumatic tire wheel include an outer shear band 1060 defining one or more grooves 540 and and/or treads surrounding a plurality of flexible spokes 1062.

Preferably, wheels 538, 938 can be removed, changed, and/or replaced without the need for fasteners, adhesives (e.g., epoxy) or special machines. For example, outer elastomeric ring 1058 can be formed from a material (e.g., urethane rubber) having sufficient elasticity to be stretched by hand over the cogs of inner elastomeric ring 1050.

Outer resin layer 1058 can be fabricated from a two-part urethane resin that is mixed, vacuum degassed, and then poured into a silicone mold. After molding, the tire is demolded and placed in an oven to cure for an additional eight hours. As result, the tires produced are stronger than the average automobile tire.

As a result of the grooves 540 described herein, tubing can be pulled using only two tires instead of the three tires required by conventional well-pulling devices to prevent the tube from slipping between the tires. Additionally, the grooves provide a broader contact surface (and, therefore, greater gripping power) between the tires and the tubing than found in a conventional tire having a convex profile.

EQUIVALENTS

Although preferred embodiments of the invention have been described using specific terms, such description is for illustrative purposes only, and it is to be understood that changes and variations may be made without departing from the spirit or scope of the following claims. For example, aspects of the invention can be applied to pull other materials similar to tubing or pipe such as wires, cables, ropes, and the like.

INCORPORATION BY REFERENCE

The entire contents of all patents, published patent applications, and other references cited herein are hereby expressly incorporated herein in their entireties by reference

Claims

1. A tubing-pulling system comprising:

a hydraulic power unit comprising: a power source; and a hydraulic pump;

a tubing-pulling unit; and

a hydraulic hose adapted and configured to circulate hydraulic fluid pressurized by the hydraulic pump through the tubing-pulling unit.

2. The system of claim 1, wherein the power source is an internal combustion engine.

3. The system of claim 1, wherein the power source is an electric motor.

4. The system of claim 1, wherein the power source is mounted on a wheeled cart.

5. The system of claim 1, wherein the tubing-pulling unit is removably couplable to the power source.

6. The system of claim 5, wherein upon removable coupling of the tubing-pulling unit to the power source, a handle of the tubing-pulling unit is at least about 30″ from a base of a Wheel of the wheeled cart.

7. The system of claim 1, wherein the hydraulic power unit further comprises:

one or more foot pedals adapted and configured to control flow of hydraulic fluid to the tubing-pulling unit.

8. The system of claim 1, wherein the tubing-pulling unit further comprises:

at least one casing clamp adapted and configured press against a surface of a well casing.

9. The system of claim 8, wherein the at least one casing clamp is adapted to press against an interior surface of the well casing.

10. The system of claim 9, wherein the at least one casing clamp includes a light source.

11. The system of claim 10, wherein the light source is adapted and configured to illuminate a pitless adapter within the well casing.

12. The system of claim 10, wherein the light source is adapted and configured to illuminate at least four feet of the well casing.

13. The system of claim 10, wherein the light source is a plurality of light-emitting diodes.

14. The system of claim 9, wherein the at least one casing clamp has a curved outer surface.

15. The system of claim 1, wherein the tubing-pulling unit further comprises:

a plurality of wheels adapted and configured to grip a length of tubing and rotate to pull the length of tubing.

16. The system of claim 15, wherein the plurality of wheels are airless wheels.

17. The system of claim 15, wherein the plurality of wheels each define a single circumferential groove.

18. The system of claim 15, wherein the plurality of wheels each define two circumferential grooves.

19. The system of claim 15, wherein the tubing-pulling unit further comprises:

one or more pistons adapted and configured to press the plurality of wheels against the length of tubing.

20. The system of claim 15, wherein the tubing-pulling unit further comprises:

one or more accumulators in communication with the pistons and adapted and configured to temporarily relieve excess pressure when a well component having a larger diameter than the length of tubing passes between the plurality of wheels.

21. The system of claim 15, further comprising:

a controller adapted and configured to control a rotational speed of the plurality of Wheels.

22. The system of claim 21, wherein the controller is adapted and configured to control the rotational speed of the plurality of the wheels to be between about 1 RPM and 72 RPM.

23. The system of claim 1, wherein the system is capable of generating at least 675 pounds of lifting force.