CROSS-REFERENCE TO RELATED APPLICATIONS This U.S. Non-Provisional Application claims priority to U.S. Provisional Application Ser. No. 63/529,235 filed Jul. 27, 2023 and U.S. Provisional Application Ser. No. 63/622,913 filed Jan. 19, 2024, the entire contents of which are incorporated herein by reference thereto.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT Not applicable.
BACKGROUND OF THE INVENTION Field of the Invention This invention relates to production of hydrocarbon fluids from a wellbore. In particular, the present invention is directed to systems and methods that may prevent fallback of particulate matter included in a fluid such as rod pumps and more specifically includes rod pump fall back filters to prevent such fallback.
Background of the Invention Fluids produced from a well often include particulate matter, such as sand, which may be detrimental to the performance of production equipment or may cause production equipment to fail. Accordingly, it is typically desirable to prevent such particulate matter, which may have been lifted along with the fluid being produced, from falling back onto production equipment should the flow of fluid become slowed or suspended. Preventing fallback of particulate matter in production systems that incorporate reciprocating sucker-rod pump apparatuses may be particularly desirable, as sand or other particles may build up on plunger assemblies typically employed by these apparatuses when fluid lift may slow or be suspended, which can be particularly damaging where it may be desirable to maintain integrity of close tolerances and/or polished surfaces that a plunger assembly may rely upon.
Moreover, when an oil well stops to flow, there are conventional methods to continue the flow and extend the life of the well. Conventional types of methods include gas lifting, plunger lifting, and pump lifting. Pump lifting includes different types of conventional pumps including sucker rod pumping. Drawbacks to sucker rod pumping include fallback sand between the plunger and the barrel. Sand degrades the efficiency of the pump.
Consequently, there is a need for improved systems and methods of preventing fallback of particulate matter where sucker-rod apparatuses may be employed. Further, there is a need for an improved method of sand removal and an improved sucker rod pump system.
BRIEF SUMMARY OF SOME OF THE PREFERRED EMBODIMENTS These and other needs in the art are addressed in one embodiment by a combined system comprising a tubing assembly, a rod assembly, and a fallback preventer. The tubing assembly may comprise a landing nipple, a working barrel, a standing valve, and one or more tubing strings. The rod assembly may comprise two or more rod segments, a rod coupling comprising a neck, and a plunger comprising a traveling valve. The fallback preventer may comprise an upper latch adapted to be received by the landing nipple, a top sub, a particle trap body, and a lower collet adapted to grasp the neck of the rod coupling. The particle trap body may further comprise an inner body, an upper bushing system, a lower bushing system, and a flexible valve adapted to govern flow through one or more apertures of the lower bushing system.
These and other needs in the art are also addressed in one embodiment by a method for collecting particulate matter included in a fluid being lifted by a reciprocating pump when flow of the fluid being lifted slows or becomes suspended.
In addition, these and other needs in the art are addressed in embodiments of methods for clearing particulate matter collected by a fallback preventer from the fallback preventer when flow of a fluid being lifted through the fallback preventer may be restored.
Moreover, these and other needs in the art are addressed in one embodiment by a plunger bottom hole assembly and polished sucker rod. In an embodiment, an anchoring nipple prevents the plunger bottom hole assembly from slipping. In some embodiments, a slip mechanism prevents the plunger bottom hole assembly from slipping. A cone pushes the slip into the tubing, which holds it in place.
These and other needs in the art are also addressed in an embodiment by a fallback preventer for a sucker rod pump. The fallback preventer including a particle trap body comprising a generally tubular body and an inner body comprising a generally tubular body. The fallback preventer also includes an upper bushing assembly comprising an upper bushing assembly central bore and one or more apertures surrounding the central bore. In addition, the fallback preventer includes a lower bushing assembly comprising a lower bushing assembly central bore and one or more apertures surrounding the central bore. Further, the fallback preventer includes a flexible valve comprising a flexible valve central bore and one or more flaps surrounding the central bore. Moreover, the upper bushing assembly central bore, the lower bushing assembly central bore, and the flexible valve central bore are each configured to slidably engage a rod assembly of a sucker rod pump. Additionally, the inner body is secured within the particle trap body between the upper bushing assembly and the lower bushing assembly, thereby forming an annulus between the inner body and the particle trap body. Further the flexible valve is secured between the inner body and the lower bushing assembly such that each of the one or more flaps of the flexible valve are radially aligned with each of the one or more apertures of the lower bushing assembly. In the embodiment, the fallback preventer is located above a plunger assembly secured to an end of the rod assembly. Furthermore, the fallback preventer is run in hole with the rod assembly. The upper bushing assembly and lower bushing assembly centralize the rod assembly within a tubing assembly. Each of the one or more flaps of the flexible valve are biased to close each of the one or more apertures of the lower bushing assembly when a flow of a fluid through the fallback preventer is slowed or suspended. Particulate matter included in the fluid is collected within the inner body when the flow is slowed or suspended. Particulate matter collected within the inner body is cleared from the inner body when the flow is restored. One or more axially-oriented series of apertures are disposed radially about the inner body. The particulate matter collected within the inner body is at least partially cleared when the flow is restored by directing at least a portion of the fluid through the annulus an into the inner body via the one or more axially-oriented series of apertures.
The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter that form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiments disclosed may be readily utilized as a basis for modifying or designing other embodiments for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent embodiments do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS For a detailed description of the preferred embodiments of the invention, reference will now be made to the accompanying drawings in which:
FIG. 1 illustrates embodiments of a tubing assembly, a rod assembly, and a fallback preventer;
FIG. 2 illustrates embodiments of a bushing system, flexible valve, and spacer of a fallback preventer;
FIG. 3A illustrates an embodiment of a rod segment connection of a rod assembly;
FIG. 3B illustrates an embodiment of a rod segment of a rod assembly;
FIG. 4A illustrates an embodiment of a combined system comprising a rod assembly and fallback preventer being run in-hole;
FIG. 4B illustrates an embodiment of a rod assembly being freed from a latch of a fallback preventer;
FIG. 4C illustrates an embodiment of fluid flow through a flexible valve of a fallback preventer;
FIG. 5A illustrates an embodiment of a fallback preventer collecting particulate matter included in a fluid;
FIG. 5B illustrates an embodiment of particulate matter collected m a fallback preventer being initially removed from the fallback preventer;
FIG. 5C illustrates an embodiment of remaining particulate matter collected in a fallback preventer being removed from the fallback preventer;
FIG. 6A illustrates an embodiment of a rod assembly being grasped by a latch of a fallback preventer;
FIG. 6B illustrates an embodiment of a combined system comprising a rod assembly and fallback preventer being removed from a tubing assembly;
FIG. 7A illustrates an embodiment of a plunger lifting a fluid through a pump chamber;
FIG. 7B illustrates an alternative embodiment of a plunger lifting a fluid through a pump chamber;
FIG. 7C illustrates a further embodiment of a plunger lifting a fluid through a pump chamber;
FIG. 7D illustrates a further alternative embodiment of a plunger lifting a fluid through a pump chamber.
FIG. 8 illustrates an embodiment of a sucker rod, filter and plunger bottom hole assembly;
FIG. 9 illustrates an embodiment of a locating profile and barrel run with tubing;
FIG. 10 illustrates an embodiment of the bottom hole assembly run downhole;
FIG. 11 illustrates an embodiment illustrating the bottom hole assembly no-go's in place in the locating nipple;
FIG. 12 illustrates an embodiment illustrating the bottom hole assembly no-go's in place in the locating nipple;
FIG. 13 illustrates an embodiment of the plunger lowered into the barrel;
FIG. 14(a) illustrates a normal pump cycle with the ball falling with the flow;
FIG. 14(b) illustrates a normal pump cycle with the ball rising with the flow;
FIG. 14(c) illustrates a normal pump cycle with the ball falling with the flow;
FIG. 14(d) illustrates a normal pump cycle with the ball rising with the flow;
FIG. 15(a) illustrates an embodiment with the pump stopped and sand falling back;
FIG. 15(b) illustrates an embodiment with the pump stopped and sand falling back;
FIG. 16(a) illustrates an embodiment with the pump started and the sand disposed back in the flow stream;
FIG. 16(b) illustrates an embodiment with the pump started and the sand disposed back in the flow stream;
FIG. 16(c) illustrates an embodiment with the pump started and the sand disposed back in the flow stream;
FIG. 16(d) illustrates an embodiment with the pump started and the sand disposed back in the flow stream;
FIG. 17(a) illustrates an embodiment of a fallback filter attached to the plunger before the run downhole;
FIG. 17(b) illustrates an embodiment of a barrel run downhole with the tubing;
FIG. 17(c) illustrates an embodiment of a plunger and filter no-goed on the top of the barrel;
FIG. 18(a) illustrates an embodiment illustrating the set down weight shearing the pins and setting the slips;
FIG. 18(b) illustrates a zoomed view of the slips of FIG. 18(a);
FIG. 18(c) illustrates an embodiment illustrating the second set of shear pins shearing and allowing the plunger to go into the barrel;
FIG. 18(d) illustrates an embodiment a zoomed view of the shear pins of FIG. 18(c);
FIG. 19 illustrates an embodiment of the plunger lifting the fluids to the surface;
FIG. 20 illustrates an embodiment of the plunger lifting the fluids to the surface;
FIG. 21(a) illustrates an embodiment of the ball landing on the seat;
FIG. 21(b) illustrates an embodiment of the sucker rod being lifted again;
FIG. 21(c) illustrates an embodiment of the empty filter and pumping returning to normal;
FIG. 22(a) illustrates an embodiment of removing the plunger by lifting the plunger;
FIG. 22(b) illustrates an embodiment of removing the plunger with removing the cone;
FIG. 22(c) illustrates an embodiment of the entire plunger bottom whole assembly being returned to the surface;
FIG. 23 illustrates an embodiment of a sucker rod pump and sand screen in a normal pumping operation;
FIG. 24 illustrates an embodiment of a sucker rod pump and sand screen with the pump off and the sand falling back into the sand screen filter;
FIG. 25 illustrates an embodiment of a sucker rod pump and sand screen when the pump is turned back on and the fluid begin to flow;
FIG. 26 illustrates an embodiment of a sucker rod pump and sand screen after the fluid has begun removing the sand;
FIG. 27 illustrates an embodiment of a sucker rod pump and sand screen after the capture sand has been removed by the fluid;
FIG. 28 illustrates an embodiment of a fallback filter in a normal pumping operation;
FIG. 29(a) illustrates an embodiment of a fallback filter in a normal pumping operation;
FIG. 29(b) illustrates an embodiment of a fallback filter with the pump off and the sand falling back;
FIG. 29(c) illustrates an embodiment of a fallback filter with the pump off and the sand settled in the filter;
FIG. 29(d) illustrates an embodiment of a fallback filter with the pump back on and the fluid flow pushing sand back into the flow stream;
FIG. 29(e) illustrates an embodiment of a fallback filter with the pump back on and the fluid flow pushing sand back into the flow stream;
FIG. 29(f) illustrates an embodiment of a fallback filter with a normal pumping operation;
FIG. 30(a) illustrates an embodiment of a fallback filter with a normal pumping operation;
FIG. 30(b) illustrates an embodiment of a fallback filter with the pump off and the sand falling back;
FIG. 30(c) illustrates an embodiment of a fallback filter with the pump off and the sand settled in the filter;
FIG. 30(d) illustrates an embodiment of a fallback filter with the pump on and the fluid flow pushing sand back into the flow stream;
FIG. 30(e) illustrates an embodiment of a fallback filter with the pump on and the fluid flow pushing sand back into the flow stream;
FIG. 30(f) illustrates an embodiment of a fallback filter with a normal pumping operation;
FIG. 31(a) illustrates an embodiment of a fallback filter with a normal pumping operation;
FIG. 31(b) illustrates an embodiment of a fallback filter with the pump off and the sand falling back;
FIG. 31(c) illustrates an embodiment of a fallback filter with the pump on and the fluid flow pushing sand back into the stream;
FIG. 31(d) illustrates an embodiment of a fallback filter with the pump on and the fluid flow pushing sand back into the flow stream;
FIG. 31(e) illustrates an embodiment of a fallback filter in a normal pumping operation;
FIG. 32(a) illustrates an embodiment of a fallback filter with a normal pumping operation;
FIG. 32(b) illustrates an embodiment of a fallback filter with the pump off and the sand falling back;
FIG. 32(c) illustrates an embodiment of a fallback filter with the pump on and the fluid flow pushing sand back into the stream;
FIG. 32(d) illustrates an embodiment of a fallback filter with the pump on and the fluid flow pushing sand back into the flow stream; and
FIG. 32(e) illustrates an embodiment of a fallback filter in a normal pumping operation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS In the following description the term proximal is used to describe the portion of the component being referred to that is closest to a well opening, or well mouth, and the term distal is used to refer to the portion of the component being referred to that is furthest from the well opening. Additionally, the term downstream is used to describe a direction of fluid flow which is generally oriented. toward a proximal direction, and the term upstream is used to describe a direction of fluid flow which is generally oriented toward a distal direction.
FIG. 1 illustrates embodiments of tubing assembly 100, rod assembly 200, and fallback preventer 300, which together may provide a system and method for trapping particulate matter included in well fluids being produced from a geological formation, thereby preventing the particulate matter from falling back onto equipment which may be located further downhole.
In embodiments, tubing assembly 100 may principally comprise upper tubing string 110, landing nipple 120, lower tubing string 130, working barrel 140, and standing valve 150. In an embodiment, tubing assembly 100 may be installed in a casing of a wellbore such that the location of standing valve 150 may correspond to a depth within the wellbore where fluids to be produced from the wellbore can be accessed by standing valve 150.
Upper tubing string 110 may be any known tubing string that may be generally tubular in form and may provide an inner flow path for communicating fluids between a producing zone of a geological formation and the well opening. In embodiments, upper tubing string 110 may provide a known type of connection about its distal end, for example a threaded connection, which may allow upper tubing string 110 to be secured to landing nipple 120.
Landing nipple 120 may be formed as a generally tubular body that may provide a known form of connection at both its proximal and distal ends, for example a threaded connection, which may allow landing nipple 120 to be secured to upper tubing string 110 and lower tubing string 130, respectively. In embodiments, landing nipple 120 may be formed having inner profile 122, one or more dimensions of which may correspond to one or more dimensions of upper collet 310 of fallback preventer 300, which will later be described. In embodiments, inner profile 122 may be formed having a reduced inner diameter that may provide ramps 124a,b at its proximal and distal ends, respectively, and may further provide key 126 and shoulder 128 located about a central portion of internal profile 122, as seen in FIG. 1. In an embodiment, ramp 124a may be located and shaped to correspond to a distal surface profile of latch 316 of upper collet 310. In an embodiment, ramp 124b may be located and shaped to correspond to one or more dimensional characteristics of vent 318 of upper collet 310. In an embodiment, the location, size, and inner profile of key 126 may correspond to the location, size, and outer profile of latch 316 of upper collet 310. In an embodiment, the location and size of shoulder 128 may correspond to the location and size of shoulder 312 of upper collet 310.
Lower tubing string 130 may be any known tubing string that may be generally tubular in form and may provide an inner flow path for communicating fluids between landing nipple 120 and working barrel 140. In embodiments, lower tubing string 130 may provide a known type of connection about its proximal and distal ends, for example a threaded connection, which may allow lower tubing string 130 to be secured to landing nipple 120 and working barrel 140, respectively.
Working barrel 140 may be formed as a generally tubular body that may provide a known form of connection at its proximal end, for example a threaded connection, which may allow working barrel 140 to be secured to a distal end of lower tubing string 130, and may further be formed to provide means for securing standing valve 150 about its distal end. In embodiments, working barrel 140 may be formed having inner surface 142, one or more dimensions of which may correspond to one or more dimensions of plunger 240 of rod assembly 200, which will later be described. In embodiments, inner surface 142 may be formed having a reduced inner diameter and a length that may be sized to allow an outer surface of plunger 240 to remain in sliding contact against inner surface 142 during certain operational conditions as will be described. In embodiments, inner surface 142 may be provided with a polished finish, which may assist in allowing plunger 240 to slidably engage inner surface 142. In operation, plunger 240 being in slidable engagement against inner surface 142 may thereby form pump chamber 144, as seen in FIG. 7A, which may comprise a volume defined by one or more distal surfaces of plunger 240, one or more internal surfaces of working barrel 140, and one or more surfaces of standing valve 150 or ball 158.
Standing valve 150 may be formed having pump inlet 152 comprising a pump inlet central bore 187 suitable to allow well fluids to communicate into pump chamber 144. Standing valve 150 may further comprise features that may correspond to ball valve designs known to one of ordinary skill in the art. For example, standing valve 150 may comprise ball trap 154, ball seat 156, and ball 158, each of that may act in concert to disrupt fluid communication through pump inlet 152 when fluid flow through pump chamber 144 may be biased toward the distal direction. In this manner, standing valve 150 may function as a check valve which may principally allow fluid to flow in a proximal direction into production tubing string 100.
As shown in embodiments of FIG. 1, rod assembly 200 may principally comprise rod system 210 and plunger 240.
Rod system 210 may be formed from a plurality of rod segments 212, each of which may vary in length and may be provided at proximal and distal ends with a form of connection that may enable each of the plurality of segments to be coupled together. In the embodiment of rod system 210 illustrated in FIG. 1, two segments of rod system 210 are visible, upper segment 212, passing through fallback preventer 300, and lower segment 212L located distally in relation to lower collet 370. FIGS. 3A and 3B illustrate embodiments of a form of connection which may be provided at either end of rod segment 212. As can be seen, rod segment 212 may principally comprise rod body 214, and may further comprise at proximal and distal ends transition 216, flange 218, wrench square 220, thrust bearing surface 222, pin shoulder 224, and thread 226. In embodiments, two rod segments 212 may be coupled together via threaded rod coupling 230, which may be provided with two or more flat surfaces 232 such that a tool such as a wrench may apply a first torque to rod coupling 230 while an opposing, second torque may be applied to wrench square 220 of one of the rod segments 212. Returning now to FIG. 1, lower rod segment 212L may be coupled to adjacent rod segment 212 via latch coupling 234, which, in addition to one or more flat surfaces 236 for applying a torque with a tool such as a wrench, may be further provided with neck 238. In embodiments, an outer diameter of latch coupling 234 and an outer diameter of neck 238 may correspond to one or more dimensional characteristics of lower collet 370 of fallback preventer 300 in a manner which will later be described. In embodiments, the length of lower segment 212L may be selected to correspond to a length of fallback preventer 300, a length of lower tubing string 130 of tubing assembly 100, or combinations thereof.
Plunger 240 may be formed as a generally tubular body, providing a central bore having outlet 244 located about a proximal end of plunger 240 and inlet 246 located about a distal end of plunger 240, thereby allowing fluid communication through plunger 240. Plunger 240 may further be provided with connection 242, which may offer a suitable means of connecting plunger 240 to a distal end of lower segment 212L. In embodiments, one or more dimensions of plunger 240 may correspond to one or more dimensions of working barrel 140. For example, the length and external diameter of plunger 240 may correspond to length and internal diameter of working barrel inner surface 142, which thereby may allow all or a portion of plunger 240 to remain in sliding engagement against inner surface 142 over a length of a reciprocating stroke of rod assembly 200 during certain operational conditions that will later be described. In embodiments, plunger 240 may be formed to provide traveling valve 248, which may correspond to ball valve designs known to one of ordinary skill in the art. For example, traveling valve 248 may comprise ball restrictor 250, ball seat 252, and ball 254, each of which may act in concert to disrupt fluid communication through plunger 240 when fluid flow through plunger 240 may be biased toward the distal direction. In this manner, traveling valve 248 may function as a check valve, which may principally allow fluid to flow in a proximal direction through plunger 240.
In embodiments shown in FIG. 1, in embodiments, fallback preventer 300 may principally comprise upper collet 310, top sub 320, particle trap body 330, and lower collet 370.
Upper collet 310 may be formed as a generally tubular body that may provide a known form of connection at its distal end, for example a threaded connection, which may allow upper collet 310 to be secured to a proximal end of top sub 320. In embodiments, upper collet 310 may be formed having one or more external features, which may correspond to one or more internal features of inner profile 122 of landing nipple 120. For example, upper collet 310 may be formed to provide shoulder 312, which may correspond to shoulder 128 of landing nipple 120. In this manner, when fallback preventer 300 may be installed into tubing assembly 100, shoulder 312 may prevent fallback preventer 300 from traveling in a distal direction any further than corresponding shoulder 128 may allow. In embodiments, upper collet 310 may be provided with one or more seals 314 located about an exterior surface of upper collet 310, which may prevent fluid communication between upper collet 310 and landing nipple 120 when shoulder 312 is brought into resting engagement against shoulder 128. In embodiments, upper collet 310 may be provided with one or more latches 316 located about its exterior surface. Each of the one or more latches 316 may be formed having an exterior profile, which may correspond to all or a portion of inner profile 122 of landing nipple 120. For example, latch 316 may be formed to provide one or more distal surfaces that may correspond in shape with ramp 122a of landing nipple 120, such that ramp 122a may cause latch 316 to be displaced toward an inner radial position, which latch 316 may otherwise be biased away from. Additionally, a location, size, and outer profile of a raised surface feature of latch 316 may correspond to the location, size, and inner profile of key 126, such that when shoulder 312 is brought into resting engagement against shoulder 128, latch 316 may be allowed to return to the radial position it may be biased toward. In this manner, each of the one or more latches 316 may lock fallback preventer 300 in a seated position within landing nipple 120 unless a force is applied to fallback preventer 300 in the proximal direction sufficient enough to cause each of the one or more latches 316 to be displaced to an inner radial position, which may allow fallback preventer 300 to be removed from landing nipple 120. In embodiments, upper collet 310 may be formed to provide one or more vents 318 that may allow gasses included in a well fluid to communicate between an inner surface of upper collet 310 and the annular space located between fallback preventer 300 and tubing assembly 100 when fallback preventer 300 is seated within tubing assembly 100 in the manner just described. In an embodiment, the location and orientation of each of the one or more vents 318 may correspond to the location and shape of ramp 122b of landing nipple 120 as previously described.
Top sub 320 may be formed as a generally tubular body that may provide a form of connection at its proximal and distal ends, for example a threaded connection, which may allow a proximal end of top sub 320 to be secured to a distal end of upper collet 310 and a distal end of top sub 320 to be secured to a proximal end of particle trap body 330. Top sub 320 may be formed having one or more inner surface profiles, which may allow an inner surface of a distal end of upper collet 310 to be joined to an inner surface of a proximal end of particle trap body 330.
Particle trap body 330 may be formed as a generally tubular body that may provide a known form of connection at its proximal and distal ends, for example a threaded connection, which may allow a proximal end of particle trap body 330 to be secured to a distal end of top sub 320 and a distal end of particle trap body 330 to be secured to a proximal end of lower collet 370. Particle trap body 330 may be formed having a length that may correspond at least in part to the length of lower tubing string 130, so as to allow plunger 240 to remain at least partially in sliding engagement with working barrel 140 as previously described, and may further correspond with a length of rod segment 212 passing through particle trap body 330, so as to allow rod segment 212 to travel in the distal direction under operational conditions, which will later be described. In embodiments, particle trap body 330 may house upper bushing assembly 332, cap 334, inner body 336, spacer 338, flexible valve 340, and lower bushing assembly 342.
Upper bushing assembly 332 and lower bushing assembly 342 may each comprise at least one bushing 350 and at least one guide ring 358 as illustrated in FIG. 1 and further illustrated in FIG. 2. Bushing 350 may be formed as a generally disc-shaped body having central bore 352, one or more radially-spaced apertures 354, and one or more spacers 356. In embodiments, central bore 352 may be provided with an inner profile adapted to receive guide ring 358 such that an inner diameter of guide ring 358, when inner guide ring 358 is positioned within central bore 352, may correspond to an outer diameter of rod body 214 of the rod segment 212 passing through particle trap body 330. In embodiments, a radial dimension of spacer 356 may correspond at least in part to a difference between the inner diameter of particle trap body 330 and the outer diameter of inner body 336, which together may define annulus 344 when inner body 336 is secured within particle trap body 330. In this manner, each of the spacers 356 may allow fluid communication between bushing 350 and an inner surface of particle trap body 330 such that the fluid communication may continue into annulus 344 as shown in FIG. 5B and in a manner which will later be described. In embodiments, each of the one or more apertures 354 may be sized to correspond with a rate of fluid flow through fallback preventer 300. In embodiments, guide ring 358 may be provided with a scarf cut 360, which may assist installation of guide ring 358 within central bore 352. In embodiments, upper bushing assembly 332 and lower bushing assembly 342 may each centralize rod assembly 200 within fallback preventer 300, and thus may centralize rod assembly 200 within tubing assembly 100 or within working barrel 140.
As shown in embodiments of FIG. 1, inner body 336 may be formed as a generally tubular body having an outer diameter that may allow annulus 344 to be defined between the inner surface of particle trap body 330 and the outer surface of inner body 336. The radial size of annulus 344 thus formed may correspond at least in part to a desired rate of fluid flow through annulus 344. In embodiments, inner body 336 may be provided with one or more axially-oriented series of apertures 346, wherein each of the one or more series of apertures 346 may be spaced radially about the circumference of inner body 336. In this manner, fluid that may communicate into annulus 344 may further communicate into an inner volume of inner body 336 as shown in FIG. 5B and in a manner that will later be described.
Cap 334 and spacer 338 may each be formed as a generally ring-shaped body. In embodiments, cap 334 may be housed within particle trap body 330 between upper bushing assembly 332 and inner body 336, and spacer 338 may be housed within particle trap body 330 between inner body 336 and flexible valve 340.
In embodiments as shown in FIGS. 1 and 2, flexible valve 340 may be formed as a generally disc-shaped body having an outer diameter that may correspond in whole or in part to an outer diameter of inner body 336, and may feature a central bore 362, which may correspond in size to central bore 352 of bushing 350. In embodiments, flexible valve 340 may comprise one or more radial cuts 364 that may adjoin one or more circumferential cuts 366, thereby forming one or more flaps 368. In embodiments, the quantity, size, and/or radial position of the one or more flaps 368 may correspond to the quantity, size, and/or radial position of the one or more apertures 354 of bushing 350 provided at lower bushing assembly 342. In this manner, each of the one or more flaps 368 may flexibly modulate in concert with fluid communication through its corresponding aperture 354 between an open configuration and a closed configuration, where fluid flow in the proximal direction may cause flap 368 to be biased toward the open configuration, and fluid flow in the distal direction may cause flap 368 to be biased toward the closed configuration with flap 368 brought into resting contact against a surface of bushing 350, thereby preventing fluid communication through its corresponding aperture 354.
In embodiments as shown in FIG. 1, lower collet 370 may be provided with a form of connection at is proximal end, for example a threaded connection, which may allow lower collet 370 to be secured to a distal end of particle trap body 330. In embodiments, lower collet 370 may be formed to include, or may be provided with, one or more fingers 372 which may be adapted to grasp latch coupling 234 at neck 238 with a desired grasping force. In embodiments, the grasping force may be selected such that, when grasping neck 238, the grasping force may enable lower collet 370 to retain fallback preventer 300 at an axial location about rod assembly 200 while fallback preventer 300 may be run in hole. In embodiments, lower collet 370 or fingers 372 may be formed to provide a release force, such that when shoulder 312 of upper collet 310 is brought into engagement against shoulder 128 of landing nipple 120, fingers 372 may release neck 238 such that rod assembly 200 may be freed to move axially in relation to fallback preventer 300 in the distal direction. In embodiments, when rod assembly 200 is moved axially in the proximal direction, one or more surfaces of latch coupling 234 may be brought into contact with one or more surfaces of fingers 372, which may initially prevent rod assembly 200 from moving further in a proximal direction. Following this initial contact, when the release force is applied to rod assembly 200 in the proximal direction, fingers 372 may expand to receive latch coupling 234, thereafter grasping latch coupling 238 at neck 238.
Operation In operation, embodiments of tubing string 100, rod assembly 200, and fallback preventer 300 may together provide methods of collecting particulate matter included in a fluid if flow of the fluid may slow or become suspended, as well as methods of clearing the particulate matter after being collected, which may correspond to restoration of fluid flow.
In embodiments shown in FIG. 4A, once tubing assembly 100 may be disposed at a desired depth in a wellbore, rod assembly 200 and fallback preventer 300 may be run in hole as a combined system wherein latch coupling 234 of rod assembly 200 is grasped by fingers 372 of lower collet 370 at neck 238 with the grasping force previously described. The combined system of rod assembly 200 and fallback preventer 300 may then be run in the distal direction until upper collet 310 enters landing nipple 120 and shoulder 312 of upper collet 310 is brought into resting engagement against shoulder 128 of landing nipple 120. Prior to shoulder 312 contacting shoulder 128, ramp 124a of landing nipple 120 may cause latch 316 of upper collet 310 to be displaced to an inward radial position. At or about the same time that shoulder 312 may contact shoulder 128, latch 316 may return to an outward radial position to which it may be biased as the surface profile of latch 316 aligns with key 126 of landing nipple 120. Latch 316 being fully seated into the profile of key 126 may thereby secure upper collet 310 within landing nipple 120, and thereby secure fallback preventer 300 in a location within tubing assembly 100, which may be suitable for operation conditions.
FIG. 4B illustrates an embodiment of rod assembly 200 released from lower collet 370. In such an embodiment, the release force previously described has been applied to rod assembly 200, thereby causing fingers 372 of lower collet 370 to release neck 238 of latch coupling 234 and thus allowing rod assembly 200 to travel in the distal direction a distance to allow plunger 240 to come into sliding engagement against inner surface 142 of working barrel 140, and thereby forming pump chamber 144.
FIG. 4C illustrates an embodiment of rod assembly 200 moved in the proximal direction relative to the embodiment of FIG. 4B, which may cause fluid to communicate through apertures 354 of lower busing 250, thereby causing flaps 368 of flexible valve 340 to open, and in turn allowing fluid to pass through fallback preventer 300.
In embodiments shown in FIG. 5A, an embodiment of fallback preventer 300 collecting particulate matter 400 is illustrated. In such an embodiment, reciprocal axial modulation of rod assembly 200 has been suspended, which may cause fluid flow through fallback preventer 300 to also become suspended. Particulate matter 400 included in the fluid may therefore fall in the distal direction, which may be caused by gravitational forces acting upon particulate matter 400. As particulate matter 400 begins to collect in fallback preventer 300, particulate matter 400 may settle on a proximal surface of flaps 368 of flexible valve 340, which may in turn bias flaps 368 to a closed configuration against a proximal surface of busing 350, and thus closing apertures 354.
FIG. 5B illustrates an embodiment of particulate matter 400 beginning to be cleared from fallback preventer 300 as reciprocal axial modulation of rod assembly 200 is restored. In the embodiment illustrated, the amount of particulate matter 400 collected within fallback preventer 300 is sufficient enough to prevent flaps 368 from opening, which may prevent fluid from flowing in a proximal direction through apertures 354 of lower bushing 350. As a result, the flow of fluid in the proximal direction may instead be directed through annulus 344 via spacing between bushing 350 and the inner surface of particle trap body 330 defined by spacers 356 of bushing 350. Subsequently, fluid that has entered annulus 344 may continue to flow in a proximal direction by entering inner body 336 through the one or more series of apertures 346 distributed radially about inner body 336, as shown. In turn, fluid thus entering the series of apertures 346 may begin to incrementally lift particulate matter 400 along with the fluid flow in the proximal direction, which may begin to clear particulate matter 400 from fallback preventer 300.
FIG. 5 C illustrates an embodiment of particulate matter 400 continuing to be cleared from fallback preventer 300. Continued fluid flow in the proximal direction may continue to lift any remaining particulate matter 400 from fallback preventer 300, which, may in turn allow flaps 358 of flexible valve 340 to open, and in turn restore fluid flow through apertures 354 of lower bushing 350.
FIGS. 6A and 6B illustrate an embodiment of fallback preventer 300 being removed from tubing assembly 100. In this embodiment, rod assembly 200 is lifted in a proximal direction a distance above an upstroke of a pump to which rod assembly 200 may be or may have been connected. Movement of rod assembly 200 in the proximal direction a sufficient distance may cause latch coupling 234 to come into initial contact against a surface of lower collet 370 or of one or more of its fingers 372. Thereafter, movement of rod assembly 200 in the proximal direction may be continued by applying sufficient force to rod assembly 200 in the proximal direction that may cause fingers 372 to expand radially in order to receive latch coupling 234, after which fingers 273 may subsequently contract radially, thereby grasping neck 238 of latch coupling 234 and arriving at the configuration shown in FIG. 6A. As shown in embodiments of FIG. 6B, upon rod assembly 200 becoming grasped by lower collet 370, forces applied to rod assembly 200 in the proximal direction may be transferred to fallback preventer 300. Sufficient force thus applied to rod assembly 200 may in turn cause the one or more latches 316 of upper collet 310 to be displaced toward an inward radial position, which may in turn allow latches 316 to clear key 126 of landing nipple 120. Upon becoming thus cleared, rod assembly 200 and fallback preventer 300 may then continue to be lifted from tubing assembly 100 in the proximal direction, and as all or a portion of the one or more latches 316 clears ramp 124a of landing nipple 120, latches 316 may then return to the outward radial position toward which they may be biased. The combined system of rod assembly 200 and fallback preventer 300 may then be free to be removed from the wellbore.
FIGS. 7A through 7D illustrate operation of standing valve 150, plunger 240, and traveling valve 248. FIG. 7A illustrates plunger 240 located within working barrel 140 as rod assembly 200 begins movement in the proximal direction. As can be seen, ball 254 of traveling valve 254 is in resting contact against ball seat 252, and ball 158 of standing valve 150 is in resting contact against ball seat 156. Progressing to FIG. 7B, continued movement of rod assembly 200 in the proximal direction may cause pump chamber 144 to expand, thereby encouraging ball 158 to become unseated from ball seat 156 and thus allowing fluid to enter standing valve 150 at inlet 152. In embodiments, ball trap 154 may prevent ball 158 from being fully lifted into pump chamber 144. Continuing to FIG. 7C, as rod assembly 200 transitions toward movement in the distal direction, ball 158 may be allowed to return to a seated position against ball seat 156. As rod assembly continues to move further in the distal direction, shown in FIG. 7D, ball 254 of traveling valve 248 may be caused to become unseated from ball seat 252, thereby allowing fluid to enter inlet 246 of plunger 240. This sequence may then repeat, thereby defining a reciprocating stroke of rod assembly 200, which in turn enables fluid to be lifted through pump chamber 144.
In further embodiments as shown in FIG. 8, FIG. 8 illustrates an embodiment of a sucker rod 505, filter 650, and plunger bottom hole assembly 610. It is to be understood that the no-go seals 520 prevent movement past it. FIG. 9 illustrates an embodiment of a locating profile 570 and barrel tubing 595.
In an embodiment as shown in FIGS. 8-10, plunger bottom hole assembly 610 is run downhole on a sucker rod 505. The plunger bottom hole assembly 610 is run downhole by any suitable means known to one of ordinary skill in the art. The plunger bottom hole assembly 610 passes through the locating nipple 685 until reaching the no-go seals 520. In an embodiment, the space-out between the locating nipple 685 and the barrel tube 595 is calculated into the length of the polished sucker rod 505.
In the embodiments shown in FIGS. 11 and 12, the lock 510 includes the lock collet 515 and no-go seals 520. When the plunger bottom hole assembly 610 reaches the no-go seals 520, the lock collet 515 snaps in place holding the plunger bottom hole assembly 610 in place in the locating nipple 685. The no-go seals 520 stop the plunger bottom hole assembly 610 as they are run in.
As shown in the embodiment of FIG. 13, the plunger bottom hole assembly 610 is lowered into the barrel tube 595. In embodiments as shown, after the lock collet 515 lands in the locating nipple 685, weight is continuing to set down, which lowers the plunger bottom hole assembly 610 into the barrel tube 595 until the plunger bottom hole assembly 610 is spaced out correctly into the barrel tube 595.
After the plunger bottom hole assembly 610 is spaced out correctly into the barrel tube 695, a normal pump cycle begins as shown in the embodiments of FIGS. 14(a)-14(d) is carried out. As shown in such FIGS. 14(a)-14(d), the floating ball 535 rises and falls with the fluid flow 635. It is to be understood that filter 650 is not limited to a floating ball but may be any suitable check valve. In embodiments, the check valve is any solid body that substantially prevents sand from passing thereby when the check valve is in a closed position. In an embodiment, the check valve is a floating ball, cone, flat plat or the like.
As shown in the embodiments of FIGS. 15(a) and 15(b), the pump is stopped, and the sand (i.e., particulate matter 400) falls back. As shown, the particulate matter 400 that falls back is captured in the tool body 645. The floating ball 635 drops into the opening 690 and seals the tool, thereby keeping the particulate matter 400 in the tool body 645. As shown, slots 655 are cut into the tool body 645. In embodiments, the slots 655 are of a size sufficiently small to prevent the particulate matter 400 from moving through the slots 655. In an embodiment, most of the fluid flow 635 is through the slots 655 with a minor amount of the fluid flow 635 outside of the center.
As shown in FIGS. 16(a)-16(d), the pump is re-started, and the particulate matter 400 is put back in the fluid flow 635. As shown in FIG. 16(a), the first flow path is around the tool body 645. The fluid is pushed through the slots 655 in the tool body 645, mixing with the particulate matter 400 and lifting the particulate matter 400 to the surface. As shown in FIG. 16(b), the fluid flow 635 goes into the slots 655 and lifts the particulate matter 400 with the fluid flow 635. FIG. 16(c) shows an embodiment that once enough particulate matter 400 is lifted off the floating ball 535, the floating ball 535 lifts off the seat 540 and flow passes around it. In the embodiment shown in FIG. 16(d), once sufficient particulate matter 400 is removed, the floating ball 535 pops up with the fluid flow 635, and substantially all the particulate matter 400 is removed.
It is to be understood that the floating balls 535 may take up any axial loads on the plunger 560. In embodiments, there may be more than one floating ball 535. When pumping, the plunger 560 may bend, which causes axial loads that may damage the plunger 560. Therefore, the loads may be balanced on the floating balls 535 reducing loads on the plunger 560 as the floating balls 535 rotate with the plunger 560.
In the embodiment as shown in FIG. 17(a), the fallback preventer filter 650 is attached to the plunger 560 before the run downhole. FIG. 17(b) illustrates an embodiment of the barrel tube 595 run downhole with the tubing. FIG. 17(c) illustrates an embodiment of the plunger 560 and the fallback preventer filter 650 stopped by the slip 675 with the cone 670 pushed against the slip 675.
In the embodiments shown in FIGS. 18(a) and 18(b), the set down weight shears the first set of shear pins 660 and sets the slips 675. As shown in the embodiments of FIGS. 18(c) and 18(d), once fully set, the second set of shear pins 665 shears, allowing the plunger 560 to go into the barrel tube 595.
In the embodiments as shown in FIGS. 19 and 20, the plunger bottom hole assembly 610 lifts the fluids to the surface, and the floating ball 535 lifts and falls with the fluid flow 635. As shown in the embodiment of FIG. 21(a), once the pumping stops, the floating ball 535 lands on the seat 540, and the particulate matter 400 is contained in the fallback preventer filter 650. In the embodiment of FIG. 21(b), once the sucker rod 505 is lifted again and the pumping starts, fluid (i.e., some fluid) is pushed into the annular area 695 around the fallback preventer filter 650. This fluid is pushed into the particulate matter 400 thus sufficiently lightening the particulate matter 400 for the floating ball 535 to come off the seat 540 and the fallback preventer filter 650 to empty. In addition, as shown in the embodiment of FIG. 21(c), the fallback preventer filter 650 is now empty, and the pumping may return to normal operation.
As shown in the embodiment of FIG. 22(a), when it is time to remove the plunger bottom hole assembly 610, the plunger bottom hole assembly is 610 lifted until the plunger bottom hole 610 assembly contacts the bottom 680 of the fallback preventer filter 650. As shown in the embodiment of FIG. 22(b), the cone 670 is removed, which unsets the slip 675. In the embodiment as shown in FIG. 22(c), the entire plunger bottom hole assembly 610 is returned to the surface.
In embodiments shown in FIG. 23, fallback preventer filter 500 is disposed in tubing 700. A pump rod 705 is attached to fallback preventer filter 750. Sucker rod pump 735 is disposed in tubing 700 between fallback preventer 750 and insert nipple 745. Fluid flow 740 is the flow of fluid. Valve rod guide 710 has pump rod 705 extending therethrough. Fallback preventer filter 750 includes wiper seals 715, sand screen 720, floating poppet 725, seat 730, by-pass port 755, and sand fin 775. Fallback preventer filter 750 is threaded between valve rod guide 710 and upper barrel connector 780. As shown in the embodiments of FIGS. 23, 31(a), and 32(a), a normal pumping operation is illustrated with the pump (not shown) operable with fluid flow 740 passing substantially through the middle of fallback preventer filter 750 and thereby production ports 770 and sand fins 775. It is to be understood that fallback preventer 750 may have one or more than one production port 770 and sand fin 775, alternatively more than one production port 770 and sand fin 775. As shown, floating poppet 725 is disposed above seat 730 by the force of fluid flow 740. Sand screen 720 may include any suitable sand screen known to one of ordinary skill in the art.
As shown in the embodiments of FIGS. 24, 31(b), and 32(b), the pump is off and particulate matter 400 is falling back with no fluid flow 740. As illustrated, particulate matter 400 is falling back and is directed into fallback preventer filter 750 by sand fins 775. The fallback particulate matter 400 is trapped in the sand screen 720 by the pressure of the fallback particulate matter 400 pushing floating poppet 725 into contact with seat 730. In embodiments, there are more than one floating poppet 725 and more than one seat 730. In embodiments, some fluid may flow back down through sand screen 720 and passed sand screen 720 to lubricate the pump. Particulate matter 400 is prevented from falling down passed sand screen 720.
In the embodiments shown in FIGS. 25, 31(c), and 32(c), the pump is back on causing fluid flow 740. Initially, in some embodiments as shown, fluid flow 740, when the pump first comes back on, may not provide sufficient force to push floating poppet 725 up off seat 730. In such embodiments, fluid flow 740 passes through by-pass ports 755 disposed on sand screen 720 below seat 730. Fluid flow 740 passes through by-pass ports 755 to annulus 785 and into sand screen 720. Particulate matter 400 is passed out of sand screen 720 with the fluid flow 740.
FIGS. 26, 31(d), and 32(d) illustrate embodiments when sufficient particulate matter 400 has been removed from sand screen 720 by fluid flow 740 to allow fluid flow 740 to push floating poppet 725 off seat 730 and allow fluid flow 740 to enter the middle of sand screen 720, which allows normal fluid flow 740 to resume through sand screen 720 and tubing 700. It is to be understood that fluid flow 740 is then minimized through by-pass ports 755.
FIGS. 27, 31(e), and 32(e) illustrate embodiments when fluid flow 740 has removed all particulate matter 400 and normal pumping operations have resumed.
FIG. 28 illustrates an embodiment of the embodiments of FIG. 23 in which fallback preventer filter 750 includes flap 765 instead of floating poppet 725. Flap 765 is described above. In embodiments, flap 765 is a tri-flapper check valve. As shown in the embodiments of FIGS. 28, 29(a), and 30(a), a normal pumping operation is illustrated with the pump (not shown) operable with fluid flow 740 passing substantially through the middle of fallback preventer filter 750 and thereby production port 770 and sand fin 775. As shown, flap 765 is in the open position by the force of fluid flow 740 with fluid flow 740 flowing passed flap 765.
As shown in the embodiments of FIGS. 29(b) and 30(b), the pump is off and particulate matter 400 is falling back with no fluid flow 740. As illustrated, particulate matter 400 is falling back and is directed into fallback preventer filter 750 by sand fins 775. The fallback particulate matter 400 is trapped in the sand screen 720 by the pressure of the fallback particulate matter 400 pushing flap 765 down to provide a seal with seat 730 to prevent further downward flow of particulate matter 400. In embodiments, some fluid may flow back down through sand screen 720 and passed sand screen 720 to lubricate the pump. Particulate matter 400 is prevented from falling down passed sand screen 720. FIGS. 29(c) and 30(c) illustrate embodiments in which the pump is still off and particulate matter 400 has settled in fallback preventer filter 750. In embodiments, there are more than one flap 765 and more than one seat 730.
In the embodiments shown in FIGS. 29(d) and 30(d), the pump is back on causing fluid flow 740. Initially in some embodiments as shown, fluid flow 740, when the pump first comes back on, may not provide sufficient force to push open flap 765. In such embodiments, fluid flow 740 passes through by-pass ports 755 disposed on sand screen 720 below seat 730. Fluid flow 740 is passed through by-pass ports 755 to annulus 785 and into sand screen 720. Particulate matter 400 is passed out of sand screen 720 with the fluid flow 740.
FIGS. 29(e) and 30(e) illustrate embodiments when sufficient particulate matter 400 has been removed from sand screen 720 by fluid flow 740 to allow fluid flow 740 to push flap 765 open and allow fluid flow 740 to enter the middle of sand screen 720, which allows normal fluid flow 740 to resume through sand screen 720 and tubing 700. It is to be understood that fluid flow 740 is then minimized through by-pass ports 755.
FIGS. 29(f) and 30(f) illustrate embodiments when fluid flow 740 has removed all particulate matter 400 and normal pumping operations have resumed.
It is to be understood that flap 765 and floating poppet 725 act as check valves.
Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations may be made herein without departing from the spirit and scope of the invention as defined by the appended claims.
