Lift apparatus for driving a downhole reciprocating pump
A lift apparatus and method for driving a downhole reciprocating pump is disclosed. The apparatus includes a hydraulic cylinder having a piston and a hydraulic fluid port, the piston being coupled to a rod for driving the reciprocating pump, the piston being moveable between first and second ends of the cylinder in response to a flow of hydraulic fluid through the hydraulic fluid port. The apparatus also includes a variable displacement hydraulic pump coupled to receive a substantially constant rotational drive from a prime mover for operating the hydraulic pump, the hydraulic pump having an outlet and being responsive to a displacement control signal to draw hydraulic fluid from a reservoir and to produce a controlled flow of hydraulic fluid at the outlet. The apparatus also includes a hydraulic fluid line connected to deliver hydraulic fluid from the outlet of the hydraulic pump through the hydraulic fluid port to the cylinder for causing the piston to move through an upstroke away from the first end and toward the second end of the cylinder. The apparatus further includes a valve connected between the hydraulic fluid port and the reservoir, the valve being responsive to a valve control signal for controlling discharge of hydraulic fluid from the hydraulic fluid port of the cylinder back to the reservoir to facilitate movement of the piston through a downstroke away from the second end toward the first end of the cylinder. The valve is operable to prevent flow of hydraulic fluid through the valve during the upstroke and the hydraulic pump is operable to prevent flow of hydraulic fluid back into the outlet of the hydraulic pump during the downstroke.
1. A lift apparatus for driving a downhole reciprocating pump, the apparatus comprising:
a hydraulic cylinder having a piston and a hydraulic fluid port, the piston being coupled to a rod for driving the reciprocating pump, the piston being moveable between first and second ends of the cylinder in response to a flow of hydraulic fluid through the hydraulic fluid port;
a variable displacement hydraulic pump coupled to receive a substantially constant rotational drive from a prime mover for operating the hydraulic pump, the hydraulic pump having an outlet and being responsive to a displacement control signal to draw hydraulic fluid from a reservoir and to produce a controlled flow of hydraulic fluid at the outlet;
a hydraulic fluid line connected to deliver the controlled flow of hydraulic fluid from the outlet of the hydraulic pump through the hydraulic fluid port to the cylinder for causing the piston to move through an upstroke away from the first end and toward the second end of the cylinder;
a valve connected between the hydraulic fluid port and the reservoir, the valve being responsive to a valve control signal for controlling discharge of hydraulic fluid from the hydraulic fluid port of the cylinder back to the reservoir to facilitate movement of the piston through a downstroke away from the second end toward the first end of the cylinder; and
wherein:
the hydraulic fluid line bypasses the valve such that the flow of hydraulic fluid during the upstroke does not pass through the valve;
the valve is operable to prevent flow of hydraulic fluid through the valve during the upstroke; and
the hydraulic pump is operable to prevent flow of hydraulic fluid back into the outlet of the hydraulic pump during the downstroke.
2. The apparatus of claim 1 wherein the hydraulic fluid line comprises a common portion in communication with the hydraulic fluid port, wherein the common portion carries fluid flow from the hydraulic pump during the upstroke and to the valve during the downstroke.
3. The apparatus of claim 1 wherein the hydraulic fluid line is routed between the outlet of the hydraulic pump and the hydraulic fluid port through at least one bend, the at least one bend having a bend radius of at least about 25 mm to reduce flow losses within the hydraulic fluid line.
4. The apparatus of claim 1 wherein the hydraulic pump is configured to produce a unidirectional flow of fluid at the outlet having a flow rate ranging from a substantially no flow condition to a maximum flow rate in proportion to the displacement control signal.
5. The apparatus of claim 4 wherein the hydraulic pump comprises a swashplate movable through a range of angles between 0° corresponding to the substantially no flow condition to a maximum angle corresponding to the maximum flow rate and wherein the hydraulic pump is configured to prevent the swashplate being angled at less than 0° for preventing flow back into the outlet and through the hydraulic pump.
6. The apparatus of claim 1 wherein the hydraulic fluid line includes a check valve disposed between the outlet of the pump and the hydraulic fluid port, the check valve being operable to permit flow from the outlet to the hydraulic fluid port during the upstroke while preventing flow of hydraulic fluid back into the outlet of the hydraulic pump during the downstroke.
7. The apparatus of claim 1 further comprising:
a first sensor located proximate the first end of the cylinder and operable to produce a first signal indicating a proximity of the piston to the first sensor;
a second sensor located proximate the second end of the cylinder and operable to produce a second signal indicating a proximity of the piston to the second sensor; and
a controller operably configured to generate the displacement control signal and the valve control signal in response to receiving the first signal and the second signal.
8. The apparatus of claim 7 wherein the first and second sensors are positioned proximate to but spaced inwardly from the respective first and second ends of the cylinder to cause the first and second signals to be generated in when the piston is in proximity to the respective first and second ends of the cylinder.
9. The apparatus of claim 7 wherein the controller is operably configured to generate a displacement control signal having a time varying waveform for controlling the upstroke, the waveform including:
a first ramped portion that causes the hydraulic pump to deliver an increasing flow of hydraulic fluid for accelerating the piston away from the first end of the cylinder;
a constant portion that causes the hydraulic pump to deliver a substantially constant flow for moving the piston at a substantially constant velocity; and
a second ramped portion that causes the hydraulic pump to deliver a reducing flow for decelerating the piston as the piston approaches the second end of the cylinder.
10. The apparatus of claim 9 wherein the controller is operably configured to generate the constant portion of the waveform to target a desired velocity of the piston for the upstroke based on a calculated velocity of the piston during a previous upstroke of the piston, the velocity being calculated based on the first and second signals.
11. The apparatus of claim 10 wherein the controller is operably configured to receive operator input of one of the desired velocity and an upstroke time.
12. The apparatus of claim 9 wherein the controller is operably configured to, in response to receiving the second signal, commence the second ramped portion following a delay period.
13. The apparatus of claim 12 wherein the controller is operably configured to calculate the delay period based on a calculated velocity of the piston between the first and second sensors during a current upstroke of the piston.
14. The apparatus of claim 9 wherein the controller is operably configured to generate the first and second ramped portions of the waveform for the upstroke based on the first and second signals received during a previous upstroke of the piston.
15. The apparatus of claim 7 wherein the controller is operably configured to generate a valve control signal having a time varying waveform for controlling the downstroke, the waveform including:
a first ramped portion that causes the valve to permit an increasing flow of hydraulic fluid permitting the piston to accelerate away from the second end of the cylinder;
a constant portion that causes the valve to permit a substantially constant flow for moving the piston at a substantially constant velocity; and
a second ramped portion that causes the valve to permit a reducing flow for decelerating the piston as the piston approaches the first end of the cylinder.
16. The apparatus of claim 15 wherein the controller is operably configured to generate the constant portion of the waveform for targeting a desired velocity of the piston for the downstroke based on a calculated velocity of the piston during a previous downstroke of the piston, the velocity being calculated based on the first and second signals.
17. The apparatus of claim 16 wherein the controller is operably configured to receive operator input of one of a desired velocity and a downstroke time.
18. The apparatus of claim 15 wherein the controller is operably configured to, in response to receiving the first signal, commence the second ramped portion following a delay period.
19. The apparatus of claim 18 wherein the controller is operably configured to calculate the delay period based on a calculated velocity of the piston between the second and first sensors during the downstroke of the piston.
20. The apparatus of claim 15 wherein the controller is operably configured to generate the first and second ramped portions of the waveform for the downstroke based on the first and second signals received during a previous downstroke of the piston.
21. The apparatus of claim 1 wherein the valve comprises an electrically controllable proportional throttle valve.
22. The apparatus of claim 1 wherein the hydraulic pump comprises a swashplate pump in which an angle of the swashplate is configurable over a range of angles in response to the displacement control signal and wherein the range of angles is constrained to produce a unidirectional flow at the outlet.
23. A method for operating a pumpjack lift, the pumpjack comprising a hydraulic cylinder having a piston and a hydraulic fluid port, the piston being coupled to a rod for driving a downhole reciprocating pump, the method comprising:
producing a displacement control signal operable to cause a variable displacement hydraulic pump to draw hydraulic fluid from a reservoir and to produce a controlled flow of hydraulic fluid at an outlet of the hydraulic pump, the hydraulic pump being coupled to receive a substantially constant rotational drive from a prime mover;
delivering the controlled flow of hydraulic fluid from the outlet of the hydraulic pump through a hydraulic fluid line connected to the hydraulic fluid port of the cylinder to cause the piston to move through an upstroke away from a first end and toward a second end of the cylinder;
producing a valve control signal for controlling discharge of hydraulic fluid back to the reservoir from the hydraulic fluid port of the cylinder through a valve connected between the hydraulic fluid port and the reservoir to facilitate movement of the piston through a downstroke away from the second end and toward the first end of the cylinder, wherein the hydraulic fluid line bypasses the valve such that the flow of hydraulic fluid during the upstroke does not pass through the valve; and
preventing flow of hydraulic fluid through the valve during the upstroke and preventing flow of hydraulic fluid back into the outlet of the hydraulic pump during the downstroke.
24. The method of claim 23 wherein producing the displacement control signal comprises:
receiving a first signal indicating a proximity of the piston to a first sensor located proximate the first end of the cylinder;
receiving a second signal indicating a proximity of the piston to a second sensor located proximate the second end of the cylinder; and
causing a controller operably to generate the displacement control signal and the valve control signal in response to receiving the first signal and the second signal.
25. The method of claim 24 wherein producing the displacement control signal comprises causing the controller to generate a displacement control signal having a time varying waveform for controlling the upstroke, the waveform including:
a first ramped portion that causes the hydraulic pump to deliver an increasing flow of hydraulic fluid for accelerating the piston away from the first end of the cylinder;
a constant portion that causes the hydraulic pump to deliver a substantially constant flow for moving the piston at a substantially constant velocity; and
a second ramped portion that causes the hydraulic pump to deliver a reducing flow for decelerating the piston as the piston approaches the second end of the cylinder.
26. The method of claim 24 wherein producing the valve control signal comprises causing the controller to generate a valve control signal having a time varying waveform for controlling the downstroke, the waveform including:
a first ramped portion that causes the valve to permit an increasing flow of hydraulic fluid permitting the piston to accelerate away from the second end of the cylinder;
a constant portion that causes the valve to permit a substantially constant flow for moving the piston at a substantially constant velocity; and
a second ramped portion that causes the valve to permit a reducing flow for decelerating the piston as the piston approaches the first end of the cylinder.