US20170198582A1

US20170198582A1 - Well site pump with integrated driver and hydraulic motor and method of using same

Info

Publication number: US20170198582A1
Application number: US15/313,852
Authority: US
Inventors: James William Weir; Frank Benjamin Springett
Original assignee: National Oilwell Varco LP
Current assignee: National Oilwell Varco LP
Priority date: 2014-05-30
Filing date: 2015-05-15
Publication date: 2017-07-13
Also published as: WO2015183600A1; EP3149333A1

Abstract

In at least one aspect, this disclosure relates to a wellsite pump for a well site having a wellbore penetrating a subterranean formation. The well site has a conduit to pass a wellsite fluid about the wellsite. The wellsite pump includes a housing having an intake and an outtake, at least one hydraulic motor to pump the wellsite fluid from the intake and through the outtake, at least one driver coupled to the hydraulic motor and movable therewith, and a power source. The intake is in fluid communication with the conduit, and the outtake is positioned a distance upstream of the intake. The hydraulic motor includes a rotor and a stator. The power source drives the driver and the hydraulic motor coupled thereto whereby the wellsite fluid is advance from the conduit to a location upstream therefrom.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a 35 U.S.C. §371 national stage entry of PCT/US2015/031201, filed May 15, 2015, and entitled “Wellsite Pump with Integrated Driver And Hydraulic Motor And Method of Using Same,” which claims the benefit of U.S. Provisional Application No. 62/005,648, filed on May 30, 2014, and entitled “Wellsite Pump with Integrated Driver and Hydraulic Motor and Method of Using Same,” the entire contents of each being hereby incorporated by reference herein for all purposes.

BACKGROUND

The disclosure relates generally to techniques for performing wellsite operations. More specifically, the disclosure relates to techniques, such as pumps and motors, for passing fluid about a wellsite.
Oilfield operations may be performed to locate and gather valuable downhole fluids. Some such oilfield operations are performed at onshore and/or offshore locations. Offshore wellsites may have surface platforms with a riser extending to a wellhead at the sea floor. The riser may include a series of tubulars that form an elongate fluid path for passage of fluids.
A drilling tool may be deployed through the riser and the wellhead to form a wellbore. The drilling tool may include a drill string, a bottomhole assembly and a drill bit. Drilling mud may be passed through the drilling tool and out the drill bit, and passed back to the surface through the riser.
Pumps may be used at the wellsite to pump the drilling mud through the downhole tool and back to surface. Examples of pumps are provided in US Publication Nos. 2013/0287616, 2013/084175, 2014/056731, 2005/089427, 2010/038134, 2010/074780, 2011/68014, 20111250084, 2012122760, 2006/0514380, and WO20131124626, the entire contents of which are hereby incorporated by reference herein.

SUMMARY

In at least one aspect, this disclosure relates to a wellsite pump for a wellsite having a wellbore penetrating a subterranean formation. The wellsite has a conduit to pass a wellsite fluid about the wellsite. The wellsite pump includes a housing having an intake and an outtake, at least one hydraulic motor to pump the wellsite fluid from the intake and through the outtake, at least one driver coupled to the hydraulic motor and movable therewith, and a power source to drive the driver and the hydraulic motor coupled thereto whereby the wellsite fluid is advanced from the conduit to a location upstream therefrom. The intake is in fluid communication with the conduit. The outtake is positioned upstream from the intake. The hydraulic motor includes a rotor and a stator.
The wellsite pump may also include a dock operatively connecting the intake to the conduit, a support, and/or a mascerator. The conduit may be a riser, a drill string, coiled tubing, a choke line, a kill line, return line, auxiliary line, a subsea stack, and/or cables. The conduit may extend from a fluid source at a surface location. The fluid source may include an air source, a fluid tank, and/or a mud pit. The outtake may be in fluid communication with the conduit, a fluid source, a fluid storage, and/or an auxiliary wellsite.
The hydraulic motor may include a progressive cavity motor comprising a rotor and a stator. The rotor may have at least one rotor lobe and the stator has at least one stator lobe. The wellsite pump may also include a fluid circuit extending between the intake and the outtake. The fluid circuit may include at least one fluid control device to control the flow of the wellsite fluid therethrough. The fluid control device may be a valve, a flowline and/or a bypass.
The wellsite pump may also include electronics to operate the driver. A plurality of hydraulic motors and/or a plurality of drivers may be provided. The hydraulic motors and the drivers may be connected in series or in parallel.
The driver may include a hydraulic motor and the power source may be a driver fluid passing about the driver. The driver fluid may provide a pressure differential to drive the driver. The driver fluid may be drilling mud, sea water, and/or hydraulic fluid. The driver may include an electric motor and the power source may be electronics to drive the driver.
The power source may include a supply pumping unit includes a hydraulic motor driven by a pressure differential across the hydraulic motor, with the supply pumping unit operatively connected to the driver to pump a driver fluid through the driver. The wellsite pump may also include at least one coupling. Each coupling may couple the hydraulic motor to the driver.
In another aspect, the disclosure relates to a wellsite pump for a wellsite having a wellbore penetrating a subterranean formation. The wellsite has a conduit to pass a wellsite fluid about the wellsite. The wellsite pump includes a housing having an intake and an outtake, at least one hydraulic motor to pump the wellsite fluid from the intake and through the outtake, at least one driver operatively connected to the hydraulic motor via a coupling to translate movement therebetween; and a power source to drive the driver and thereby the hydraulic motor coupled thereto whereby the wellsite fluid is advanced from the conduit to a location upstream therefrom. The intake is in fluid communication with the conduit. The outtake is upstream from the intake. The hydraulic motor includes a rotor and a stator.
The coupling may include connectors, bearings, an intermediate adapter and a coupling housing. The coupling may include a safety catch, an end adapter, and a top sub. The coupling may include a seal coupling including at least one seal. The seal may include a barrier seal, a static seal, and/or ball seals. The coupling may include a linkage coupling including a linkage. One end of the linkage may be coupled to the hydraulic motor, and the other end coupled to the driver. The linkage coupling may provide orbital and/or rotational movement. The coupling may include a housing with an inlet and an outlet.
Finally, in another aspect, the disclosure relates to a method of pumping a wellsite fluid about a wellsite having a wellbore penetrating a subterranean formation. The wellsite has a conduit to pass the wellsite fluid about the wellsite. The method involves operatively connecting a wellsite assembly to the conduit. The wellsite assembly includes a housing, a hydraulic motor, and a driver. The method further involves driving the driver with a power source, and advancing the wellsite fluid from the conduit to a location upstream therefrom by driving the hydraulic motor with the driver.
The method may also involve driving the driver with a power source which comprises rotating the driver with an electric motor, driving the driver with a power source comprises passing a driver fluid through the driver, connecting an intake of the wellsite assembly to the conduit and an outtake of the wellsite assembly to the conduit a distance upstream from the intake, passing the wellsite fluid from the intake to the outtake, passing the wellsite fluid through at least one wellsite pump in series or parallel, increasing one of flow rate and pressure of the wellsite fluid by passing the wellsite fluid through a plurality of the wellsite pumps, rotating the driver and the hydraulic motor via a coupling, sealing at least a portion of the coupling, and/or passing a driver fluid through the driver.

BRIEF DESCRIPTION DRAWINGS

So that the above recited features and advantages can be understood in detail, a more particular description, briefly summarized above, may be had by reference to embodiments that are illustrated in the appended drawings. The appended drawings illustrate examples and are, therefore, not to be considered limiting of its scope. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.

FIG. 1A is a schematic view of an offshore wellsite having a riser extending from a surface platform to subsea equipment, and a wellsite pump assembly along the riser. FIG. 1B is a schematic diagram of a portion of the wellsite depicting pumping thereabout.

FIGS. 2A-2C are schematic views of various configurations of well site pump assemblies having a plurality of wellsite pumps.

FIG. 3 is a detailed view of a portion of an integrated wellsite pump depicting a hydraulic motor.

FIGS. 4A-4F depict cross-sectional views of various configurations of a rotor of a hydraulic motor.

FIG. 5A is a schematic view of a wellsite pump assembly including multiple integrated wellsite pumps having fluid outlets therebetween. FIG. 5B is a schematic view of a portion 5B of one of the multiple integrated wellsite pumps of FIG. 5A

FIG. 6A is a schematic view of an integrated wellsite pump with a sealed coupling. FIG. 6B is a schematic view of a portion of an integrated wellsite pump having another sealed coupling.

FIG. 7 A is a schematic view of an integrated wellsite pump with a linkage coupling. FIG. 7B is a schematic view of an integrated wellsite pump depicting a linkage coupling.

FIG. 8 is a flow chart depicting a method of pumping a wellsite fluid.

DETAILED DESCRIPTION

The description that follows includes exemplary systems, apparatuses, methods, and instruction sequences that embody techniques of the inventive subject matter. However, it is understood that the described embodiments may be practiced without these specific details.
An integrated wellsite pump for pumping a wellsite fluid (e.g., drilling mud, air, gas, etc.) about a wellsite is provided. The wellsite pump integrates a hydraulic motor and a driver with a coupling. The coupling translates rotational and/or orbital movement of the driver to the hydraulic motor to drive the hydraulic motor. A power source, such as electricity and/or a driver fluid (e.g., sea water), may be used to drive the driver. The driver drives the hydraulic motor via the coupling to pump the wellsite fluid.
One or more of the wellsite pumps and/or wellsite pump assemblies may be connected to a wellsite conduit, such as a riser, a drill string, coiled tubing, choke or kill line, return line, auxiliary line, fluid source, and/or other conduit, to pass the wellsite fluid from the conduit to a location upstream therefrom. Multiple wellsite pumps may be connected in series or parallel to pump the wellsite fluid from the conduit to a location upstream therefrom. The driver may be used to provide a power boost to the hydraulic motor and/or one or more of the wellsite pumps may be used to provide a power boost as wellsite fluid is pumped from one wellsite pump to another.
FIG. 1A depicts an example environment in which subject matter of the present disclosure may be utilized. This figure depicts a wellsite 100 having a platform 102 and subsea equipment 104, with a riser 106 therebetween. The platform 102 has a rig 108 and other surface equipment 110 for operating the wellsite 100. The subsea equipment 104 is positioned about a wellhead 112 located on sea floor 114 adjacent a wellbore 116. The subsea equipment 104 is schematically depicted as a box adjacent the wellhead 112, but may be positioned about the sea floor 114 and may include various subsea components, such as strippers, blowout preventers, manifolds and/or other subsea devices for performing subsea operations.
The riser 106 may include multiple tubulars 118 connected to form an elongate passage (or conduit) joining the rig 108 on the platform 102 to the subsea equipment 104 on the sea floor 114 for the passage of wellsite fluid therebetween. The riser 106 may also be provided with one or more external tubings, such as electrical 120 or fluid lines 122 (e.g., choke and kill, glycol, hydraulics, and/or riser-fill-up, etc.), for performing various functions, such as passing electrical signals and/or fluids between the platform 102 and the subsea equipment 104. The tubings 120, 122 may include various tubing, cables, or other communication mechanisms, such as a riser, a drill string, coiled tubing, choke or kill line, return line, auxiliary line, fluid source, and/or other conduit. The tubings 210, 122 may run along the riser 106 from the platform 102 to the subsea equipment 104.
The riser 106 may be used to extend the wellbore 116 through the water, to pass a downhole tool 124 to the wellbore, and/or for allowing drilling mud to be captured as it returns to surface. The riser 106 may be, for example, a drill through umbilical line between the subsea equipment 104 and the rig 108 at the surface.
The downhole tool 124 may be a drilling tool with a bit 125 at an end thereof deployed from the platform 102 through the riser 106, and advanced into the sea floor 114 to form the wellbore 116. As shown, the downhole tool 124 is a drilling tool deployed by Kelly 127 by a drill string 129 through the riser 106. A surface mud pit 126 with a pump P is provided to pass drilling mud through the downhole tool 124 out the bit 125 and back up through the riser 106 to the mud pit 126.
A wellsite pump assembly 130 a is positioned along the riser 106 to pump wellsite fluid (e.g., the mud) from the riser 106 to the platform 102. One or more wellsite pump assemblies 130 a-c (or wellsite pump assemblies) may be positioned at one or more locations about the wellsite 100, such as the locations as shown, to perform desired pumping about one or more of the conduits (e.g., riser 106).
The wellsite pump assembly 130 a may have an intake 132 in fluid communication with a conduit, such as riser 106, to draw wellsite fluid therefrom. The wellsite pump assembly 130 a-c may also have an outtake 134 in fluid communication with various locations of the wellsite 100, such as tubing 122, a driver fluid source 133, a fluid source line 128, an auxiliary wellsite 135, an auxiliary line 136, or other location, to pass the wellsite fluid thereto. The wellsite fluid may be passed by the wellsite pump assembly 130 a-c a distance upstream from the intake 132 to a desired, location, such as a portion of the riser 106 upstream therefrom. The driver fluid source (e.g., tank) 133 may be used to provide driver fluid, such as sea water to the wellsite pump assembly 130 a-c. In some cases, certain fluids, such as sea water may be discharged from the wellsite pump assembly 130 a-c back to the sea.
The wellsite pump assembly 130 a-c may be provided with various features to facilitate operation thereof. For example, the wellsite pump assembly 130 a-c may be provided with a dock 138 to provide a quick release mechanism to fluidly connect the wellsite pump assembly 130 a to the riser 106. Docks 138 may be placed at various locations about the wellsite 100 to receive the intake 132 of the wellsite pump assembly 130 a-c. The wellsite pump assembly 130 b may be supported along the wellsite by a support 140, such as a shelf coupled to the riser 106. A macerator 139 (or other device) may be operatively connected to the conduit to break down particles in the wellsite fluid entering the wellsite pump assembly 130 a-c.
The wellsite pump assembly 130 a-c may be used in a variety of applications, such as the subsea application of FIG. 1A. In the example of FIG. 1A, two wellsite pump assemblies 130 a,b are positioned along the riser 106 and another wellsite pump assembly 130 c is positioned about a subsea stack 104 in a subsea application and usable as a subsea mud lift pump for pumping mud, fluids, and/or cuttings from a subsea location to a location upstream therefrom (e.g., back into the riser 106 for recirculation). It will be appreciated thatthe one or more wellsite pump assemblies 130 may be used in subsea and/or other applications, such as a variety of land or water based oilwell applications.
The wellsite pump assembly 130 may be used in applications that may require transmitting power a great distance and/or extracting that power in a useful manner. Such pumping may involve pumping drilling fluids to the surface. Such pumping may also involve pumping out of the riser 106 at a rate approximate to the rate that fluid is pumped from mud pit 126 into the riser 106 to balance pressure across a hydrostatic head.
Some subsea applications may involve pumping at any depth, such as depths over about 4000 to about 5000 feet (about 1219.2 to about 1524 m). Some subsea applications may involve placement of the wellsite pump assemblies in a submerged location for a period of time, such as the length of the drilling process (e.g., several weeks). Some applications may involve lengthy operational times, such as a week of continuous running. In addition, certain environments (e.g., subsea) may be cold, difficult to access, corrosive, and/or intrusive.
Figure IB is a schematic diagram depicting pumping about a portion of the wellsite 100. As shown by this diagram, the pump assembly 130 c is fluidly coupled to the subsea stack 104. The subsea stack 104 may be used to pump the driver fluid through the pump assembly 130 c as indicated by the dashed arrows, and to pump wellsite fluids through the pump assembly 130 c as indicated by the solids arrows.
Pumps 131 are provided in the wellsite pump assembly 130 c to pump the driver fluid and the wellsite fluid. Each of the wellsite pumps 131 includes a hydraulic motor 150 and a driver 152 connected by a coupling 154. Driver fluid is pumped from the subsea stack 104 through the drivers 152 of each of the wellsite pumps 131 in series to provide a power boost to the hydraulic motors 150. As the driver fluid passes from the subsea stack 104 through the drivers 152, the pressure of the driver fluid reduces across each of the drivers 152 in series from an initial pressure Pa (e.g., about 5000 psi (351.62 kg/cm)) and reduces to a pressure Pb (e.g., about 4000 psi (281.29 kg/cm)), Pc (e.g., of about 3000 psi (210.97 kg/cm)), Pd (e.g., about 2000 psi (140.65 kg/cm)), and Pe (e.g., about 1000 psi (70.32 kg/cm)) after each driver 152 in series. The last driver 152 has a pressure Pv that vents to an exterior of the pump assembly 130 c, such as the surrounding ocean.
The pressure drop from Pe to Pv may be used to provide power to the hydraulic motors 150. Wellsite fluid is pumped from the subsea stack 104 to a supply pumping unit (SPU) 151. The SPU 151 is driven by the pressure drop from Pe to Pv. The power from the SPU 151 may be fluidly coupled to the hydraulic motors 150 to pass the wellsite fluid through each of the hydraulic motors 150 in series. As the wellsite fluid passes from the subsea stack 104 through the hydraulic motors 150, the pressure of the wellsite fluid increases across each of the hydraulic motors 150 in series from an initial pressure Pu (e.g., about 1000 psi (70.32 kg/cm)) and reduces to a pressure Pw (e.g., about 2000 psi (140.65 kg/cm)), Px (e.g., of about 3000 psi (210.97 kg/cm)), Py (e.g., about 4000 psi (281.29 kg/cm)), and pz (e.g., about 5000 psi (351.62 kg/cm)) after the hydraulic motors 150 in series. The last hydraulic motor 150 has a pressure pz that recirculates back to the subsea stack 104 after passing through the wellsite pumps 131. The recirculated wellsite fluid may be provided back to the subsea stack 104 or other portions of the wellsite at a pressure increase driven by the driver fluid passing through the wellsite pump assembly 130 c.
FIGS. 2A-2C depict various configurations of a wellsite pump assembly including multiple wellsite pumps fluidly connected to provide a power boost by selectively increasing pressure and/or flow rate using the wellsite pumps. FIG. 2A depicts a wellsite pump assembly 230 including wellsite pumps 231 connected in parallel and having hydraulic drivers. FIG. 2B depicts a wellsite pump assembly 230′ including wellsite pumps 231′ connected in parallel and having electric drivers. FIG. 2C depicts a wellsite pump assembly 230″ including wellsite pumps 231 connected in series.
As shown in FIG. 2A, the wellsite pump assembly 230 includes multiple (n) wellsite pumps 231 connected in parallel and housed within housing 270. Each of the wellsite pumps 231 includes a hydraulic motor 250 and a driver 252 connected by a coupling 254. The hydraulic motor 250 is fluidly coupled to the conduit (e.g., riser 106 of FIG. 1) by dock 138 to receive wellsite fluid therefrom. The hydraulic motors 250 of each of the wellsite pumps 231 are fluidly coupled to pass the wellsite fluid from one of the hydraulic motors 250 to the next in series as indicated by the arrows.
The hydraulic motor 250 may be, for example, a progressive cavity motor, such as a Moineau motor, with a rotor 262 and stator 263 positioned in a motor housing (or can) 265. An example motor 250 is shown in FIG. 3. FIG. 3 depicts a portion of the wellsite pump 231 with the motor 250 therein. The rotor 262 of the motor is rotationally movable in the stator 263 by the flow of wellsite fluid therethrough. The stator 263 may be an elastomeric lining with a helical rotor rotationally and/or orbitally movable therein. The rotor 262 is coupled to the coupling 254 and rotatable thereby. The rotor 250 may have any number of lobes, such as those depicted in FIGS. 4A-4F.
Referring back to 2A, the driver 252 is depicted as being the same as the hydraulic motor 250. The coupling 254 operatively connects the rotor 262 of the hydraulic motor 250 and the rotor 262 of the driver 252 to translate movement therebetween such that the driver 252 may drive the hydraulic motor 250.
The hydraulic pumps 250 may be fluidly connected by a fluid circuit 253. The fluid circuit 253 may extend from the dock 138 and intake 132, to the hydraulic motors 250, between the hydraulic pumps 250, and to an outtake 134. As shown, the fluid circuit may flow through one of more of the hydraulic pumps 250, bypass at least one of the hydraulic pumps, and/or flow directly from the intake 132 and outtake 134. The fluid circuit 253 may include fluid control devices, such as flowlines and valves 256 as shown, to provide selective fluid communication of the wellsite fluid through the wellsite pump assembly 230. The wellsite fluid may be selectively passed through the wellsite pump assembly 230, through one or more of the wellsite pumps 231, and/or through one or more of the hydraulic pumps 250 via the fluid circuit 253.
The driver 252 of FIG. 2A is depicted as a hydraulic pump 252 fluidly coupled to the driver fluid source 133 to receive driver fluid (e.g., seawater) therefrom. The hydraulic pump 252 of each of the wellsite pumps 231 are fluidly coupled to pass the driver fluid from one of the hydraulic pumps 252 to the next in series as indicated by the arrows.
The drivers 252 may be fluidly connected by a fluid circuit 255. The fluid circuit 255 may extend from the fluid source 133 through an inlet 257 to the driver 252, between the driver 252, and to an outlet 259. The fluid circuit 255 may include fluid control devices, such as flowlines and valves 256 as shown, to provide selective fluid communication of the driver fluid through the wellsite pump assembly 230. The driver fluid may be selectively passed through the wellsite pump assembly 230, through one or more of the well site pumps 231, and/or through one or more of the drivers 252 via the fluid circuit 255. In some cases, the valve(s) 256 may be closed so that the wellsite fluid does not pass to the next wellsite pump 231.
The driver fluid may be, for example, sea water pumped from the fluid source 133 through the drill string 129 and into the driver 252 at a high pressure to drive the driver 252. This flow may be used to provide torque to the driver 252 which is then translated by the coupling 254 to the hydraulic motor 250. Torque from the driver 252 drives the hydraulic motor 252.
The hydraulic motor 252 draws the wellsite fluid from the riser 106 into the wellsite pump assembly 230 via the intake 132. The wellsite fluid is then pushed through the hydraulic motor(s) 252 and out the outtake 134. The outtake 134 may be positioned upstream from the intake 132 to pump the wellsite fluid for recirculation or storage. The flow of the driver fluid may be controlled to provide the desired pumping of well site fluid from the riser 106. The driver fluid may then be discharged from the wellsite assembly by outlet 259 into the sea or other location.
The flow of the wellsite fluid through the wellsite pumps 231 may be selected to provide a desired increase in fluid pressure and/or flow rate. As shown, passing the wellsite fluid through a first of the wellsite pumps 231 may increase the pressure to PI and the flow rate to F 1. Passing the wellsite fluid through a second wellsite pump 231 may further increase the pressure to P2 and the flow rate to F2. The wellsite fluid may be passed to any number of well site pumps 231 to further increase the pressure to Pn and flow rate to Fn.
One or more of the wellsite pumps 231 may be used during pumping. The number of well site pumps 231 may be increased to provide additional head pressure and/or flow rate as needed. Additional wellsite pumps 231 may also be used to provide redundancy in case of failure of a given wellsite pump 231. One or more of the wellsite pumps 231 may be positioned in one or more housings 270.
The wellsite pump 231 may be modular for selective replacement of portions thereof. The hydraulic motor 250 and the driver 252 may both be a hydraulic motor, such as a progressive cavity motor with a stator 263 with a rotor 262 orbitally and rotationally positioned therein. The rotor(s) 262 rotate as the driver fluid passes through the driver 252. Power generated by the rotation of the driver 252 may then be used to power the hydraulic motor 250 to pump the wellsite fluid therethrough, thereby providing a boost of power during pumping. In some cases, the hydraulic motor 250 and the driver 252 may be identical, and in some cases having different sizes or different features.
Various devices, such as processors, controllers, and/or other electronics 271, may be provided for operation of the wellsite pumps 231 and/or assembly 230. The electronics may be used to power and/or control operation of the wellsite assembly 230 and/or portions thereof to provide desired flow.
The wellsite pump assembly 230′ of FIG. 2B is similar to wellsite pump assembly 230 of FIG. 2A, except that the wellsite pump assembly 230′ includes a wellsite pump 231′ with a driver 252′ in the form of an electric motor. The driver 252′ includes a connector 260, a shaft 258, and a motor 261. The motor 261 may be driven by electricity to pump the driver fluid from fluid source 133 through the drivers 252′ and out the outlet 259. The motor 261 rotates shaft 258 and connector 260 is connected to coupling 254 to translation movement therebetween.
Each wellsite pump 231 may be connected to a single driver 252′ for independent driving thereby. In some cases, a single driver 252′ may be connected to multiple wellsite pumps 231 as indicated by the dotted line. One or more of the driver(s) 252′ may be activated to drive one or more of the hydraulic motors 250.
The wellsite pump assembly 230″ of FIG. 2C is similar to wellsite pump assembly 230 of FIG. 2A, except that the wellsite pumps 231 are connected in series. In this case, a fluid circuit 253′ is connected to permit the wellsite fluid to pass vertically between the hydraulic pumps 250 and/or the driver fluid to pass vertically between the drivers 252.
FIGS. 5A and 5B show another arrangement of the wellsite pump assembly 530. This version of the wellsite pump assembly 530 positioned in housing 570 and includes wellsite pumps 531. The wellsite pumps 531 are shown in greater detail as including a hydraulic motor 550 and a driver 552 connected by a coupling 554.
The hydraulic motors 550 and the drivers 552 each have a safety catch 574, an end adapter 576, and a top sub 577 attached thereto. The hydraulic motors 550 and the drivers 552 are each connected to the safety catches 574 which are connected by top sub 577 to the adapter 576.
The coupling 554 is connected between the hydraulic motor 550 and the driver 552. The coupling 554 includes a pair of connectors 578, a pair of bearings 580, an intermediate adapter 582, and a coupling housing 581. The hydraulic motor 550 and the driver 552 are each connected to opposite ends of the connector 578 by the bearings 580. The bearings 580 are each connected to the adapter 582 in the coupling housing 581. The coupling housing 581 has the intermediate adapter 582 and an end of each of the bearings 580 rotationally supported therein.
The wellsite pumps 531 may be fluidly connected in series or parallel to permit passage of wellsite fluid through one or more of the wellsite pumps 531. Wellsite fluid may pass from one hydraulic motor 550 to an adjacent hydraulic motor 550 through motor outlets 572. Valves may be provided to selectively direct the wellsite fluid through or around one or more wellsite pumps 531.
The drivers 552 may be fluidly connected in series or parallel to permit passage of the driver fluid through one or more of the wellsite pumps 531. The driver fluid may pass from one driver 552 to an adjacent driver 552 through driver outlets 573. Valves may be provided to selectively direct the wellsite fluid through or around one or more wellsite pumps 531.
Wellsite fluid passes into intake 132 through the hydraulic motors 550 and out outtake 134. Wellsite fluid may also be passed between connectors 578 of a first wellsite pump 531 and to an adjacent wellsite pump. Motor outlets 572 extend through a pump housing 583 adjacent the connectors 578 to fluidly connect adjacent wellsite pumps 531. The wellsite fluid may advance through one or more of the wellsite pumps 531 until the fluid exits the outtake 134.
As shown by the wellsite pumps 531, fluid pressure of the wellsite fluid may be increased by passing through multiple wellsite pumps 531. In an example, the wellsite fluid may increase from a pressure PI of about 0 psi (0 kg/cm) at the wellsite pump 531 to pressure P2 of about 1000 psi (70.32 kg/cm) as it passes to a second wellsite pump 531. The pressure may increase to pressure P3 of about 2000 psi (140.65 kg/cm) at a third wellsite pump 531, and to a pressure P4 of about 3000 psi (210.97 kg/cm) at a fourth well site pump 531, and exits at a pressure P5 of about 4000 psi (281.29 kg/cm) at the fourth wellsite pump 531. One or more wellsite pumps 531 may be provided with various configurations to selectively adjust the pressures and flow rates of the wellsite fluid passing through the hydraulic motors 550 of the wellsite pump assembly 530.
As also shown by the wellsite pumps 531, the driver fluid may be passed into intake 257 through multiple wellsite pumps 531 to drive the drivers (e.g., hydraulic motors) 552. In an example, the driver fluid may decrease from a pressure P5 at the wellsite pump 531 to pressure P4 as it passes to a second wellsite pump 531. The pressure may increase to pressure P3 at a third wellsite pump 531, and to a pressure P2 at a fourth wellsite pump 531, and exits out outtake 259 at a pressure PI at the fourth wellsite pump 531. One or more wellsite pumps 531 may be provided with various configurations to selectively provide for pressures and flow rates of the driver fluid passing through the drivers 552 of the wellsite pump assembly 530.
As shown in FIGS. 5A and 5B, the coupling 554 translates movement from the driver 552 to the motor 550. Bearings 580 are provided to support rotation therebetween. In this version, the intermediate adapters 582 rotate within the bearings 580 to translate rotation through the wellsite pump 531.
FIG. 6A shows an alternate wellsite pump 631. The wellsite pump 631 is similar to the wellsite pump 530 of FIGS. 5A and 5B, except that the wellsite pump 631 has a seal coupling 654 with a barrier seal 686. The barrier seal 686 fluidly isolates the driver 552 from the hydraulic motor 550. The wellsite pump 530 is provided with a motor outlets 672 and a driver outlet 673 extending into the coupling housing 681. Static seals 688 are also provided on either side of the barrier 686 for fluid isolation therebetween. The outlets 672, 673 may be positioned between the barrier seal 686 and the static seals 688.
One or more of the wellsite pumps 631 may be fluidly connected by the outlets 672, 673 to define a wellsite assembly for passing the wellsite fluid therethrough. Driver fluid passes into inlet 257 through driver 552 and out driver outlet 673. Barrier seal 686 prevents the driver fluid from passing to the motor 550. Wellsite fluid passes into intake 132 through hydraulic motor 550 and out motor outlet 673. Barrier seal 686 prevents the wellsite fluid from passing to the driver 552.
FIG. 6B shows a portion of another wellsite pump 631′ having another seal coupling 654′. As shown in this version, the coupling 654′ is depicted as a linkage with ball seals 688′ on either side thereof. The seal coupling 654′ couples driver 552 with hydraulic motor 550. The coupling 654′ has a driver end 687 depicted as being rotationally and orbitally driven by driver 552. The coupling 654′ has a motor end 689 depicted as being rotationally and orbitally movable with rotor 262 of hydraulic motor 550. This dual rotational and orbital movement is used to translate movement from the driver 552 to the hydraulic motor 550. The coupling 654 of FIG. 6A may move with the same motion as the coupling 654′ of FIG. 6B.
FIG. 7 A show another alternate wellsite pump 731. The wellsite pump 731 is similar to the wellsite pump 630 of FIGS. 6A and 6B, except that the wellsite pump 731 has a linkage coupling 754. The linkage 786 is depicted as coupled between the driver 552 and the motor 550 and rotating within the housing 581. As shown in this view, the coupling 754 is depicted as having a linkage 786 coupled to bearings 580 to translate movement from driver 552 to hydraulic motor 550.
FIG. 7B shows another version of the linkage coupling 754′ having a driver end 787 depicted as being rotationally driven by the driver 552. The coupling 754′ has a motor end 789 depicted as being rotationally and orbitally movable with rotor 262 of hydraulic motor 550. This dual rotation and single orbital motion may be used to translate movement from the driver 552 to the hydraulic motor 550. The coupling 754 of FIG. 7A may move with the same motion as the coupling 754′ of FIG. 7B.
While FIGS. 2A-7B show various configurations of well site pump assemblies, wellsite pumps, couplings, hydraulic motors, drivers and associated components, it will be appreciated that various combinations of features of the various devices may be used.
FIG. 8 is a flow chart depicting a method 800 of pumping wellsite fluid about a wellsite, such as the wellsite of FIG. 1A. The wellsite has a conduit to receive the wellsite fluid therefrom. The method involves 890—operatively connecting a wellsite assembly to the conduit to receive the wellsite fluid therefrom. The wellsite assembly includes a driver and a hydraulic motor with a coupling operatively connected therebetween. The method involves 892—driving the pump with a power source (e.g., electricity or a driver fluid passing therethrough), 894—driving the hydraulic motor with the pump via the coupling, and 896—advancing the wellsite fluid from the conduit to a location upstream therefrom by passing the wellsite fluid through the hydraulic motor.
The method may involve passing the wellsite fluid through a plurality of the wellsite pumps in series, passing the wellsite fluid through a plurality of the wellsite pumps in parallel, increasing flow rate and/or pressure of the wellsite fluid by passing the wellsite fluid through a plurality of the wellsite pumps, selectively diverting the wellsite fluid through at least one of the wellsite pumps, rotating a pump end of the coupling with the driver, rotating and orbiting a motor end of the coupling with a rotor of the hydraulic motor, rotating and orbiting a pump end of the coupling with the driver, rotating and orbiting a motor end of the coupling with a rotor of the hydraulic motor, sealing at least a portion of the coupling, and/or discharging the driver fluid from the driver.
The methods may be performed in any order, and repeated as desired.
It will be appreciated by those skilled in the art that the techniques disclosed herein can be implemented for automated/autonomous applications via software configured with algorithms to perform the desired functions. These aspects can be implemented by programming one or more suitable general-purpose computers having appropriate hardware. The programming may be accomplished through the use of one or more program storage devices readable by the processor(s) and encoding one or more programs of instructions executable by the computer for performing the operations described herein. The program storage device may take the form of, e.g., one or more floppy disks; a CD ROM or other optical disk; a read-only memory chip (ROM); and other forms of the kind well known in the art or subsequently developed. The program of instructions may be “object code,” i.e., in binary form that is executable more-or-less directly by the computer; in “source code” that requires compilation or interpretation before execution; or in some intermediate form such as partially compiled code. The precise forms of the program storage device and of the encoding of instructions are immaterial here. Aspects of the subject matter may also be configured to perform the described functions (via appropriate hardware/software) solely on site and/or remotely controlled via an extended communication (e.g., wireless, internet, satellite, etc.) network.
While the embodiments are described with reference to various implementations and exploitations, it will be understood that these embodiments are illustrative and that the scope of the inventive subject matter is not limited to them. Many variations, modifications, additions and improvements are possible. For example, one or more pumps and/or drivers with various combinations of the features herein may be provided.
Plural instances may be provided for components, operations or structures described herein as a single instance. In general, structures and functionality presented as separate components in the exemplary configurations may be implemented as a combined structure or component. Similarly, structures and functionality presented as a single component may be implemented as separate components. These and other variations, modifications, additions, and improvements may fall within the scope of the inventive subject matter.

Claims

1. A wellsite pump for a wellsite having a wellbore penetrating a subterranean formation, the wellsite having a conduit to pass a wellsite fluid about the wellsite, the wellsite pump comprising:

a housing having an intake and an outtake, the intake in fluid communication with the conduit;

at least one hydraulic motor to pump the wellsite fluid from the intake and through the outtake, the at least one hydraulic motor comprising a rotor and a stator;

at least one driver coupled to the at least one hydraulic motor and movable therewith;

at least one coupling to movable couple the at least one hydraulic motor to the at least one driver, the at least one coupling fluidly isolating the at least one hydraulic motor from the at least one driver; and

a power source to drive the at least one driver and the at least one hydraulic motor coupled thereto whereby the wellsite fluid is advanced from the conduit to a location upstream of the conduit.

2. The wellsite pump of claim 1, further comprising a dock operatively connecting the intake to the conduit.

3. The wellsite pump of claim 1, further comprising a support.

4. The wellsite pump of claim 1, further comprising a mascerator.

5. The wellsite pump of claim 1, wherein the conduit is one of a riser, a drill string, coiled tubing, a choke line, a kill line, return line, auxiliary line, a subsea stack, and cables.

6. The wellsite pump of claim 1, wherein the conduit extends from a fluid source at a surface location.

7. The wellsite pump of claim 6, wherein the fluid source comprises one of an air source, a fluid tank, and a mud pit.

8. The wellsite pump of claim 1, wherein the outtake is in fluid communication with one of the conduit, a fluid source, a fluid storage, an auxiliary wellsite, and combinations thereof.

9. The wellsite pump of claim 1, wherein the at least one hydraulic motor comprises a progressive cavity motor comprising a rotor and a stator.

10. The wellsite pump of claim 9, wherein the rotor has at least one rotor lobe and the stator has at least one stator lobe.

11. The wellsite pump of claim 1, further comprising a fluid circuit extending between the intake and the outtake.

12. The wellsite pump of claim 11, wherein the fluid circuit comprises at least one fluid control device to control the flow of the wellsite fluid therethrough.

13. The wellsite pump of claim 12, wherein the fluid control device comprises at least one of a valve, a flowline, a bypass, and combinations thereof.

14. The wellsite pump of claim 1, further comprising electronics to operate the at least one driver.

15. The wellsite pump of claim 1, wherein the at least one hydraulic motor comprises a plurality of hydraulic motors and the at least one driver comprises a plurality of drivers.

16. The wellsite pump of claim 15, wherein the plurality of hydraulic motors and the plurality of drivers are connected in series.

17. The wellsite pump of claim 15, wherein the plurality of hydraulic motors and the plurality of drivers are connected in parallel.

18. The wellsite pump of claim 1, wherein the at least one driver comprises a hydraulic motor and the power source comprises a driver fluid passing about the at least one driver.

19. The wellsite pump of claim 18, wherein the driver fluid provides a pressure differential to drive the at least one driver.

20. The wellsite pump of claim 18, wherein the driver fluid comprises one of drilling mud, sea water, hydraulic fluid, and combinations thereof.

21. The wellsite pump of claim 1, wherein the at least one driver comprises an electric motor and the power source comprises electronics to drive the at least one driver.

22. The wellsite pump of claim 1, wherein the power source comprises a supply pumping unit comprising a hydraulic motor driven by a pressure differential across the at least one hydraulic motor, the supply pumping unit operatively connectable to the driver to pump a driver fluid through the driver.

23. (canceled)

24. A wellsite pump for a wellsite having a wellbore penetrating a subterranean formation, the wellsite having a conduit to pass a wellsite fluid about the wellsite, the wellsite pump comprising:

at least one hydraulic motor to pump the wellsite fluid from the intake and through the outtake, the at least one hydraulic motor comprising a rotor and a stator; and

at least one driver operatively connected to the at least one hydraulic motor via at least one coupling to translate movement therebetween, the at least one coupling to movably couple the at least one hydraulic motor to the at least one driver, the at least one coupling fluidly isolating the at least one hydraulic motor from the at least one driver; and

a power source to drive the at least one driver and thereby the at least one hydraulic motor coupled thereto whereby the wellsite fluid is advanced from the conduit to a location upstream of the conduit.

25. The wellsite pump of claim 24, wherein the at least one coupling comprises connectors, bearings, an intermediate adapter and a coupling housing.

26. The wellsite pump of claim 24, wherein the at least one coupling comprises a safety catch, an end adapter, and a top sub.

27. The wellsite pump of claim 24, wherein the at least one coupling comprises a seal coupling comprising at least one seal.

28. The wellsite pump of claim 26, wherein the at least one seal comprises at least one of a barrier seal and a static seal.

29. The wellsite pump of claim 26, wherein the at least one seal comprises ball seals.

30. The wellsite pump of claim 24, wherein the at least one coupling comprises a linkage coupling comprising a linkage, one end of the linkage coupled to the at least one hydraulic motor, the other end of the linkage coupled to the at least one driver.

31. The wellsite pump of claim 24, wherein the linkage coupling comprising at least one of orbital and rotational movement.

32. The wellsite pump of claim 24, wherein the at least one coupling comprises a housing with an inlet and an outlet.

33. A method of pumping a wellsite fluid about a wellsite having a wellbore penetrating a subterranean formation, the wellsite having a conduit to pass the wellsite fluid about the wellsite, the method comprising:

operatively connecting a wellsite assembly to the conduit, the wellsite assembly comprising a housing, at least one hydraulic motor, and at least one driver;

driving the at least one driver with a power source by rotating the at least one driver and the at least one hydraulic motor via at least one coupling;

fluidly isolating the at least one driver from the at least one hydraulic motor with the at least one coupling; and

advancing the wellsite fluid from the conduit to a location upstream of the conduit by driving the at least one hydraulic motor with the driver.

34. The method of claim 33, wherein the driving the at least one driver with a power source comprises rotating the at least one driver with an electric motor.

35. The method of claim 33, wherein the driving the at least one driver with a power source comprises passing a driver fluid through the at least one driver.

36. The method of claim 33, wherein the operatively connecting comprises connecting an intake of the wellsite assembly to the conduit and an outtake of the wellsite assembly to the conduit a distance upstream from the intake, and wherein the advancing comprises passing the wellsite fluid from the intake to the outtake.

37. The method of claim 33, wherein the advancing comprises passing the wellsite fluid through a plurality of the at least one hydraulic motor in one of series and parallel.

38. The method of claim 33, wherein the advancing comprises increasing one of flow rate and pressure of the wellsite fluid by passing the wellsite fluid through a plurality of the at least one hydraulic motor.

39. (canceled)

40. The method of claim 33, further comprising sealing at least a portion of the at least one coupling.

41. The method of claim 33, wherein the driving comprises passing a driver fluid through the at least one driver.