Abstract:
A pumping apparatus and method incorporates at least one and preferably as many as four components that are configured to improve debris removal capabilities as compared to prior art apparatuses. The apparatus and method impart cyclonic motion to pumped fluid, in a manner that tends to separate entrained solids and other impurities, and further that helps draw solid impurities away from the pump barrel. In a preferred embodiment, a cyclonic effect first occurs in a seat plug having a funnel-shaped accumulator region leading to an interior passage therethrough, and at least one off-center opening extending from the interior passage to the exterior of the plug. In one embodiment, that effect is continued at a plunger adapter that has a plurality of inward-angled rings, and that also features off-center openings through which debris may pass to the interior of the plunger adapter. A top plunger adapter may also be provided, having angled veins and openings therethrough to impart cyclonic motion to the pumped fluid as it exits the interior of the top plunger adapter. Finally, it may also be desired to provide a cage having angled veins, to continue the cyclonic effect on the fluid as it travels northward and into the pump barrel.

Description:
BACKGROUND OF THE INVENTION 
   1. Field of Invention 
   This invention relates generally to fluid pumping apparatuses and, more specifically, to an improved debris removal device and method. 
   2. Background of the Invention 
   In general terms, a fluid pumping system begins with an above-ground pumping unit, which creates the up and down pumping action that moves the fluid (or other substance being pumped) out of the ground and into a flow line, from which the fluid is taken to a storage tank or other such structure. 
   Below ground, a shaft is lined with piping known as “tubing.” Into the tubing is inserted a sucker rod, which is ultimately, indirectly, coupled at its north end to the pumping unit. The sucker rod is coupled at its south end, indirectly, to the fluid pump itself, which is also located within the tubing and which is sealed at its base to the tubing. The sucker rod will typically couple to the fluid pump at a coupling known as cage. 
   Beginning at the south end, fluid pumps generally include a standing valve, which has a ball therein, the purpose of which is to regulate the passage of fluid (or other substance being pumped) from downhole into the pump, allowing the pumped matter to be moved northward out of the system and into the flow line, while preventing the pumped matter from dropping back southward into the hole. Fluid is permitted to pass through the standing valve and into the pump by the movement of the ball off of its seat, and fluid is prevented from dropping back into the hole by the seating of the ball. 
   North of the standing valve, coupled to the sucker rod, is a pump plunger with a traveling valve attached thereto. The purpose of the plunger/traveling valve is to regulate the passage of fluid from within the pump northward in the direction of the flow line, while preventing the pumped fluid from dropping back in the direction of the standing valve and hole. 
   Actual movement of the pumped substance through the system will now be discussed. Fluid is pumped from a hole through a series of “downstrokes” and “upstrokes” of the fluid pump, which motion is imparted by the above-ground pumping unit. During the upstroke, formation pressure causes the ball in the standing valve to move upward, allowing the fluid to pass through the standing valve and into the barrel of the fluid pump. This fluid will be held in place between the standing valve and the traveling valve. In the traveling valve, the ball is located in the seated position. It is held there by the pressure from the fluid that has been previously pumped. The fluid located above the traveling valve is moved northward in the direction of the cage at the end of the fluid pump. 
   On the downstroke, the ball in the traveling valve unseats, permitting the fluid that has passed through the standing valve to pass therethrough. Also during the downstroke, the ball in the standing valve seats, preventing the pumped fluid from moving back down into the hole. 
   The process repeats itself again and again, with fluid essentially being moved in stages from the hole, to above the standing valve and in the fluid pump, to above the traveling valve and out of the fluid pump. As the fluid pump fills, the fluid passes through the cage and into the tubing. As the tubing is filled, the fluid passes into the flow line, from which the fluid is taken to a storage tank or other such structure. 
   There are a number of problems that are regularly encountered during fluid pumping operations. Fluid that is pumped from the ground is generally impure, and includes solid impurities such as sand, as well as water and gas. Solid impurities may be harmful to a pumping apparatus and its components for a number of reasons. For example, sand can become trapped between the barrel and the plunger, between which there is only an extremely narrow tolerance. This can create scarring and damage to the plunger or barrel and in some instances can even cause the pump to become stuck, requiring the extraction of pump components for repair. Solid impurities can also enter between the ball and seat of the traveling valve in particular, preventing proper seating, possibly leading to damage and inefficiency. 
   An additional problem with prior art pumping apparatuses is that emulsification of impurities can occur, requiring post-pumping treatment to separate the pumped fluid and the various impurities entrained therein. 
   The present invention addresses these problems encountered in prior art pumping systems and provides other, related, advantages. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of an embodiment of a seat plug component of a cyclonic debris removal apparatus consistent with an embodiment of the present invention. 
       FIG. 2  is a perspective view of an embodiment of a cyclone plunger component of a cyclonic debris removal apparatus consistent with an embodiment of the present invention. 
       FIG. 3  is a perspective view of an embodiment of a cyclone top plunger adapter component of a cyclonic debris removal apparatus consistent with an embodiment of the present invention. 
       FIG. 4  is an end, cross-sectional view of the cyclone plunger of  FIG. 2 . 
       FIG. 5  is a perspective view illustrating coupling of the cyclone plunger of  FIG. 2  to the cyclone top plunger adapter of  FIG. 3 . 
       FIG. 6  is a perspective, cross-sectional view of seat plug component of  FIG. 1 . 
       FIG. 7  is a perspective, cross-sectional view of the cyclone plunger of  FIG. 2 . 
       FIG. 8  is a perspective, cross-sectional view of the cyclone top plunger adapter of  FIG. 3 . 
       FIG. 9  is a side view of a pumping apparatus having an embodiment of a cyclone debris removal apparatus of the present invention inserted therein. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Referring first to  FIG. 9 , a pumping apparatus  10 , having a cyclone debris removal apparatus consistent with the present invention inserted therein, is illustrated. Moving left to right within the drawing figure, corresponding to movement from north to south within a typical pumping system, the components of the pumping apparatus  10  will be described. The shaft is lined with tubing  12 . A valve rod/hollow valve rod  14  passes through or is attached to a valve rod guide/cyclone open cage  16 , and is coupled at its south end to a cyclone top plunger adapter  20  (shown in more detail in  FIGS. 3 ,  5  and  8 ). (North of the valve rod/hollow valve rod  14 , a cage (not shown) couples between the sucker rod (not shown) and the valve rod/hollow valve rod  14 .) A cyclone plunger adapter  22  (shown in more detail in  FIGS. 2 ,  5  and  7 ) is then interposed between the cyclone top plunger adapter  20  and a pump plunger  24 . A traveling valve  26  is located south of the pump plunger  24 , and a seat plug component  28  (shown in more detail in  FIGS. 1 and 6 ) is coupled below the traveling valve  26 . 
   It should be noted that above-listed components, beginning with the portion of the valve rod/hollow valve rod  14  located below the open cage  16  and extending to the seat plug component  28 , are located within a pump barrel  18 . 
   Continuing with  FIG. 9 , a standing valve  30  is located at the south end of the pump barrel  18 , below the seat plug component  28 . Below the standing valve  30 , from north to south, are a seating nipple  32  and gas anchor  34 . 
   Referring now to  FIGS. 1 and 6 , additional description is provided for the seat plug component  28 . Preferably, as illustrated in  FIG. 9 , this component is coupled to the south end of the traveling valve  26 , and more specifically to the cage portion of the traveling valve  26 . The seat plug component  28  preferably has a funnel-shaped evacuation accumulator region  36  at a south end thereof. This configuration moves fluid, as it is pumped northward, from a region of greater diameter to a region of lesser diameter, accelerating its rate of travel. Above the accumulator region  36  is located an inwardly-angled groove  38 , into which at least one and preferably a plurality of openings  40  are provided. Four openings  40  are preferred. It is preferred that the openings  40  be angled, so that they open in an off-centered manner to the interior of the seat plug component  28 . 
   Threaded region  42  is adapted to be coupled to the south end of the traveling valve  26 . While threaded region  42  is shown as male, it should be recognized that if the south end of the traveling valve  26  is male, than threaded region  42  should be female. 
   Referring now to  FIGS. 2 ,  5  and  7 , the cyclone plunger adapter  22  is described in greater detail. Beginning at its south end, a threaded region  44  is provided, to facilitate coupling to a corresponding threaded region on a pump plunger  24 . It can be seen that within the interior of the cyclone plunger adapter  22  and north of the threaded region  44  is provided a region of reduced inner diameter  46 . (It may be desired to provide a funnel-shaped transition area to the region  46 , similar to the accumulator region  36 .) 
   Turning now to the exterior of the cyclone plunger adapter  22 , at least one and preferably a plurality of grooves  48  are provided, with rings  50  interposed between the grooves  48 . The number of grooves  48  and rings  50  can be varied as desired. As shown in  FIGS. 2 and 5 , five grooves  48  and five rings  50  are preferred. 
   It is preferred that the outer diameter of the rings  50  progressively decrease from south to north, so that each succeeding ring  50  has a smaller outer diameter than the one below it. The amount of decrease can be varied as desired, with a decrease in the range of about ten-thousandths of an inch being preferred. As best shown in FIG.  7 —, it is preferred that the rings  50  be angled inward, to facilitate the entry of solid impurities into grooves  48 . 
   As shown in  FIGS. 2 and 7 , it is preferred that at least one and preferably a plurality of openings  52  are provided in at least one, and preferably a plurality, of the grooves  48 . It is preferred that the openings  52  be angled, so that they open in an off-centered manner to the interior of the cyclone plunger adapter  22 . 
   North of the grooves  48  and rings  50  are preferably located a pair of opposing wrench flats  54 . The wrench flats  54  are intended to facilitate coupling and de-coupling of the cyclone plunger adapter to other pump components. 
   At the north end of the cyclone plunger adapter  22  is a threaded region  56 . The threaded region  56 , in the embodiment shown in  FIG. 9 , couples to a mating threaded area in the cyclone top plunger adapter  20 . 
   Referring now to  FIGS. 3 and 5 , attention is directed to the cyclone top plunger adapter  20 . Turning first to an examination of the interior of the cyclone top plunger adapter  20 , it can be seen that there is provided a threaded region  58 , which is adapted to mate with threaded region  56  on the cyclone plunger adapter  22 . Continuing above the threaded region  56 , it can be seen that there is a passage  60 , through which pumped fluid travels northward. Passage  60  terminates at cap  62 . 
   Turning to the exterior of the cyclone top plunger adapter  20 , a plurality of veins  64  are provided. While the number of veins  64  may be varied, four veins  64  are preferred. Where the pumping apparatus  10  is used in the northern hemisphere, the veins  64  should be cut, from south to north, in a west to east direction. For use in the southern hemisphere, the channels should be cut in an east to west direction. 
   Elongated openings  66  are preferably provided in a lower portion of veins  64 , to permit the passage of pumped fluid from passage  60  out of the interior of the cyclone top plunger adapter  20  and into the upper portion of veins  64 . As best shown in  FIG. 8 , it can be seen that cap  62  is preferably positioned so that the passage  60  terminates proximate the north terminus of openings  66 , so as to more effectively direct pumped fluid from the passage  60 , through openings  66  and into the upper portion of veins  64 . 
   Referring to  FIGS. 3 ,  5  and  8 , and continuing to refer to the exterior of the cyclone top plunger adapter  20 , it can be seen that it is preferred to provide a region  68  of lesser external diameter north of the veins  64 . Alternatively, veins  64  could be permitted to continue to substantially the north terminus of the cyclone top plunger adapter  20 . 
   As best seen in  FIG. 9 , it is preferred that a notched area  65  be provided along one side of each of the veins  64 . This configuration further promotes the passage of settling solids into the veins  64 , with settling solids either passing directly into a vein  64 , or first into a notched area  65  and then into a vein  64 . 
   Referring again to  FIG. 9 , the valve rod guide/cyclone open cage  16  preferably has a plurality of angled veins  70 . The veins  70  should be cut in the same direction as the veins  64 . The veins  70  serve to continue the spiraling effect on the fluid as it proceeds northward, enhancing the separation effect. 
   Statement of Operation 
   As with a prior art system, fluid will be pumped from a hole through a series of “downstrokes” and “upstrokes” of a pump, which motion is imparted by the above-ground pumping unit. During the upstroke, formation pressure causes the ball in the standing valve  30  to move upward, allowing the fluid to pass through the standing valve and into the barrel  18 . This fluid will be held in place between the standing valve  30  and the traveling valve  26 . In the traveling valve  26 , the ball is located in the seated position. 
   On the downstroke, the ball is lifted off of the seat, permitting the fluid that has passed through the standing valve  30  to pass through the seat plug component  28  and into the traveling valve  26 . In this regard, fluid entering the interior of the seat plug component  28  will enter the funnel-shaped evacuation accumulator region  36  at a south end thereof. Thus, fluid is moved from a region of greater diameter to a region of lesser diameter, accelerating its rate of travel. 
   It should be noted that while most fluid pumped northward will travel through the interior of the seat plug component  28 , some fluid will also pass to the exterior thereof, between the exterior of the seat plug component  28  and the pump barrel  18 . The funneling of the region  36  increases the velocity of the pumped fluid as it travels northward, as compared to fluid traveling on the exterior of the seat plug component  28 . This creates a vacuum effect, drawing in fluid, and in particular solid impurities within the fluid, through openings  40  from the exterior of the seat plug component  28  to the interior thereof. The off-center configuration of the openings  40  contributes to a cyclonic effect that occurs as fluid is drawn into the interior of the seat plug component  28 . 
   Moving to the cyclone plunger adapter  22 , the fluid again passes into an area of reduced diameter when it enters the region  46 . As described above with respect to the seat plug component  28 , the reduction of diameter increases the velocity of the pumped fluid and creates a vacuum effect. This draws in fluid, and in particular debris within the fluid, from the exterior of the cyclone plunger adapter  22 —this time through openings  52  within rings  48 . The inward angle of the rings  50  facilitates the entry of solid impurities into grooves  48 . The off-center configuration of the openings  52 , as shown in FIG  4 . contributes to a cyclonic effect that occurs as fluid is drawn into the interior of the cyclone plunger adapter  22 . Still further, the decrease in the outer diameter of rings  50  increases the flow of fluid into the interior of the cyclone plunger adapter  22  through openings  52 . 
   It should be noted that the greatest probability of pump sticking and/or apparatus damage occurs on the upstroke. This is explained by the fact that on the downstroke, the seat plug component  28  diverts the majority of the pumped fluid inward, creating the herein described cyclonic effect, which draws in fluid and solid impurities. On the upstroke, the hydrostatic column of fluid above the traveling valve will seek area of least resistance, which is between the barrel and the plunger. This fluid is contaminated with solid impurities, and these impurities will tend to accumulate at the rings  50  as they settle. 
   By narrowing the outer diameter of the rings  50  as they move northward, a wedge effect is created. As the plunger is pulled upward on the upstroke, fluid between the barrel and the plunger is forced into the openings  48  at progressively greater pressure, as the diameter of the rings  50  progressively increases. This tends to prevent solid impurities from accumulating between the cyclone plunger adapter  22  and the barrel  18 . 
   As the fluid passes northward into the cyclone top plunger adapter  20 , it will enter passage  60 , and continue until reaching cap  62 . With its passage blocked by cap  62 , pumped fluid will exit via elongated openings  66 , and enter veins  64 . Angling of veins  64  imparts rotation to the cyclone top plunger adapter  20 , as well as to the other components (including the cyclone plunger adapter  22  and seat plug component  28 ), that are directly or indirectly coupled thereto. The rotation of these pump components further contributes to the drawing into the interior of pump components of debris located between pump components and the barrel  18 . Moreover, it creates a centrifuge effect on the interior of the pump components, preventing emulsification of fluid, liquid impurities (e.g., water) and solid impurities (e.g., sand). By resisting emulsification, the pumping apparatus  10  of the present invention, as herein configured, can reduce the need for treatment of pumped fluids for purposes of breaking the emulsification of pumped fluids and impurities entrained therein. 
   The veins  64 , including the upper angled portions thereof, provide at least one additional benefit. When the pumping apparatus  10  is shut down, the entrained solids located thereabove tend to settle. In prior art systems, these can become lodged between the exterior of individual pump components and the barrel  18 , causing damage and potentially even sticking of the apparatus. Here, settling solids should either pass directly into a vein  64 , or first into a notched area  65  and then into a vein  64 . 
   The northward traveling fluid will next enter the valve rod guide/cyclone open cage  16 . It will exit through openings (not shown) in the angled veins  70 , which continue the spiraling effect on the fluid as it proceeds northward, enhancing the separation effect. 
   The term “fluid” as used herein is intended to refer to any material capable of being pumped using an pumping apparatus  10  as herein described, including for example oil and water. 
   While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and details may be made therein without departing from the spirit and scope of the invention. 
   For example, and in addition to the variations discussed above, it would be possible to combine certain of the separate component portions of the pumping apparatus  10  into one-piece assemblies, so as to reduce the number of individual components parts. Thus, the cyclone plunger adapter  22  and cyclone top plunger  20  could be a one-piece assembly, or could be formed of more than two component portions. It may be desired to provide only one of the seat plug component  28 , the cyclone plunger adapter  22 , cyclone top plunger  20 , valve rod guide/cyclone open cage  16 —or any combination of two or three of these—without providing all four of these combined.