US007874369B2

(12) United States Patent (10) Patent No.: US 7,874,369 B2

Parker et al. (45) Date of Patent: Jan. 25, 2011

(54) PROGRESSIVE CAVITY PUMP (PCP) DRIVE 6,358,027 B1 3/2002 Lane

HEAD STUFFING BOX WITH SPLT SEAL 6,367,809 B1 4/2002 Weehunt
6,485,023 B2 * 1 1/2002 Budrow et al. .............. 277/370
(75) Inventors: Charles D. Parker, Sugar Land, TX 5.
w- 4
R ck 3.S. E. et al
OrnSOn et al. ..............
TOO.98
Sylam C. Lane, The Woodlands, 6,843,313 B2 1, 2005 Hult
2004/0188944 A1* 9/2004 Bjornson .................... 277/370
2004/0201 176 A1 10/2004 Bjornson
(73) Assignee: Weatherford/Lamb, Inc., Houston, TX 2005, 0011642 A1 1, 2005 Hult
(US) 2005/0045323 A1 3, 2005 Hult
(*) Notice: Subject to any disclaimer, the term of this (Continued)
past lityyed under 35 FOREIGN PATENT DOCUMENTS
CA 2 347 613 2, 2002
(21) Appl. No.: 11/531,567
(Continued)
(22) Filed: Sep. 13, 2006 OTHER PUBLICATIONS
(65) Prior Publication Data U.K. Search Report, Application No. GB0717804.9, dated Dec. 18,
2007.
US 2008/O122182 A1 May 29, 2008
51) Int. C
t. C.
(Continued)
(51) IB 9/00 (2006.01) Primary Examiner William P Neuder
27a. Assistant Examiner—David Andrews
(52) U.S. Cl. ..................... 166/379; 166/84.1; Igls. (74) Attorney, Agent, or Firm Patterson & Sheridan, LLP
(58) Field of Classification Search ................ 166/68.5, (57) ABSTRACT
166/68, 84.1, 84.5, 379; 277/326,364, 358,
277/365,361,369,329, 511 The present invention relates to a split seal for a progressive
See application file for complete search history. cavity pump (PCP) drive head stuffing box. In one embodi
(56) References Cited ment, a mechanical seal assembly for a pump is provided. The
mechanical seal assembly includes a seal housing; first and
U.S. PATENT DOCUMENTS second semi-annular mechanical seals, each at least partially
4,094,513 A 6, 1978 Kime et al.
disposed in the seal housing bore, and a seal sleeve rotatable
4,227,543 A 10/1980 Williams, Jr. relative to the seal housing; third and fourth semi-annular
4,509,762 A * 4, 1985 Garrett ....................... 277/398 mechanical seals, each disposed at least partially in the seal
5,370.401 A 12/1994 Sandgren sleeve bore, at least one of the third and fourth seals rotation
5,529,315 A 6, 1996 Borrino et al. ally coupled to the seal sleeve; and one or more biasing
5,571,268 A 11/1996 AZibert members biasing the mechanical seals into engagement.
5,863,047 A 1, 1999 Ellis
6,113,355 A 9, 2000 Hult et al. 35 Claims, 14 Drawing Sheets

re

224 208
 US 7,874,369 B2
Page 2

U.S. PATENT DOCUMENTS U-PAKCR) Injectable Pump & Valve Sealant, UTEX Industries, Inc.
2006/0032635 A1 2/2006 Rivard
(Date Unknown).
EnvirAlignTM, Advantage Products, Inc. (Date Unknown).
2006/0082069 A1 4/2006 Malavazi Mechanical Seal Hard Face Materials, The McNally Institute, http://
www.mcnallyinstitute.com/Charts/Hard Faces.html, date printed
FOREIGN PATENT DOCUMENTS Aug. 29, 2006.
EP 1348.897 10, 2003 GB Search Report, Application No. GB0717804.9, dated Mar. 26.
2008.
GB 2316 721 3, 1998
GB 2361966 11, 2001 Canadian Office Action, Application No. 2,601,492, dated May 19,
2009.
OTHER PUBLICATIONS
GBExamination Report for GBApplication No. GB07 17804.9 dated
Oct. 26, 2010.
Mechanical Seals Catalog, UTEX Industries, Inc. (Date Unknown). * cited by examiner
U.S. Patent Jan. 25, 2011 Sheet 1 of 14 US 7,874,369 B2

FIG. 1
(PRIOR ART)
U.S. Patent Jan. 25, 2011 Sheet 2 of 14 US 7,874,369 B2

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 US 7,874,369 B2
1. 2
PROGRESSIVE CAVITY PUMP (PCP) DRIVE by the rotor 46, known as interference. Radial interference,
HEAD STUFFING BOX WITH SPLT SEAL Such as five-thousandths of an inch to thirty-thousandths of an
inch, is provided to seal the chambers to prevent leakage. The
BACKGROUND OF THE INVENTION sliding or rubbing movement of the rotor 46 combined with
the forces of interference generates friction. In addition, with
1. Field of the Invention each cycle of compression and release of the elastomer 44a.
The present invention relates to a split seal for a progressive heat is generated due to internal viscous friction among the
cavity pump (PCP) drive head stuffing box. elastomer molecules. This phenomenon is known as hyster
2. Description of the Related Art esis. Cyclic deformation of the elastomer occurs due to three
FIG. 1 illustrates a known progressing cavity pump (PCP) 10
effects: interference, centrifugal force, and reactive forces
system 10 installed over a wellbore 2. The wellbore 2 is from pumping. The centrifugal force results from the mass of
partially lined with casing 4 which is cemented 5 to an inner the rotor moving in the nutational path previously described.
surface of the wellbore 2. The wellbore 2 extends into a
hydrocarbon-bearing formation 7. Such as a crude oil forma Reactive forces from torque generation are similar to those
tion. The system 10 includes a typical progressing cavity 15 found in gears that are transmitting torque. Additional heat
pump drive head 12, a wellhead frame 14, a stuffing box 16, input may also be present from the high temperatures down
an electric motor 18, and a belt and sheave drive system 20, all hole.
mounted on a flow tee 22. Alternatively, the drive system 20 Because elastomers are poor conductors of heat, the heat
may be gear driven. The flow tee 22 is shown with a blow out from these various sources builds up in the thick sections
preventer 24 which is, in turn, mounted on a wellhead 25. The 50a-e of the stator lobes 55. In these areas the temperature
drive head supports and drives a drive shaft 26, generally rises higher than the temperature of the circulating fluid or the
known as a “polished rod'. The polished rod 26 is supported formation. This increased temperature causes rapid degrada
and rotated by a polish rod clamp 28, which engages an output tion of the elastomer 44a. Also, the elevated temperature
shaft 30 of the drive head by milled slots (not shown) in both changes the mechanical properties of the elastomer 44a.
parts. Wellhead frame 14 is open sided in order to expose 25
weakening each of the stator lobes as a structural member and
polished rod 26 to allow a service crew to install a safety leading to cracking and tearing of sections 50a-e, as well as
clamp on the polished rod and then perform maintenance portions 45a-e of the elastomer at the lobe crests. This design
work on stuffing box 16. Polished rod 26 rotationally drives a can also produce uneven rubber strain between the major and
drive string 32, which, in turn, drives a progressing cavity minor diameters of the pumping section. The flexing of the
pump 34. 30
Typically, the drive string 32 is a Sucker rod String. Alter lobes 55 also limits the pressure capability of each stage of the
natively, the drive string may be a continuous rod (COROD) pumping section by allowing more fluid slippage from one
string, a coiled tubing string, or a jointed tubing string. The stage to the Subsequent stages below.
pump 34 has a stator 44a, b (see FIGS. 1A,B) coupled to Advances in manufacturing techniques have led to the
production tubing 6 and a rotor 46 (see FIGS. 1A,B) coupled 35 introduction of even wall PC pumps 34b as shown in FIG. 1B.
to the drive string 32. The pump 34 is located at the bottom of A thin tubular elastomer layer 70 is bonded to an inner surface
the wellbore 2 to produce well fluids to the surface, via the of the stator 44b or an outer surface of the rotor 46 (layer 70
production tubing 6, through the wellhead. Stuffing box 16 is bonded on stator 44b as shown). The stator 44b is typically
mounted below the drive head 12 and mounted in the well made from metal, preferably steel. These pumps 34b provide
head frame 14 such that it can be serviced from below the 40 more power output than the traditional designs above due to
drive head 12 without removing it. This necessitates mount the more rigid structure and the ability to transfer heat away
ing the drive head higher, constrains the design, and means a from the elastomer 70 to the stator 44b. With improved heat
difficult service job. transfer and a more rigid structure, the new even wall designs
FIG. 1A is a sectional view of the prior art PC pump 34a. operate more efficiently and can tolerate higher environmen
Pump housing 42 contains an elastomeric stator 44a having 45 tal extremes. Although the outer surface of the stator 44b is
multiple lobes 55 formed in an inner surface thereof. The shown as round, the outer Surface may also resemble the inner
pump housing 42 is usually made from metal, preferably surface of the stator. Further, the rotor 46 may be hollow.
steel. The stator 44a has five lobes 55, although the stator may FIG. 1C is a sectional view of the prior art retrofit stuffing
have two or more lobes. Inside the stator 44a is a rotor 46, the box 16r. The retrofit stuffing box 16r includes a housing that
rotor 46 having one lobe fewer than the stator 44.a formed in 50 has a first portion 112ra and a second or base portion 112rb.
an outer surface thereof. The inner surface of the stator 44a The second or base portion 112rb of the housing underlies
and the outer Surface of the rotor 46 also twist along respec first portion 112ra and is joined to first potion 112ra by bolts
tive longitudinal axes, thereby each forming a substantially 113. The second portion 112rb has apertures 115 adapted to
helical-hypocycloid shape. The rotor 46 is usually made from receive screws or other securing devices for the purpose of
metal, preferably steel. The rotor 46 and stator 44a interen 55 mounting stuffing box 16r. The stuffing box 16r includes an
gage at the helical lobes to form a plurality of sealing Surfaces internal sleeve 114 positioned within the first portion 112ra of
60. Sealed chambers 47 between the rotor 46 and stator 44a the housing. A first bearing 116 and a second bearing 118 are
are also formed. In operation, rotation of the Sucker rod or positioned in an annular space 120 between internal sleeve
COROD string causes the rotor 46 to nutate or precess within 114 and 112ra of the housing, such that internal sleeve 114 is
the stator 44a as a planetary gear would nutate within an 60 journalled for rotation within the first portion 112ra of the
internal ring gear, thereby pumping production fluid through housing. First bearing 116 is positioned within a bearing
the chambers 47. The centerline of the rotor 46 travels in a sleeve 122. Thrust washer 128 carries a first seal 124 and
circular path around the centerline of the stator 44a. second seal 126. First bearing 116 is separated from second
One drawback in such prior art motors is the stress and heat bearing 118 by a bearing separator 130. Second bearing 118
generated by the movement of the rotor 46 within the stator 65 engages a shoulder 119 that limits its movement within annu
44a. There are several mechanisms by which heat is gener lar space 120. A snap ring 127 is positioned above thrust
ated. The first is the compression of the stator elastomer 44a washer 128 that also limits movement within annular space
 US 7,874,369 B2
3 4
120. A leak cock 132 is provided on first portion 112ra of the ured for a particular drive head 12 whereas the retrofit stuffing
housing for Supplying lubricant to first bearing 116 and sec box is universal for any drive head 12.
ond bearing 118. FIG.1F is a sectional view of the integral stuffing box 16i
A shaft cap 134 and static seals 136 are positioned within which includes a housing 112ia and an internal sleeve 114
internal sleeve 114 to engage the drive shaft 26. Bolts 140 are positioned within housing 112. A first bearing 116, a second
used to tighten a rod clamp 142 around the drive shaft 26 in bearing 118, a thrust washer 128, and a bushing 168 are
order to prevent the drive shaft 26 from being withdrawn from positioned in an annular space 120 between internal sleeve
internal sleeve 114. 114 and housing 112ia, such that internal sleeve 114 is jour
Referring also to FIG. 1D, a mechanical seal 144 is dis nalled for rotation within housing 112. First bearing 116 is
posed in annular space 120 between internal sleeve 114 and 10 positioned within a bearing sleeve 122. Thrust washer 128
first portion 112ra of the housing to block the passage of prevents axial movement of internal sleeve 114, so that inter
produced well fluids into first bearing 116 and second bearing nal sleeve 114 does not get pushed up out of position. Thrust
118. Mechanical seal 144 has a first body 146 with a first washer 128 carries a first seal 124 and second seal 126. First
sealing surface 150 and a second body 148 with a second bearing 116 is separated from second bearing 118 by a bear
sealing surface 156. First body 146 is secured by set screws 15 ing separator 130. Second bearing 118 engages a shoulder
152 to and rotates with internal sleeve 114. An O-ring seal 154 119 that limits its movement within annular space 120. A snap
is positioned between first body 146 and internal sleeve 114 ring 127 is positioned above thrust washer 128 that also limits
and serves a static sealing function. Second body 148 is movement within annular space 120. A leak cock 132 is
secured by pins 158 to and remains stationary with housing provided on housing 112 for Supplying lubricant to first bear
110. Pins 158 project into travel grooves 160 in first portion ing 116 and second bearing 118.
111 of housing 110 so as to permit second body 148 to travel A shaft cap 134 and static seals 136 are positioned within
axially along groove 160 relative to first portion 112ra of the internal sleeve 114 to engage the drive shaft 26. Bolts 140 are
housing. An o-ring seal 162 is provided between second body used to tighten a rod clamp 142 around the drive shaft 26. Rod
148 and the first portion 112ra of the housing and serves a clamp 142 serves to preclude movement of internal sleeve
static Sealing function. 25 114 relative to the drive shaft 26. This ensures that internal
sleeve 114 and the drive shaft 26 move as a unit and avoids
Belville springs 164 are provided for biasing first sealing relative movement that would cause wear of static seals 126.
Surface 150 and second sealing Surface 156 in sealing engage Referring also to FIG. 1D, a mechanical seal 144 is dis
ment. A grease nipple 166 is provided on first portion 112ra of posed in annular space 120 between internal sleeve 114 and
the housing for Supplying lubricant to mechanical seal 144. A housing 112 to block the passage of produced well fluids into
bushing 168 is provided between second portion 112rb of first bearing 116 and second bearing 118. A mechanical seal
housing and the drive shaft 26. 144 has a first body 146 with a first sealing surface 150 and a
Operation of the stuffing box 16r is as follows. The drive second body 148 with a second sealing surface 156. First
shaft 26 is prevented from being withdrawn from internal body 146 is secured to and rotates with internal sleeve 114.
sleeve 114 by rod clamp 142 and bolts 140. During operation, 35 First body 146 secured to internal sleeve 114 with set screws
internal sleeve 114 rotates the drive shaft 26. Rotational
152. An o-ring seal 154 is positioned between first body 146
movement of internal sleeve 114 is accommodated by first and internal sleeve 114 to serve a static Sealing function.
bearing 116, second bearing 118, bushing 168 and thrust Second body 148 is secured to housing 112 by pins 158 and
washer 128. Static seal 136 is positioned to prevent leakage remains stationary with housing 112. Pin 158 projects into a
between the drive shaft 26 and internal sleeve 114. Static seal
154 is positioned to prevent leakage between first body 146
40 travel groove 160 in housing 112ia so as to prevent rotation
while permitting second body 148 to travel in groove 160
and internal sleeve 114. Static seal 162 is positioned to pre axially along housing 112ia. An o-ring seal 162 is provided
vent leakage between second body 148 and the first portion between second body 148 and housing 112ia and serves a
112ra of the housing. Mechanical seal 144 is disposed in static Sealing function.
annular space 120 between internal sleeve 14 and the first 45 Belville springs 164 are provided for biasing first sealing
portion 112ra of the housing to block the passage of produced Surface 150 and second sealing Surface 156 in sealing engage
well fluids into first bearing 116 and second bearing 118. ment. A grease nipple 166 is provided on housing 112ia for
Second sealing face 156 of second body 148 engages first supplying lubricant to mechanical seal 144. Apertures 115 are
sealing face 150 of first body 146 to form mechanical seal provided on top flange 112ib and bottom flange of housing
144, thereby preventing any passage of produced well fluids. 50 112ia for the purpose of mounting stuffbox 16i.
Spring 164 maintains the sealing faces engaged at all times, PC pumps are typically used in deep well applications such
VaS War OCCU.S.
as pumping oil from wells. These pumps are often used to
The sealing system for stuffing box 16r, as described produce heavy crude oil. Heavy crude oil is often produced
above, has very high pressure dynamic capability. It can oper from semi-consolidated sand formations. Loose sand is
ate at pressures at or above 3500 p.s. i. without leakage. At 55 readily transported to the stuffing box by the viscosity of the
ambient temperatures, stuffing box. 10 does not require any crude oil. Due the abrasive sand particles present in the crude
external cooling. For high temperature applications, external oil, premature failure of the stuffing box, particularly the
cooling can be added to stuffing box 167: mechanical seal, is common in these applications. The drive
FIG. 1E illustrates a typical progressing cavity pump drive head 12 must be removed to do maintenance work on the
head 12 with an integral stuffing box 16i mounted on the 60 conventional stuffing boxes 16i, r. This necessitates using a
bottom of the drive head 12 and corresponding to that portion service rig with two lifting lines, one to support the drive shaft
of the system in FIG. 1 which is above the dotted and dashed 26 and the other to support the drive head 12. This costs oil
line 40. The integral stuffing box 16i reduces the height of the companies money in service time, down time and environ
installation because there is no wellhead frame 14 and also mental clean up. Costs associated with stuffing box failures
reduces cost because there is no wellhead frame 14 and there 65 are one of the highest maintenance costs on many wells.
are fewer parts since the stuffing box 16i is integrated with the Another prior art design places the stuffing box above the
drive head 12. The integral stuffing box is specially config drive head so that the stuffing box may be replaced without
 US 7,874,369 B2
5 6
removing the drive head. However, this means that the stuff FIG. 4 is a sectional view of a retrofit stuffing box for a PC
ing box is at an increased elevation requiring more service pump system, according to another embodiment of the
time to reach the stuffing box and increasing the risk of injury present invention.
to service personnel. Another prior art design uses injectable FIG. 5 is a sectional view of a retrofit stuffing box for a PC
seal material. This is not a good solution as the seal material pump system, according to another embodiment of the
flows out of the seal gland and therefore must be maintained present invention.
often. FIG. 6 is a sectional view of a retrofit stuffing box for a PC
Therefore, there exists a need in the art for a stuffing box for pump system, according to another embodiment of the
a PC pump system that may be easily repaired. present invention.
10
SUMMARY OF THE INVENTION DETAILED DESCRIPTION OF THE PREFERRED
EMBODIMENT
The present invention relates to a split seal for a progressive
cavity pump (PCP) drive head stuffing box. In one embodi Unless otherwise specified and except for seals, all parts
ment, a mechanical seal assembly for a pump is provided. The 15 are made from an alloy, Such as steel or stainless steel. Unless
mechanical seal assembly includes a seal housing having a otherwise specified, all seals are made from a polymer, Such
longitudinal bore therethrough; first and second semi-annular as an elastomer or polyurethane (polyurethane may or may
mechanical seals, each at least partially disposed in the seal not be considered an elastomer, depending on the level of
housing bore, and each having two radial faces, each radial cross linking). The drive shaft 26 has been omitted for the
face of each seal abutting a radial face of the other seal; a seal sake of clarity. Use of the term coupling or attached herein
sleeve having a longitudinal bore therethrough and rotatable includes direct and indirect coupling/attachment. For
relative to the seal housing; third and fourth semi-annular example, A is coupled/attached to C would include the case
mechanical seals, each disposed at least partially in the seal where A is directly coupled/attached to C and the case where
sleeve bore, each having two radial faces, each radial face of A is directly coupled/attached to B which is directly coupled/
each seal abutting a radial face of the other seal, at least one of 25 attached to C.
the third and fourth seals rotationally coupled to the seal FIG. 2 is a sectional view of a retrofit stuffing box 200 for
sleeve; and one or more biasing members biasing longitudinal a PC pump system, according to one embodiment of the
faces the first and second seals into engagement with longi present invention. The stuffing box 200 may replace the stuff
tudinal faces of the third and fourth annular seals or longitu ing box 16 rand be used with the PC pump system 10 of FIG.
dinal faces the third and fourth seals into engagement with 30 1. The retrofit stuffing box 200 includes a rotor assembly and
longitudinal faces of the first and second annular seals a stator assembly. The rotor assembly includes a sleeve 205,
a cap 206, a male bushing 207a, a female bushing 207b, one
BRIEF DESCRIPTION OF THE DRAWINGS or more snap rings 208, one or more shaft seals 210a, b, a
spacer ring 212, an inner lubricant seal housing 215a, a lubri
So that the manner in which the above recited features of 35 cant seal 217, a bearing sleeve 220a, one or more O-ring seals
the present invention can be understood in detail, a more 222, one or more inner rings and balls of one or more bearing
particular description of the invention, briefly summarized assemblies, such as ball bearing assemblies 225a, b, a rotor
above, may be had by reference to embodiments, some of sub-assembly of a mechanical seal assembly 250 (discussed
which are illustrated in the appended drawings. It is to be separately below), and a retaining ring 222.
noted, however, that the appended drawings illustrate only 40 The sleeve 205 is a tubular or annular member having a
typical embodiments of this invention and are therefore not to longitudinal bore therethrough. Each longitudinal end of the
be considered limiting of its scope, for the invention may sleeve 205 is threaded on an outer surface thereof. The cap
admit to other equally effective embodiments. 206 is a tubular member having a bore therethrough and is
FIG. 1 is a view of a progressing cavity (PC) pump oil well threaded on an inner Surface thereof at a longitudinal end
installation in an earth formation with a typical drive head, 45 thereof. The cap 206 is axially and rotationally coupled to the
wellhead frame and stuffing box. FIG. 1A is a sectional view sleeve 205 with a threaded connection. Disposed along an
of a prior art PC pump. FIG. 1B is a sectional view of a prior inner surface of the cap 206 is the male bushing 207a. The
art even wall PC pump. FIG. 1C is a side elevation view, in male bushing 207a includes two semi-tubular segments, each
section, of a prior art retrofit stuffing box. FIG. 1D is an having an inclined outer Surface. Each segment of the male
enlarged side elevation view, in section, of a mechanical seal 50 bushing 207a is disposed along an inner surface of the cap 206
of the retrofit stuffing box of FIG. 1C. FIG. 1E is a view and an inner surface of the female bushing 207b. The male
similar to the upper end of FIG. 1 but illustrating a conven bushing 207a is axially coupled to the cap 206 by abutment
tional drive head with an integrated Stuffing box extending with a longitudinal end of the cap 206 and by abutment with
from the bottom end of the drive head. FIG. 1F is a side a Snap ring 208 disposed in a groove formed in an inner
elevation view, in section, of a prior art integral stuffing box. 55 surface of the cap 206.
FIG. 2 is a sectional view of a retrofit stuffing box for a PC The female bushing 207b is a tubular member having a
pump system, according to one embodiment of the present bore therethrough and a longitudinal cut through a wall
invention. FIG. 2A is an enlarged portion of the mechanical thereof. The female bushing 207b is axially coupled to the
seal assembly of FIG. 2. FIG. 2B is a sectional view of a split sleeve 205 by abutment with a shoulder formed in an inner
mechanical seal assembly, according to another embodiment 60 surface of the sleeve 205 and by abutment with a snap ring 208
of the present invention. FIGS. 2C and 2D are sections taken disposed in a groove formed in an inner Surface of the sleeve
along lines 2C-2C and 2D-2D, respectively of FIG.2B. FIG. 205. An inner surface of the female bushing 207b is corre
2E is a sectional view of a split mechanical seal assembly, spondingly tapered to the outer Surface of the male bushing
according to another embodiment of the present invention. 207a, so that when the cap 206 is tightened, an inner surface
FIG. 3 is a sectional view of a retrofit stuffing box for a PC 65 of the male bushing 207a is wedged into contact with an outer
pump system, according to another embodiment of the surface of the drive shaft 26, thereby axially and rotationally
present invention. coupling the drive shaft 26 with the sleeve 205.
 US 7,874,369 B2
7 8
Abutting a longitudinal end of the female bushing 207b is longitudinal end and a first longitudinal end of an inner ring of
a first longitudinal end of a first shaft seal 210a. A spacer ring the first ball bearing assembly 225a at a second longitudinal
212 abuts a second longitudinal end of the first shaft seal 210a end. The outer lubricant seal housing 215b carries an O-ring
and a first longitudinal end of the second shaft seal 210b. The seal 222 along an outer Surface thereof. A second longitudinal
spacer ring 212 is made from a relatively soft material (as end of the outer ring of the first bearing assembly 225a abuts
compared to ASTM A36 steel), such as a soft metal or a the bearing spacer 220b. The outerrings of the bearing assem
polymer, such as polytetrafluoethylene (PTFE). A shoulder blies 225a, b are press fit along an inner Surface of the housing
formed on an inner surface of the sleeve 205 provides a 230. The bearing spacer 220b is an annular or tubular member
longitudinal back stop for a second longitudinal end of the having a longitudinal bore therethrough and first and second
second shaft seal 210b. The shaft seals 210a, b are annular 10 radial lubricant ports formed through a wall thereof. The first
members, each having a chevron profile formed in a second lubricant port is in fluid communication with a first lubricant
longitudinal end thereof. The chevron profiles are oriented port formed radially through a wall of the housing and the
facing away from the cap. An inner wing of each profile second lubricant port is in fluid communication with a second
naturally extends radially inward past an outer diameter of the lubricant port formed radially through a wall of the housing.
drive shaft 26 so that the wings of each profile will be com 15 A first lubricant fitting 234a is connected to the first lubricant
pressed radially inward upon assembly of the stuffing box port of the housing and a first sample valve 232a is connected
200, thereby isolating a first portion of the sleeve 205 bore to the second lubricant port of the housing. A second longi
proximate the cap 206 from a second portion of the sleeve 205 tudinal end of the bearing spacer 220b abuts a first longitudi
bore distal from the cap 206. nal end of an inner ring of the second bearing assembly 225b.
The inner lubricant seal housing 215a is an annular mem FIG. 2A is an enlarged portion of the mechanical seal
ber and is disposed along an outer surface of the sleeve 205. assembly 250 of FIG. 2. The mechanical seal assembly 250
The inner lubricant seal housing 215a abuts a first longitudi includes the rotor sub-assembly and the stator sub-assembly.
nal end of an inner ring of a first ball bearing assembly 225a. The stator sub-assembly includes a seal housing 285, a
Disposed within the inner lubricant seal housing 215a is the mechanical seal 290, one or more O-ring seals 270, and one or
lubricant seal 217. The lubricant seal 217 is compressed into 25 more retainers, such as pins 275. The stator seal housing 285
contact with an outer surface of the sleeve 205, thereby pre is a tubular or annular member and abuts a second longitudi
venting leakage of lubricant. Such as grease, along the outer nal end of the inner ring of the second bearing assembly 225b
surface of the sleeve 205. The bearing sleeve 220a is an at a first longitudinal end of the stator seal housing 285. The
annular member and is disposed along an outer Surface of the stator seal housing 285 may be press fit into the housing 230.
sleeve 205. The bearing sleeve 220a carries two O-ring seals 30 A shoulder is formed along an outer Surface of the stator seal
222 disposed along grooves formed in an inner Surface housing 285. The outer shoulder of the stator seal housing 285
thereof. An outer surface of the bearing sleeve 220a forms abuts a shoulder formed in an inner surface of the stuffing box
two shoulders. An inner ring of each of the ball bearing housing 230. An O-ring seal 270 is disposed in a groove
assemblies 225a,b is press fit on the outer surface of the formed along the outer surface of the stator seal housing 285
bearing sleeve 220a, thereby axially and rotationally cou 35 and engages an inner Surface of the stuffing box housing 230.
pling the inner rings to the bearing sleeve. A second longitu A shoulder is formed along an inner Surface of the stator seal
dinal end of the inner ring of the first ball bearing assembly housing 285. The inner shoulder of the stator seal housing 285
225a abuts a first shoulder of the bearing sleeve 220a and a abuts a first longitudinal end of the stator mechanical seal 290.
first longitudinal end of the second bearing assembly 225b The stator mechanical seal 290 is an annular member. The
abuts a second shoulder of the bearing sleeve 220a. The 40 stator mechanical seal 290 is rotationally coupled to the stator
retaining ring 224 is threaded on an inner Surface thereof and seal housing 285 by the pins 275. Each pin 275 is press fit into
rotationally coupled to the outer surface of the sleeve 205 with a hole formed in or through the inner shoulder of the stator
a threaded connection. The retaining ring 224 is axially seal housing 285 and extends into a slot formed in the first
coupled to the sleeve 205 by abutting a shoulder formed in an longitudinal end of the stator mechanical seal 290. The stator
outer surface of the sleeve 205 and by a snap ring 208 dis 45 mechanical seal 290 is made from a material harder or sub
posed in a groove formed in an outer surface of the sleeve 205. stantially harder than ASTM A36 steel, such as a ceramic, i.e.,
An outer Surface of the retaining ring 224 may be profiled. silicon carbide. Such as alpha sintered or reaction bonded; a
The stator assembly includes a housing 230, an outer lubri metal or alloy, Such as gray cast iron, Hastelloy B. M-2 steel,
cant seal housing 215b, one or more outer rings of one or more Niresist, 316 stainless, 440C stainless, Stellite, T/C Cobalt,
bearing assemblies. Such as ball bearing assemblies 225a, b, a 50 T/C Nickle; or carbon, such as siliconized graphite, such as
bearing spacer 220b, one or more O-ring seals 222, one or PE-8148, reaction bonded, such as PR9242, reaction bonded
more lubricant sampling valves 232a, b, one or more lubricant plus graphite, such as PG9723, or alpha sintered, such as
fittings, such as Zerks 234a, b, one or more Snap rings 208, and PS-10070 or PS-10138. An o-ring seal 270 is disposed in a
a stator sub-assembly of the mechanical seal assembly 250 groove formed in an outer Surface of the stator mechanical
(discussed separately below). Alternatively, one or more 55 seal 290 and engages the stator seal housing 285. An inner
bushings (not shown) may be used instead of the ball bearing surface of the stator seal housing 285 is disposed proximate to
assemblies. The housing 230 is a tubular or annular member the outer Surface of the sleeve 205.
having alongitudinal bore therethrough and has first 230a and The rotor sub-assembly of the mechanical seal assembly
second 230b flanges formed integrally therewith. Alterna 250 includes a seal retainer 255, two or more set screws 257,
tively, the flanges 230a, b may we welded on the housing 230. 60 a seal sleeve 260, a mechanical seal 265, one or more O-ring
The first flange 230a connects the housing with the frame 14 seals 270, two or more retainers, such as pins 275, and two or
and the second flange 230b connects the housing with the more biasing members, such as springs 280. The rotor seal
flow tee 22 or other flanged wellhead equipment. retainer 255 is an annular member. An inner surface of the
The outer lubricant seal housing 215b is an annular mem rotor seal retainer 255 is disposed along an outer surface of
ber disposed along an inner surface of the housing 230. The 65 the sleeve 205. The rotor seal retainer 255 is axially and
outer lubricant seal housing 215b abuts a snap ring 208 dis rotationally coupled to the sleeve 205 by the set screws 257,
posed along the inner surface of the housing 230 at a first each set screw 257 disposed through a radial threaded hole
 US 7,874,369 B2
10
disposed through the rotor seal retainer 255 near a second respective semi-annular segments 265b,c and 290,b,c so that,
longitudinal end of the rotor seal retainer 255. A first portion when assembled, corresponding ridges and grooves of the
of the outer surface of the rotor seal retainer 255 is threaded rough radial faces interlock to form a radial seal.
and a second portion of the outer Surface forms a shoulder. An As shown, each split O-ring seal 270a is butt-cut at free
o-ring seal 270 is disposed in a groove in a first longitudinal radial ends thereof and the O-ring seal 270b includes a ball
end of the rotor seal retainer 255 and engages the outer sur and Socket fastening mechanism located at radial free ends
face of the sleeve 205 and a first longitudinal face of a radial thereof. Each groove of the O-ring seal 270a is specially
portion of the seal sleeve 260. The first longitudinal end of the configured to force the free radial ends of each O-ring seal
rotor seal retainer 255 abuts the first longitudinal face of the into radial engagement. This special configuration entails an
radial portion of the seal sleeve 260. 10 asymmetric shaped groove (cross-section shape) having one
The seal sleeve 260 is a tubular or annular member having straight longitudinal/radial endandone inclined longitudinal/
a longitudinal portion and the radial portion. An inner Surface radial end depending on whether the O-ring seal is sealing a
of the radial portion is disposed along the sleeve 205 and an radial face or a longitudinal face. Consequently, one radial/
outer Surface of the longitudinal portion faces an inner Surface longitudinal face is also longer than the other radial/longitu
of the housing 230. A second end of the longitudinal portion 15 dinal face. Alternatively, one, Some, or all of the O-ring seals
is threaded on an inner Surface and by engaged to the threaded 270a, b may have ball and socket fastening mechanisms, be
outer portion of the rotor seal retainer 255. An O-ring seal 270 butt-cut, be Scarf-cut, and/or may include adhesive joining the
is disposed in a groove formed in an inner Surface near a first free radial ends thereof. At one radial end, each O-ring seal
longitudinal end of the longitudinal portion of the seal sleeve 270b narrows into a substantially hemispherical shoulderpor
260 and engages an outer Surface of the rotor mechanical seal tion and, adjacent thereto, an annular neck portion. Immedi
265. A plurality of holes are formed in a first longitudinal face ately adjacent the neck portion is a Substantially spherical
of the radial portion of the seal sleeve 260. Disposed in each head portion. In fastening, the head portion is inserted into a
of the holes is either one of the pins 275 or one of the springs matching spherical Socket portion at the other radial end of
280. When a pin 275 is disposed in one of the holes, the pin each O-ring seal 270b such that annular collar portion sur
275 extends into a slot formed in a second longitudinal end of 25 rounds and captures the neck portion, and shoulder portion is
the rotor mechanical seal 265, thereby rotationally coupling in intimate contact with annular jacket portion.
the rotor mechanical seal 265 to the seal sleeve 260. When a FIG. 2E is a sectional view of a split mechanical seal
spring 280 is disposed in one of the holes, the spring 280 is assembly 250b, according to another embodiment of the
compressed between an end of the hole and the second lon present invention. The mechanical seal assembly 250b is
gitudinal end of the rotor mechanical seal 265. Alternatively, 30 identical to the mechanical seal assembly 250a except that a
the seal sleeve 260 and springs 280 could be coupled to the mechanical seal sleeve assembly 260a, b replaces the seal
stator mechanical seal 290 instead of the rotor mechanical sleeve 260 and the seal retainer 255. Alternatively or in addi
seal 265. The rotor mechanical seal 265 is an annular member tion to, the stator seal housing 285 may similarly be replaced
and is made from any of the materials discussed above for the by an assembly of semi-annular segments. Semi-annular seg
stator mechanical seal 290. The first longitudinal end of the 35 ments 260a, b are radially connected at radial ends thereof by
rotor mechanical seal 265 held into engagement with the threaded fasteners 292 and have gaskets (not shown) disposed
second longitudinal end of the stator mechanical seal 290 by between each pair of mating radial ends. The gaskets are
the one or more springs. To facilitate replacement of the made from a soft fibrous material or a soft metal. The
mechanical seals 265.290 without removing the drive head mechanical seal assembly 250b may also be initially installed
12, the mechanical seals 265.290 are optionally pre-weak 40 with the seals 265,270, and 290 and then the seals replaced
ened along longitudinal lines 265a,290a, respectively. Sharp with the seals 265a, b, 270a, b, and 290a, b.
blows by a technician with a hammer will serve to break each FIG. 3 is a sectional view of a retrofit stuffing box 300 for
of the mechanical seals 265.290 into two semi-annular seg a PC pump system, according to another embodiment of the
ments. The O-rings 270 may simply be cut to allow removal. present invention. Like numbered members are identical to
FIG. 2B is a sectional view of a split mechanical seal 45 those of FIG. 2 and will not be discussed again. The stuffing
assembly 250a, according to another embodiment of the box 300 may replace the stuffing box 16r and be used with the
present invention. FIGS. 2C and 2D are sections taken along PC pump system 10 of FIG.1. Although, the mechanical seal
lines 2C-2C and 2D-2D, respectively of FIG. 2B. The split assembly 250 is shown, it may be replaced by the split
mechanical seal assembly 250a includes the seal housing mechanical seal assembly 250a, as discussed above. Alterna
285, two semi-annular stator mechanical seal segments 50 tively, the mechanical seal assembly 250b may be used
290b,c and the two or more retainers, such as the pins 275, one instead of the mechanical seal assembly 250a. The housing
or more split O-ring seals 270a, b, the seal retainer 255, the 330 is a tubular member having a longitudinal bore there
two or more set screws 257, the seal sleeve 260, two semi through and has first 330a and second 330b flanges formed
annular rotor mechanical seal segments 265b, c, and the two integrally therewith. Alternatively, the flanges 330a, b may we
or more biasing members, such as the springs 280. Once the 55 welded on the housing 330. The first flange 330a connects the
mechanical seal assembly 250 has been disassembled (with housing with the frame 14 and the second flange 330b con
out removing the drive head), the mechanical seals 265.290 nects the housing with the flow tee 22 or other flanged well
broken and removed, and the O-rings 270 cut and removed, head equipment. The housing 330 has been elongated relative
the mechanical seals 265.290 may be replaced by the split to the housing 230 to accommodate one or more injectable
mechanical seals 265b,c and 290b, c and the O-ring seals 270 60 seal assemblies 350a, b.
may be replaced by split O-ring seals 270a, b. A first injectable seal assembly 350a is longitudinally dis
The mechanical seal segments 265b, c and 290b, care made posed between the secondball bearing assembly 220b and the
starting from respective annular mechanical seals 265.290, stator seal housing 285. A second injectable seal assembly
each having a pre-weakened longitudinal lines 265a,290a. 350b is longitudinally disposed between a snap ring 308
The annular mechanical seals 265.290 are then each carefully 65 disposed in a groove formed in an inner Surface of the housing
broken apart under controlled factory conditions. This creates 330 and a shoulder of the housing 330. Each of the injectable
corresponding rough radial faces on each radial face of seal assemblies 350a, b includes first 355a,c and second
 US 7,874,369 B2
11 12
355b, dinjectable material retainers. In addition, washers (not gitudinal ends of semi-annular segments 485a, b of the stator
shown) may be disposed adjacent one or more of the retainers mechanical seal housing assembly. The semi-annular seg
355a-d to further longitudinally support the retainers 355a-d. ments 485a, b are radially connected at radial ends thereof by
The washers may be coupled to the housing 330 by snap rings threaded fasteners 492b and have gaskets (not shown) dis
308. The injectable material retainers 355a-dare made from posed between each pair of mating radial ends. The gaskets
a relatively hard (as compared to rubber) polymer, Such as a are made from a soft fibrous material or a soft metal. Second
thermoplastic, such as polyetheretherketone (PEEK) or longitudinal ends of semi-annular segments 485a, b of the
PTFE, or a soft metal (as compared to ASTM A36 steel). stator mechanical seal housing assembly abut a first longitu
Each of the injectable material retainers 355a-d is a split dinal end of the second housing 430b. The second longitudi
annular member (similar to split O-ring 270b) having a first 10
nal ends of semi-annular segments 485a,b have slots formed
longitudinal end and a second longitudinal end. Alternatively, therein at outer peripheries thereof. The first longitudinal end
upon initial installation, each retainer 355a-d may be annular of the second housing 430b has corresponding slots formed
and then be removed by cutting and replaced by a split annular therein at an outer periphery thereof. Disposed in each corre
member. Alternatively, each retainer may resemble split sponding pair of slots is a pin 475. The pins 475 rotationally
O-ring 270a or any of the alternatives discussed in relation to 15
couple the semi-annular segments to the second housing
the split O-rings 270a, b. One of the longitudinal ends, which 430b. A split o-ring 270a is disposed in a groove formed in the
faces the injectable material 360, is substantially chevron first longitudinal end of the second housing 430b and engages
shaped and includes a first wing and a second wing. The the second longitudinal ends of the semi-annular segments
injectable material 360 is a mixture of grease or jelly with 485a,b. Alternatively, the split O-ring seal 270b or any of the
fibers made from a polymer, Such as a thermoplastic, such as alternatives discussed for the split O-ring seals 270a, b may be
a liquid crystalline polymer, such as Kevlar. The injectable used.
material 360 is injected into the housing 330 through a fitting, The cover 430c is an annular member and has holes radi
such as a Zerk 334a, b. The material is injected until a prede ally formed through a wall thereofnear a first longitudinal end
termined pressure is generated. The pressure causes the wings
of the retainers 355a-d to expand into engagement with an 25 thereof. Corresponding threaded holes are formed in an outer
inner diameter of the housing and an outer diameter of the surface of the first housing 430 near the second longitudinal
sleeve. The predetermined pressure may be greater than or end thereof. Threaded fasteners 492a are disposed in the
equal to the operating pressure of the stuffing box 300. Each holes and attach the cover 430c to the first housing 430. The
injectable seal assembly 350a, b may be intermittently manu cover 430c longitudinally extends past the stator mechanical
ally re-pressurized or connected, via tubing, to process pres 30 seal housing assembly 485a, b so that a second longitudinal
sure in the wellhead. In this manner, the injectable material end of the cover 430c is nearly in longitudinal alignment with
360 may fill any leak paths which develop in the stuffing box the first longitudinal end of the second housing 430b. The
300. Further, the second injectable seal assembly 350b may cover also radially holds the pins 475 in place. With the
also serve to prevent particulates in the production fluid, Such exception of the stator mechanical seal housing assembly
as sand, from entering the mechanical seal assembly 250, 35 485a, b, the rest of the mechanical seal assembly 450a is
250a. The first injectable seal assembly 350a may also pre identical to the mechanical seal assembly 250a.
vent sand from entering the ball bearing assemblies 225a, b. The configuration of the stuffing box 400 allows for the
Using the injectable seal assemblies 350a, b as a pressurizing/ removal and replacement of the mechanical seals 265b,c and
backup seal makes time between repairs longer and provides 290b, c without having to remove the bearing assemblies
a better sealandless leakage potential. Alternatively, only one 40 225a, b. Further, a similarly configured integral stuffing box
of the injectable seal assemblies 350a, b may be used. Alter version (which would replace the stuffing box 16i of FIG. 1)
natively, a side feed rope seal may be used instead of the would allow for replacement of the mechanical seals 265b,c
injectable material 360. and 290b,c without removing the drive head 12 or the bearing
FIG. 4 is a sectional view of a retrofit stuffing box 400 for assemblies 225a, b. When it is desired to remove the mechani
a PC pump system, according to another embodiment of the 45 cal seals 265b, c and 290b, c, the PC pump system 10 is shut
present invention. Like numbered members are identical to down. The lubricant fitting 434, sampling valve 432, and
those of FIG. 2 and will not be discussed again. The stuffing cover fasteners 492a are removed, thereby allowing the cover
box 400 may replace the stuffing box 16r and be used with the 430c to slide to the second housing flange 430d, thereby
PC pump system 10 of FIG.1. The housing assembly includes exposing the stator mechanical seal housing assembly 485a,
a first housing 430, a second housing 430b, a stator mechani 50 b.
cal seal housing assembly 485a, b, and an optional cover Three or more jack assemblies 495 are set on a first longi
430c. The first housing 430 is a tubular or annular member tudinal end of the second housing flange 430d. Each of the
having alongitudinal bore therethrough and has a flange 430a jackassemblies 495 includes a housing 495a, ajack rod 495b,
formed integrally therewith. The second housing 430b is a and a manual actuator 495c. The jack housing 495a includes
tubular or annular member having a longitudinal bore there 55 a base plate attached thereto at a second longitudinal end
through and has a flange 430d formed integrally therewith. thereof and is set on a first longitudinal end of the second
Alternatively, the flanges 430a, d may we welded on the housing flange 430d near an outer Surface thereof So as to
respective housings 430,430b. The flange 430a connects the provide sufficient radial clearance for removal of the stator
first housing 430 with the frame 14 and the flange 430d mechanical seal housing assembly 485a,b. The jack rod 495b
connects the second housing 430b with the flow tee 22 or 60 is threaded on an outer surface thereof and one of the jack
other flanged wellhead equipment. housing 495a and the mechanical actuator 495c is threaded
The mechanical seal assembly 450a is identical to the on an inner Surface thereof, thereby axially coupling the jack
mechanical seal assembly 250a except that a stator mechani rod to the jack housing. The actuator 495c may either be
cal seal housing assembly 485a, b replaces the stator mechani attached to a first longitudinal end of the jack rod 495b or
cal seal housing 285. Alternatively, a similarly modified 65 longitudinally and radially coupled for rotation to a first lon
mechanical seal assembly 250b may be used instead. A sec gitudinal end of the jack housing 495a. Turning of the actua
ond longitudinal end of the first housing 430 abuts first lon tor 495b will longitudinally raise or lower the jack rod 495b.
 US 7,874,369 B2
13 14
The jack rod 495b includes a support plate longitudinally and 270a, b. Alternatively, a similar configuration could be used
radially coupled thereto at the first longitudinal end of the jack for an integral stuffing box (which would replace the integral
rod 495b. The support plate may pivot relative to the jack rod stuffing box 16.i). The housing 530 includes an optional con
495b. Alternatively, the jack assemblies 495 may be hydrau ventional stuffing assembly 550. Alternatively, the stuffing
lic, pneumatic, or any other type of jack and may be manually assembly 550 may be replaced with an injectable seal assem
or automatically actuated. bly 350a, a second mechanical seal assembly 250a, or the
The jack rods are raised, in tandem, to engage a second space occupied by the stuffing assembly left vacant (or the
longitudinal end of the first housing flange 430a. The jack housing could be shortened). The stuffing assembly 550 acts
rods 495b are further raised, thereby raising the first housing as a secondary seal which may prevent any leaks through the
flange 430a until a longitudinal clearance is created between 10 mechanical seal assembly 250a from entering the bearing
the stator seal housing assembly 485a, b and the first housing assemblies 225a, b. Although not replaceable without remov
430, thereby indicating that weight of the first housing 430 is ing the drive head 12, the conventional stuffing assembly 550
fully supported by the jack assemblies 495. The stator may still be effective as a secondary seal even after its primary
mechanical seal assembly fasteners 492b are removed and the seal service life has expired.
semi-annular segments of the stator mechanical seal assem 15 The conventional stuffing assembly 550 includes a stator
bly 485b,c are removed. The mechanical seals 265a, b and Sub-assembly and a rotor Sub-assembly. The stator Sub-as
290a, b are removed and replaced. Alternatively, as discussed sembly includes a seal retainer 552, first 555a and second
in relation to FIG. 2, seals 265,290, and 270 could be initially seals 555b, first 556a and second 556b seal housings, one or
installed in the mechanical seal assembly 450a and later more O-ring seal assemblies 522, first 558a and second 558b
replaced with seals 265b,c, 290b, c, and 270a, b. bushings, and one or more pins 559. The rotor sub-assembly
FIG. 5 is a sectional view of a retrofit stuffing box 500 for includes a seal 560.
a PC pump system, according to another embodiment of the The seal retainer 552 is an annular member having an outer
present invention. Like numbered members are identical to Surface disposed along an inner Surface of the housing and an
those of FIG. 2 and will not be discussed again. The stuffing inner Surface proximally facing an outer Surface of the sleeve
box 500 may replace the stuffing box 16r and be used with the 25 205. A first longitudinal end of the seal retainer 552 abuts a
PC pump system 10 of FIG.1. The housing assembly includes second longitudinal end of the outer ring of the second bear
a first housing 530 and a flange assembly 530c,d. The first ing assembly 225b. A longitudinal face of the seal retainer
housing 530 is a tubular or annular member having a longi 552 abuts a shoulder formed in an inner surface of the housing
tudinal bore therethrough and has a first flange 530a and a 530 and faces an outer portion of a first longitudinal end of the
second flange 530b formed integrally therewith. Alterna 30 first seal housing 556a. A radial shoulder of the seal retainer
tively, the flanges 530a, b may be welded on the housing 530. 552 is press fit with a radial shoulder of the first seal housing
Abutting a second longitudinal end of the housing 530 is a 556a. A second longitudinal end of the seal retainer 552 abuts
first longitudinal end of the flange assembly 530c, d. Alterna a first longitudinal face of the first seal housing 556a and a
tively, the flange assembly 530c, d may abut the first longitu first longitudinal end of the first stator seal 555a. The seal
dinal end of the housing 530. In this alternative, the secondary 35 housings 556a, b are annular members. The stator seals
seal assembly 550 may be omitted and the housing 530 short 555a, b are annular members, each having a radial lip extend
ened accordingly. Further, in this alternative, the flange 530a ing outwardly at a first longitudinal end thereof and a chevron
may have extra holes to facilitate attachment of the flange shaped second longitudinal end. The first stator seal 555a is
assembly thereto. The flange assembly 530c, d includes semi radially disposed between a second radial shoulder of the first
annular segments 530c.d radially attached with threaded fas 40 seal housing 556a and an outer surface of the sleeve 205. The
teners 592. As shown, the flange assembly 530c, d is specifi first stator seal lip extends into a groove formed in the first
cally configured, however, the flange assembly 530c, d may longitudinal face of the first seal housing 556.a. Pressure
be a conventional American Petroleum Institute (API) split acting on wings of the second longitudinal end of the first
flange. The flange assembly 530c,d may be rotationally stator seal 555a radially expands the wings into engagement
coupled to the housing by using long studs when attaching the 45 with a first radial face of the first seal housing and the outer
first housing flange 530b and flange assembly 530c, d to the surface of the sleeve 205. The second longitudinal end of the
flow tee 22 or other flanged wellhead equipment. Alterna first stator seal 555a proximally faces a second longitudinal
tively, pins (not shown) may be press fit into first longitudinal face of the first stator seal housing 556a. An O-ring assembly
ends of the flange segments and received in corresponding 522 is disposed in a groove formed in an inner surface of the
holes in the first housing 530. An optional split o-ring 270a is 50 first seal housing 556a. The O-ring assembly 522 includes an
disposed in grooves formed in first longitudinal ends of the o-ring seal and a back-up ring. The o-ring seal engages an
flange segments 530c, d and engages a second longitudinal inner surface of the housing 530.
end of the first housing flange 530b. Alternatively, the split The first bushing 558a is an annular member having an
O-ring 270b or any of the alternatives discussed in relation to inner Surface disposed along an outer Surface of the sleeve
the split O-rings 270a, b may be used. 55 205 and an outer surface press fit along a second radial face of
Disposed in the flange assembly 530c, d is the mechanical the first seal housing 556a. A first longitudinal end of the first
seal assembly 250a. Alternatively, as discussed in relation to bushing 558a abuts a longitudinal shoulder of the first seal
FIG. 2, the mechanical seal assembly 250 may initially be housing 556a. The first bushing 558a has two radial holes
installed in the flange assembly 530c, d and later replaced with formed through a wall thereof. The holes are in fluid commu
the mechanical seal assembly 250a. Alternatively, the 60 nication with two radial holes formed through a wall of the
mechanical seal assembly 250b may be used instead of the first seal housing 556a. A second longitudinal end of the first
mechanical seal assembly 250a. The seals 265b,c, 290b,c, bushing 558a abuts a first longitudinal end of the second
and 270a, b of the mechanical seal assembly 250a are replace stator seal 555b. A recess is formed in an outer surface of the
able, without having to remove the bearing assemblies 225a, first seal housing 556a to serve as a lubricant chamber. A
b, by lifting the housing 530 with a crane (not shown), disas 65 second longitudinal end of the first seal housing 556a abuts a
sembling the flange assembly 530c, d, lifting the stator seal first longitudinal face of the second seal housing 556b and a
housing 285, and removing the seals 265b,c, 290b, c, and first longitudinal end of the second stator seal 555b.
 US 7,874,369 B2
15 16
An outer surface of the second seal housing 556b is dis o-ring 270 may replace the split o-ring 270a located in the
posed along an inner surface of the housing 530. A first radial outer Surface of the modified Stator mechanical seal housing
face of the second seal housing 556b is press fit with a fourth 685. Alternatively, a similarly modified mechanical seal
radial face of the first seal housing 556a. The second stator assembly 250b may be used instead. The modified stator
seal 555b lip extends into a groove formed in the first longi mechanical seal housing 685 is an annular or tubular member
tudinal face of the second seal housing 556b. Pressure acting and facilitates disassembly of the mechanical seal assembly
on wings of the second stator seal 555b expands the wings 650a through the access port in the housing.
radially outward into engagement with a first radial face of the The stator mechanical seal housing 685, access panel 630c
second seal housing 556b and an outer surface of the sleeve and access port allow removal and replacement of the seals
205. A second longitudinal end of the second stator seal 555b 10 265b,c, 290b, c, and 270a, b (except for the o-ring 270/270a
proximally faces a second longitudinal face of the second seal located in the outer Surface of the stator mechanical seal
housing 556b. An O-ring assembly 522 is disposed in a housing 685) of the mechanical seal assembly 650a without
groove formed in an inner Surface of the second seal housing having to disassemble the stuffing box 600 To accomplish
556b and the o-ring seal of the assembly 522 engages an inner this, the fasteners 692 would be removed. The access panel
surface of the housing 530. 15 630c would then be removed. The set screws 257 may then be
The second bushing 558b is an annular member having an loosened, and the rotor Sub-assembly of the mechanical seal
outer Surface press fit along a second radial face of the second assembly 650a may be longitudinally slid away from the
seal housing 556b and an inner surface proximally facing the stator sub-assembly of the mechanical seal assembly 650a.
outer surface of the sleeve 205. The second bushing 558b is The split mechanical seals 265b,c and 290b, c may then be
made from a metal or alloy, such as aluminum or bronze. A removed. The o-ring 270b may then be removed and replaced.
first longitudinal end of the second bushing 558b proximally The stator mechanical seal housing 685 may have an access
faces a third longitudinal face of the second seal housing hole drilled through a wall thereof to allow a tool to be
556b. One or more pins 559 are press fit into one or more inserted to pry the stator mechanical seals 265b, c from the
holes formed in a second longitudinal end of the second seal stator mechanical seal housing. The seal sleeve 260 may then
housing 556b. The pins 559 are received in one or more 25 be unscrewed from the seal retainer 255 in order to replace the
corresponding holes formed in a second longitudinal shoul o-ring 270a located in the longitudinal face of the seal retainer
der of the housing 530, thereby rotationally coupling the 255. The mechanical seal assembly 650a is now disas
second seal housing 556b to the housing 530. sembled. The process may be reversed in order to install
The rotor seal 560 is an annular member having a straight replacement mechanical seals 265b, c and 290b, c along with
longitudinal portion near a first longitudinal end thereofanda 30 associated o-rings 270a.
tapered longitudinal portion near a second longitudinal end The wall of the housing 630 proximate to the access port
thereof. The tapered longitudinal portion tapers outwardly may be reinforced to allow the housing to sustain ordinary
from a first longitudinal end of the tapered portion near a first loading of a stuffing box housing. Alternatively, as discussed
longitudinal end of the rotor seal 560 toward a second longi in relation to FIG. 2, seals 265,290, and 270 could be initially
tudinal end of the tapered portion near a second longitudinal 35 installed in the mechanical seal assembly 650a and later
end of the rotor seal 560. An inner surface of the rotor seal S60 replaced with seals 265b,c, 290b, c, and 270a, b.
is disposed along an outer surface of the sleeve 205. At least At least some embodiments of the present invention allow
a portion of the tapered portion of the inner Surface engages the seals to be replaced at a lower elevation making the
the outer surface of the sleeve 205. The first longitudinal end operation safer and the stuffing boxes 200-600 easier to reach.
of the rotor seal 560 proximally faces a first radial face of the 40 Using split seals makes the repair process more expedient,
second bushing 558b. An outer surface of the rotor seal 560 thereby returning the PC pump 34 to service sooner.
proximally faces an inner surface of the second bushing 558b. Alternatively, the split seal assemblies 250a, 250b, 450a,
The second longitudinal end of the rotor seal 560 proximally 650a may be used with other pumps and may be directly
faces a second radial face of the second bushing 558b. The mounted on a pump shaft. Alternatively, any of the retrofit
first longitudinal end of the rotor seal 560 is concave and the 45 stuffing boxes 200-600 may be integral stuffing boxes.
second longitudinal end of the rotor seal 560 is convex. While the foregoing is directed to embodiments of the
FIG. 6 is a sectional view of a retrofit stuffing box 600 for present invention, other and further embodiments of the
a PC pump system, according to another embodiment of the invention may be devised without departing from the basic
present invention. Like numbered members are identical to scope thereof, and the scope thereof is determined by the
those of FIG. 2 and will not be discussed again. The stuffing 50 claims that follow.
box 600 may replace the stuffing box 16r and be used with the What is claimed is:
PC pump system 10 of FIG.1. The housing assembly includes 1. A stuffing box having a mechanical seal assembly for a
a housing 630 and an access panel 630c. The housing 630 is pump, comprising:
a tubular orannular member having alongitudinal bore there an outer housing having a longitudinal bore therethrough;
through and has a first flange 630a and a second flange 630b 55 a seal housing having a longitudinal bore therethrough,
formed integrally therewith. Alternatively, the flanges 630a, b wherein the seal housing is disposed in the outer housing
may be welded on the housing 630. bore;
The access panel 630c is disposed in an access portformed first and second semi-annular mechanical seals, each at
in the housing 630. The access panel 630c is a semi-annular least partially disposed in the seal housing bore, and
member or semi-tubular member. The access panel 630c is 60 each having two radial faces, each radial face of each
removably attached to the housing 630c with threaded fas seal abutting a radial face of the other seal;
teners 692. A gasket 670 seals an interface between the access a seal sleeve having a longitudinal bore therethrough and
panel 630c and the housing 630. The gasket 670 is made from rotatable relative to the seal housing:
a soft fibrous material or a soft metal. The mechanical seal third and fourth semi-annular mechanical seals, each at
assembly 650a is identical to the mechanical seal assembly 65 least partially disposed in the seal sleeve bore, each
250a except that a modified stator mechanical seal housing having two radial faces, each radial face of each seal
685 replaces the stator mechanical seal housing 285 and the abutting a radial face of the other seal, at least one of the
 US 7,874,369 B2
17 18
third and fourth seals rotationally coupled to the seal 18. A progressive cavity pump (PCP) system, comprising:
sleeve but axially movable relative to the seal sleeve; the stuffing box of claim 1, wherein the outer housing is
one or more biasing members biasing longitudinal faces of attached to a wellhead;
the third and fourth seals into engagement with longitu a drive String disposed through the stuffing box, wherein
dinal faces of the first and second seals; and the internal sleeve is rotationally coupled to the drive
an internal sleeve that extends through the seal sleeve bore. String; and
2. The stuffing box of claim 1, wherein the first and second a PC pump disposed in a wellbore extending from the
semi-annular mechanical seals are each made from a material wellhead, a rotor of the PC pump rotationally coupled to
harder than ASTM A36 steel and the third and fourth semi the drive string.
annular mechanical seals are each made from a material 10 19. The progressive cavity pump (PCP) system of claim 18,
harder than ASTM A36 Steel. wherein the stuffing box further comprises a bearing disposed
3. The stuffing box of claim 2, wherein the first and second between the internal sleeve and the outer housing to facilitate
semi-annular mechanical seals are each made from a ceramic rotation of the internal sleeve within the outer housing.
material and the third and fourth semi-annular mechanical 20. The stuffing box of claim 1, further comprising:
seals are each made from a ceramic material. 15 a second outer housing having a longitudinal bore there
4. The stuffing box of claim 2, wherein the first and second through; wherein the outer housing includes second and
semi-annular mechanical seals are each made from ceramic, third semi-annular outer housings, each having two
metal, alloy, or carbon and the third and fourth semi-annular radial faces, each radial face of each housing abutting a
mechanical seals are each made from ceramic, metal, alloy, or radial face of the other housing, the second and third
carbon. semi-annular outer housings together forming the lon
5. The stuffing box of claim 1, wherein at least one of the gitudinal bore therethrough, the second and third semi
first and second semi-annular mechanical seals is rotationally annular outer housings rotationally coupled to the Sec
coupled to the seal housing. ond outer housing and abutting a longitudinal end of the
6. The stuffing box of claim 1, wherein the seal sleeve is second outer housing, and wherein:
disposed in the outer housing bore, or the seal housing is 25 the seal housing is disposed in the longitudinal bore of the
rotationally coupled to the outer housing. outer housing,
7. The stuffing box of claim 6, wherein the seal sleeve is at least one of the first and second semi-annular mechanical
disposed in the outer housing bore. seals is rotationally coupled to the seal housing; and
8. The stuffing box of claim 6, wherein the internal sleeve the seal sleeve is disposed in the longitudinal bore of the
is at least partially disposed in the outer housing bore and 30 outer housing.
rotatable relative to the outer housing. 21. A progressive cavity pump (PCP) system, comprising:
9. The stuffing box of claim 6, wherein the seal housing is the stuffing box of claim 20, wherein the outer housings are
disposed between the outer housing and the internal sleeve, attached to a wellhead;
the seal sleeve is disposed between the outer housing and the a drive String disposed through the stuffing box, wherein
internal sleeve, and the seal sleeve is rotationally coupled to 35 the internal sleeve is rotationally coupled to the drive
the internal sleeve. String:
10. The stuffing box of claim 6, further comprising: a PC pump disposed in a wellbore extending from the
an injectable seal assembly disposed in the outer housing wellhead, a rotor of the PC pump rotationally coupled to
bore, the injectable seal assembly comprising: the drive string.
a first split annular injectable material retainer;
40 22. The stuffing box of claim 20, further comprising a
secondary seal assembly disposed in the second outer hous
a second split annular injectable material retainer; and ing bore.
a quantity of injectable sealing material disposed 23. The stuffing box of claim 22, wherein the secondary
between the two injectable material retainers. seal assembly comprises:
11. The stuffing box of claim 10, wherein the injectable 45 an injectable seal assembly, comprising:
sealing material is a mixture of grease or jelly and fibers. a first split annular injectable material retainer;
12. The stuffing box of claim 6, wherein the seal housing is a second split annular injectable material retainer, and
rotationally coupled to the outer housing. a quantity of injectable sealing material disposed
13. The stuffing box of claim 6, wherein the internal sleeve between the two injectable material retainers.
is at least partially disposed in the outer housing bore and 50 24. The stuffing box of claim 23, wherein the injectable
rotatable relative to the outer housing, and the seal sleeve is sealing material is a mixture of grease or jelly and fibers.
rotationally coupled to the internal sleeve. 25. The stuffing box of claim 1,
14. The stuffing box of claim 13, wherein the seal housing wherein the outer housing includes an access port disposed
is disposed between the outer housing and the internal sleeve through a wall thereof;
and the seal sleeve is disposed between the outer housing and 55 a semi-annular access panel disposed in the access port and
the internal sleeve. attached to the outer housing, wherein the first, second,
15. The stuffing box of claim 6, further comprising a bear third, and fourth semi-annular mechanical seals are
ing disposed between the internal sleeve and the outer hous located proximate to the access port.
ing to facilitate rotation of the internal sleeve within the outer 26. A progressive cavity pump (PCP) system, comprising:
housing. 60 the stuffing box of claim 25, wherein the outer housing is
16. The stuffing box of claim 6, further comprising bear attached to a wellhead;
ings positioned in an annular space between the internal a drive String disposed through the stuffing box, wherein
sleeve and the outer housing, Such that the internal sleeve is the internal sleeve is rotationally coupled to the drive
journalled for rotation within the outer housing. String:
17. The stuffing box of claim 6, further comprising static 65 a PC pump disposed in a wellbore extending from the
seals positioned within the internal sleeve, the static Seals wellhead, a rotor of the PC pump rotationally coupled to
being adapted to engage a rod. the drive string.
 US 7,874,369 B2
19 20
27. A method of performing maintenance on a stuffing box, a PC pump disposed in a wellbore extending from the
compr1S1ng: wellhead, a rotor of the PC pump rotationally coupled to
providing the stuffing box of claim 25: the drive string.
removing the access panel from the outer housing: 31. A method of performing maintenance on the stuffing
separating the seal sleeve from the seal housing: 5 box of claim 29, comprising:
separating the outer housings from the seal housings;
removing and replacing the first, second, third and fourth separating the seal housings;
semi-annular mechanical seals; and removing and replacing the first, second, third, and fourth
attaching the access panel to the outer housing. semi-annular mechanical seals; and
28. The stuffing box of claim 1, wherein the seal housing 10 re-assembling the stuffing box.
comprises first and second semi-annular seal housings, each 32. The method of claim 31, wherein the outer housings are
having two radial faces, each radial face of each seal housing separated from the seal housings by placingjacks between the
abutting a radial face of the other seal housing, the seal hous two outer housings and lifting the second outer housing from
ings together forming the longitudinal bore therethrough. the seal housings using the jacks.
29. The stuffing box of claim 28, further comprising: 15 33. A method of assembling the stuffing box of claim 1,
a second outer housing having a longitudinal bore there comprising:
through, providing the stuffing box of claim 1:
wherein: removing the first, second, third, and fourth semi-annular
each seal housing has first and second longitudinal ends, mechanical seals from the stuffing box by separating
them from each other into one or more pieces; and
the first longitudinal ends abuts alongitudinal end of the installing new first, second, third, and fourth semi-annular
outer housing, mechanical seals into the stuffing box.
the second longitudinal end abuts a longitudinal end of 34. The method of claim 33, wherein the seal housing is
the second outer housing. disposed between the outer housing and the internal sleeve.
30. A progressive cavity pump (PCP) system, comprising: 25 35. The stuffing box of claim 1, wherein the seal sleeve
the stuffing box of claim29, wherein the outer housings are comprises first and second semi-annular seal sleeves, each
attached to a wellhead; having two radial faces, each radial face of each seal sleeve
a drive string disposed through the stuffing box, wherein abutting a radial face of the other seal sleeve, the seal sleeves
the internal sleeve is rotationally coupled to the drive together forming the longitudinal bore therethrough.
String: k k k k k