Downhole Pump Pilot Valve for Gas Lock and Sand Control
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Solution Overview
Problem
Conventional downhole rod pumps face issues with gas lock, fluid hammer, sand accumulation, and inefficiency in multi-phase and deviated wells, leading to reduced operational efficiency and increased maintenance costs.
Innovation Solution
A fluid pump apparatus with a barrel and plunger system featuring a standing valve and a traveling valve, where a pilot mechanism helps control fluid flow and sand removal through annuli and apertures, utilizing inertia and fluid pressure to prevent gas lock and fluid pound, and a flexible connector for deviated wells to reduce wear and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional rod pump with ball-and-seat valves is used, then the pump structure is simple, but it experiences gas lock, fluid hammer, and sand accumulation problems
Solution Approach 1:
A pilot valve is introduced as an intermediary component that controls the main traveling valve. The pilot valve responds to fluid pressure changes and inertial forces to timing the opening and closing of the traveling valve, preventing gas lock and fluid hammer while maintaining reliable operation
Solution Approach 2:
The valve control system transitions from static ball-and-seat valves to a dynamic pilot-valve controlled system. The traveling valve is dynamically opened and closed based on real-time fluid pressure changes and plunger motion, allowing the system to adapt to varying operating conditions and prevent harmful phenomena
2Productivity
If the traveling valve is tightly sealed to prevent leakage, then pump efficiency is improved, but sand and debris accumulate in the valve seat
Solution Approach 1:
The traveling valve is periodically opened and closed in a controlled manner during each pump stroke. The valve opens during the downstroke to allow sand and debris to escape, then closes tightly during the upstroke to maintain pump efficiency. This periodic action prevents permanent sand accumulation while maintaining sealing performance
Solution Approach 2:
The pilot valve performs preliminary action by opening the traveling valve before the plunger reaches the position where sand accumulation becomes problematic. This timing allows sand to be flushed out during the opening phase, preventing it from settling in the valve seat during subsequent operation
3Ease of operation
If the pump operates in deviated wells with rigid rod connectors, then the pump structure is simple, but wear and damage increase
Solution Approach 1:
The rigid rod connector is replaced with a flexible cable or hose that can accommodate the angular deviations and movement patterns required in deviated wells. This flexible connection maintains pump operation while significantly reducing wear and damage to both the connector and well infrastructure
4Productivity
If the pump runs at high speed to increase production, then productivity is improved, but gas lock and fluid hammer occur more frequently
Solution Approach 1:
The pilot valve system provides automatic feedback based on fluid pressure changes and plunger motion. As the plunger moves and fluid pressure changes, the pilot valve senses these conditions and automatically adjusts the traveling valve position to prevent gas lock and fluid hammer, allowing high-speed operation without sacrificing reliability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enhances operational efficiency, reduces maintenance, and effectively handles gas and sand issues, ensuring consistent hydrocarbon production with reduced sensitivity to gas locks and sand plugging, while maintaining pump fillage and minimizing fluid pound.
Implementation Method 1
utilizing inertia and fluid pressure to prevent gas lock and fluid pound
Implementation Method 2
utilizing inertia and fluid pressure to prevent gas lock and fluid pound
Data Source
AI summary
A fluid pump apparatus for an artificial lift system has a barrel, a standing valve positioned at a lower end of the barrel so as to be movable between an open position and a closed position, a plunger reciprocatingly mounted in the barrel, a traveling valve positioned in an interior of the plunger so as to control fluid flow through the plunger, and a pilot slidably positioned in the plunger. The plunger has a first aperture at an upper portion thereof and a second aperture extending through a wall of the plunger so as to open to a channel extending through the channel. The traveling valve is slidably movable within an interior of the plunger. The plunger has a seat that is cooperative with a surface of the traveling valve. The pilot is cooperative at the surface of the traveling valve so as to move the traveling valve.