Dual-Poppet Jetted Check Valve for Debris Clearing
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Solution Overview
Problem
Check valves in oil and gas operations face issues with debris settlement during shutdown, leading to solids interference and repeated opening/closing due to gas slugging, which can damage the downhole pumping system and result in inconsistent flow.
Innovation Solution
A jetted check valve with a primary and secondary poppet mechanism that creates a secondary flow path to remove debris and a primary flow path to allow production fluids to flow, utilizing a nozzle effect to clear settled debris when the pump is restarted.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional check valve is used, then the valve structure is simple, but debris settles on top of the check valve during shutdown causing solids interference and preventing fluid flow when the pump is restarted
Solution Approach 1:
The check valve is segmented into multiple functional components: a primary poppet for flow control and a secondary poppet with jetting nozzle for debris removal. This segmentation allows the valve to perform both flow control and self-cleaning functions independently, resolving the contradiction between reliability and complexity by distributing functions across separate elements.
Solution Approach 2:
The secondary poppet performs preliminary debris removal action before the primary poppet opens for normal flow. By jetting fluid through the secondary poppet's nozzle during shutdown or before restart, debris is cleared from the valve seat in advance, ensuring reliable opening of the primary poppet when the pump restarts.
2Reliability
If a conventional check valve is used, then the device complexity is low, but the check valve chatter occurs during gas slugging causing repeated opening and closing that damages the pumping system
Solution Approach 1:
The secondary poppet acts as an intermediary element between the primary poppet and the debris/gas mixture. It provides a separate flow path that allows gas and debris to be managed independently, preventing them from interfering with the primary poppet's operation and causing chatter.
Solution Approach 2:
The invention uses hydraulic jetting through the secondary poppet's nozzle to control debris and gas flow. By directing high-velocity fluid through the secondary path, gas slugging is managed hydraulically, stabilizing the primary poppet's position and preventing chatter during gas-rich flow conditions.
3Productivity
If the check valve opens to allow fluid flow, then production fluids can reach the surface, but debris interference prevents the valve from opening properly after shutdown
Solution Approach 1:
The secondary poppet extracts the debris removal function from the primary flow path. By creating a separate jetting path through the secondary poppet, debris is removed through this dedicated extraction path, clearing the way for the primary poppet to open and allow productive fluid flow without interference.
4Adaptability or versatility
If a single poppet design is used, then the valve structure is simple, but it cannot simultaneously remove debris and allow production flow
Solution Approach 1:
The dual poppet design provides universality by enabling the check valve to perform multiple functions: the primary poppet handles production flow control while the secondary poppet handles debris removal and gas slugging management. This multi-functionality allows a single valve assembly to adapt to different operational conditions without requiring separate devices.
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
Effectively removes debris and ensures consistent fluid flow by opening the primary flow path, preventing damage and costly workovers, and maintaining efficient operation of the downhole pumping system.
Implementation Method 1
A jetted check valve with a primary and secondary poppet mechanism that creates a secondary flow path to remove debris and a primary flow path to allow production fluids to flow, utilizing a nozzle effect to clear settled debris when the pump is restarted.
Data Source
AI summary
A jetted check valve includes a body with an upper opening and a lower opening. The jetted check valve also includes a primary poppet slidably disposed in the body to allow the flow of fluid from the lower opening and out of the upper opening and prevent the flow of fluid from the upper opening through the lower opening. The jetted check valve further includes a secondary poppet slidably disposed at least partially within the primary poppet to allow the flow of fluid from the lower opening and out of the upper opening and prevent the flow of fluid from the upper opening through the lower opening. A method of removing debris from above a jetted check valve and permitting production fluids to flow up hole through the jetted check valve. The method includes creating a secondary flow path in the jetted check valve to remove debris that settled up hole of the jetted check valve when production of an oil and gas well has been halted. The method also includes creating a primary flow path in the jetted check valve to permit production fluids to flow up hole through the jetted check valve.