Mechanically Actuated Plug Valve for High-Gas Pumping
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Solution Overview
Problem
Conventional mechanically actuated positive displacement pumps with ball and seat valves are inefficient when pumping fluids with high gas to oil ratios, leading to pressure drops, gas separation, and gas lock conditions, which reduce volumetric efficiency and shorten pump lifespan, especially when operating at inclination angles other than vertical.
Innovation Solution
A mechanically actuated traveling valve with a plug and seat configuration, where the annular flow area outside the plug is equal to the annular flow area inside the seat, and the conical flow area generated by the separation distance between the sealing surfaces is equal to or greater than the annular flow area inside the seat, minimizing pressure drop and maximizing flow, allowing the valve to be located anywhere along the plunger or at the discharge end, reducing oil seepage and improving fluid handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional ball and seat valves are used in mechanically actuated positive displacement pumps, then the pump structure is simple and easy to manufacture, but the pump efficiency decreases when handling fluids with high gas to oil ratios due to pressure drops and gas separation
Solution Approach 1:
The patent changes the geometric parameters of the valve components, specifically designing the plug with a specific shape and positioning it at a precise distance from the seat to optimize flow characteristics. The plug is positioned at a distance of 0.06 to 0.12 inches from the seat, creating an optimized flow path that reduces pressure drops and improves gas handling capability while maintaining manufacturing feasibility.
2Productivity
If the plug is positioned close to the seat to minimize flow area, then the pressure differential increases to open the valve, but this causes gas lock conditions and fluid pounding that harm the pump
Solution Approach 1:
The patent optimizes the plug-to-seat distance parameter to a specific range (0.06 to 0.12 inches) that balances two competing requirements: maintaining sufficient pressure differential to open the valve efficiently while avoiding excessive pressure that causes gas lock and fluid pounding. This precise parameter control resolves the contradiction between volumetric efficiency and pump reliability.
Solution Approach 2:
The patent introduces a mechanically actuated traveling valve system where the plug can dynamically position itself relative to the seat during pump operation. The mechanical actuation system allows the valve to respond dynamically to pressure conditions, opening and closing at optimized moments in the pump cycle to prevent gas lock while maintaining efficient fluid displacement.
3Productivity
If the annular flow area outside the plug is made equal to the annular flow area inside the seat, then the pressure drop is minimized and flow is maximized, but the valve configuration becomes more complex
Solution Approach 1:
The patent establishes specific geometric relationships between valve components, setting the annular flow area outside the plug equal to the annular flow area inside the seat. This parameter optimization creates balanced flow paths that minimize pressure drops and maximize flow rate. The specific dimensional relationships are designed to achieve this flow balance while maintaining reasonable manufacturing complexity.
4Adaptability or versatility
If the pump operates at inclination angles other than vertical, then the adaptability increases, but fluid seepage across the valve increases reducing efficiency
Solution Approach 1:
The patent employs spherical or curved sealing surfaces on the plug and seat components. This curvature design allows the sealing surfaces to maintain contact and effectiveness at various inclination angles, preventing fluid seepage even when the pump is installed in non-vertical orientations. The spherical geometry adapts to gravitational forces from different directions, maintaining seal integrity across a range of operating positions.
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
This configuration enhances volumetric efficiency, reduces fluid seepage, and extends pump lifespan by minimizing pressure drop and maximizing flow across the valve, enabling efficient operation at any inclination angle and handling high gas content fluids effectively.
Implementation Method 1
fluid flows in one direction when the plug becomes separated from the seat by the pressure differential at both sides of the valve
Implementation Method 2
the conical flow area generated by the separation distance between the sealing surfaces of the valve plug and seat must be equal to or greater than the annular flow area inside the valve seat, minimizing pressure drop and maximizing flow
Data Source
AI summary
A mechanically actuated traveling valve for use in fluid pumping equipment is provided. More particularly, a mechanically actuated traveling plug valve having a valve seat and a valve plug is provided for use in any positive displacement pump with a reciprocating element (either the plunger or the cylinder) capable of pumping fluids of any viscosity, with any gas to liquid ratio, operating at any inclination angle.