Plunger Check Valve Cage Geometry for Faster Ball Actuation
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Solution Overview
Problem
Downhole linear reciprocating pumps, specifically ball-type check valves, face challenges such as corrosion, gas-interference, abrasion, cyclic fatigue, and demanding operational parameters, leading to reduced performance and durability.
Innovation Solution
The design includes improved ball-type check valves with fluid dynamic forces that reduce fluid pressure on the ball, increased hydrodynamic lifting forces, shortened ball-races, and enhanced geometries for ball-stops and flow passages, such as quartic curve profiles, to improve durability and actuation speed, and reduced pressure drops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional ball-type check valves are used in downhole pumps, then the structure is simple and easy to manufacture, but the durability is reduced due to corrosion, abrasion, and cyclic fatigue
Solution Approach 1:
The patent applies composite materials by combining a ball element with a cage structure that contains multiple flow passages. The cage acts as a protective composite structure that shields the ball from direct exposure to corrosive and abrasive downhole environments, while maintaining the one-way valve function. This composite arrangement improves durability by protecting individual components from corrosion and abrasion.
Solution Approach 2:
The valve is segmented into distinct functional components: the ball element for sealing, the cage structure for protection and flow control, and multiple flow passages for fluid routing. This segmentation allows each component to be optimized independently and replaced separately, improving overall reliability without excessive complexity.
2Speed
If the ball-race length is shortened to improve actuation speed, then the speed of actuation increases, but the kinetic energy of the ball increases causing more severe impacts on ball-stops
Solution Approach 1:
The cage structure serves as a protective cushioning element that absorbs and distributes the impact forces when the ball strikes the ball-stops. By positioning the cage between the ball and the external environment, it provides beforehand protection against severe impacts, allowing shorter ball-race lengths for faster actuation without compromising impact resistance.
Solution Approach 2:
The cage acts as a flexible protective shell that can deform slightly to absorb impact energy while maintaining structural integrity. This shell structure protects the ball and internal components from severe impact forces, enabling faster actuation speeds with shorter ball-race lengths.
3Speed
If fluid passages are designed to increase hydrodynamic lifting force on the ball, then the speed of actuation improves, but the pressure drop across the valve increases
Solution Approach 1:
The valve uses multiple flow passages instead of a single large passage, providing partial flow paths that collectively achieve the required flow capacity. This partial action approach creates sufficient hydrodynamic lifting force across multiple smaller passages to actuate the ball quickly, while the distributed flow paths reduce the pressure drop compared to a single restrictive passage.
Solution Approach 2:
The cage structure with multiple flow passages arranged in different spatial dimensions creates hydrodynamic forces from multiple directions. This dimensional arrangement of flow passages generates cumulative lifting force on the ball while distributing the pressure drop across multiple pathways, reducing the overall pressure loss.
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 solution enhances the durability and speed of actuation of ball-type check valves, reducing kinetic energy and pressure drops, thereby improving the overall performance and longevity of downhole pumps.
Implementation Method 1
fluid dynamic forces of production fluid around the ball of the disclosed embodiments, such that there are lowered fluid pressure acting normal to the ball surface in areas where there is faster movement of fluids around the ball. As the fluid passages are designed in the disclosed embodiments, accordingly, there is a reduced pressure on the upper section of the ball as it moves through disclosed cylindrical casings. Further, an increased effective area of differential pressure is provided whereby there is an increased hydrodynamic lifting force on the ball, improving the speed of action
Data Source
AI summary
Valve assemblies and related pumps, plungers, lift assemblies, and methods may include an insert disposed in an internal flow path of a plunger. The insert includes protrusions, each individually extending into the internal flow path of the plunger and converging at an apex of the insert to define a cage in which the restriction element is configured to move axially through the internal flow path.